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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2004 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.

    ALL ENGINES 

    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
    Fig 1: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface
    G02762834Courtesy of FORD MOTOR CO.
  1. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
  2. Install the engine front cover with engine front cover gasket on the front cover to cylinder block dowel and loosely install the bolts.
    Fig 2: Installing Engine Front Cover With Engine Front Cover Gasket On Front Cover To Cylinder Block Dowel
    G02762835Courtesy of FORD MOTOR CO.

    3. ROMEO ENGINE (4.6L) 

  3. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
    Fig 3: Tightening Front Cover Fasteners In Sequence
    G02762836Courtesy of FORD MOTOR CO.

    4. WINDSOR ENGINE (5.4L) 

  4. Tighten the engine front cover fasteners in sequence in three stages.

    Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 lb-ft).

    Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

    Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).

    Fig 4: Engine Front Cover Fastener Tightening Sequence
    G02762837Courtesy of FORD MOTOR CO.

    5. ALL ENGINES 

  5. Position the belt idler pulley and install the bolt.
    Fig 5: Installing Belt Idler Pulley Bolt
    G02762838Courtesy of FORD MOTOR CO.
  6. Connect the CMP sensor electrical connection.
    Fig 6: Connecting CMP Sensor Electrical Connection
    G02762839Courtesy of FORD MOTOR CO.
  7. Install a new crankshaft front seal. For additional information, refer to CRANKSHAFT FRONT SEAL .
  8. Loosely install the bolts, then tighten the bolts in the two stages following the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
    Fig 7: Tightening Bolts In Sequence
    G02762840Courtesy of FORD MOTOR CO.
  9. Connect the crankshaft position sensor electrical connector.
    Fig 8: Connecting Crankshaft Position Sensor Electrical Connector
    G02762841Courtesy of FORD MOTOR CO.
    10. NOTE: The front lower hole in the power steering pump is not used.
    Fig 9: Installing Power Steering Pump Bolts
    G02762842Courtesy of FORD MOTOR CO.
  10. Position the power steering pump and install the bolts.
  11. Install the drain plug.
    Fig 10: Installing Drain Plug
    G02762843Courtesy of FORD MOTOR CO.
  12. Install the valve covers. For additional information, refer to VALVE COVER LH , VALVE COVER RH - 4.6L  or VALVE COVER RH - 5.4L .
  13. Fill the engine with clean engine oil.
  14. Install the water pump. For additional information, refer to ENGINE COOLING .
  15. Install the radiator. For additional information, refer to ENGINE COOLING .
  16. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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