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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. 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 clean sealing surfaces.
    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: Locating Sealant Application Areas
    G03886057Courtesy 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 in Fig 1.
  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 Front Cover To Cylinder Block Dowel
    G03885297Courtesy 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 - Romeo Engine (4.6L)
    G03885298Courtesy 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 5 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: Tightening Front Cover Fasteners In Sequence - Windsor Engine (5.4L)
    G03885299Courtesy of FORD MOTOR CO.

    5. All engines 

  5. Position the belt idler pulley and install the bolt.
    Fig 5: View Of Belt Idler Pulley Bolt With Torque Specification
    G03885300Courtesy of FORD MOTOR CO.
  6. Connect the CMP electrical connection.
    Fig 6: Identifying Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy 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 two stages following the sequence shown in Fig 7.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
      Fig 7: Identifying Tightening Sequence Of Bolts
      G03887023Courtesy of FORD MOTOR CO.
  9. Connect the crankshaft position sensor electrical connector.
    Fig 8: Locating CKP Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
    10. NOTE: The front lower hole in the power steering pump is not used.
    Fig 9: Identifying Tightening Torque Of Power Steering Pump Bolts
    G03885304Courtesy of FORD MOTOR CO.
  10. Position the power steering pump and install the bolts.
  11. Install the drain plug.
    Fig 10: Installing Oil Drain Plug
    G03885305Courtesy 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 coolant 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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