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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 973 (Engine - 5.4L (3V) - F150 Pickup) >> In-Vehicle Repair >> Engine Front Cover >> Installation

Engine Front Cover: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the CKP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    2. 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 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. 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 And Oil Pan-To-Cylinder Block Surface
    G03919915Courtesy of FORD MOTOR CO.
  2. 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.
  3. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.
    Fig 2: Installing New Engine Front Cover Gasket On Engine Front Cover And Positioning Engine Front Cover Onto Dowels
    G03881967Courtesy of FORD MOTOR CO.
  4. Tighten the engine front cover fasteners in the sequence shown in 2 stages.
    • Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).
    • Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).
    Fig 3: Tightening Engine Front Cover Fasteners In Sequence
    G03963046Courtesy of FORD MOTOR CO.
  5. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
    Fig 4: Identifying Installing Sequence Of Front Oil Pan/Cover Bolts
    G03920544Courtesy of FORD MOTOR CO.
  6. Connect the CKP sensor electrical connector.
  7. Position the power steering pump assembly and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 5: Installing Power Steering Pump Bolts
    G03962601Courtesy of FORD MOTOR CO.
  8. Using the special tool, install a new O-ring seal on the pressure line fitting.
    Fig 6: Installing New O-Ring Seal On Pressure Line Fitting Using Special Tool
    G03955529Courtesy of FORD MOTOR CO.
  9. Connect the power steering pressure tube.
    • Tighten to 65 Nm (48 lb-ft).
    Fig 7: Connecting Power Steering Pressure Tube
    G03962599Courtesy of FORD MOTOR CO.
  10. Using the special tool, install the power steering pump pulley.
    Fig 8: Installing Power Steering Pump Pulley Using Special Tool
    G03963051Courtesy of FORD MOTOR CO.
  11. Position the power steering pressure hose support bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 9: Installing Power Steering Pressure Tube Support Bracket Nut
    G03933414Courtesy of FORD MOTOR CO.
  12. Position the transmission cooler tube support bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 10: Installing Transmission Cooler Tube Support Bracket Nut
    G03933415Courtesy of FORD MOTOR CO.
    13. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
  13. Using a new O-ring seal, install the RH CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
  14. Connect the RH CMP sensor electrical connector.
  15. Install the LH radio ignition interference capacitor and the nut.
    • Tighten to 10 Nm (89 lb-in).
    16. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
  16. Using a new O-ring seal, install the LH CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
  17. Connect the LH CMP sensor electrical connector.
  18. Install the RH radio ignition interference capacitor and the nut.
    • Tighten to 10 Nm (89 lb-in).
  19. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  20. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  21. Install the 3 accessory drive idler pulleys and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  22. Position the upper radiator hose support bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 11: Installing Upper Radiator Hose Support Bracket Nut
    G03963041Courtesy of FORD MOTOR CO.
  23. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
    Fig 12: Lubricating Engine Front Cover And Crankshaft Seal Inner Lip With Clean Engine Oil
    G03881970Courtesy of FORD MOTOR CO.
  24. Using the special tools, install a new crankshaft front seal into the engine front cover.
    Fig 13: Installing New Crankshaft Front Seal Into Engine Front Cover Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    25. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 14: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03919877Courtesy of FORD MOTOR CO.
  25. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  26. Use the special tool to install the crankshaft pulley.
    Fig 15: Installing Crankshaft Pulley Using Special Tool
    G03919878Courtesy of FORD MOTOR CO.
  27. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 16: Installing Crankshaft Pulley Bolt & Washer
    G04672695Courtesy of FORD MOTOR CO.
  28. Rotate the tensioner clockwise and install the accessory drive belt.
    Fig 17: Rotating Tensioner Clockwise And Installing Accessory Drive Belt
    G03886148Courtesy of FORD MOTOR CO.
  29. Install the RH valve cover. For additional information, refer to VALVE COVER - RH .
  30. Install the LH valve cover. For additional information, refer to VALVE COVER - LH .
  31. Install the engine cooling fan. For additional information, refer to ENGINE COOLING .
  32. Fill the crankcase with clean engine oil.
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