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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2011 Mercury Milan, 2011 Lincoln MKZ, and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  1. Clean and inspect the mounting surfaces of the engine and the front cover.
    2. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
    Fig 1: Locating Bead Of Silicone Gasket And Sealant On Front Cover
    G07781942Courtesy of FORD MOTOR CO.
  2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
  3. Install the engine front cover. Tighten the bolts in the sequence shown in illustration, to the following specifications:
    • Tighten the 8-mm bolts to 10 Nm (89 lb-in).
    • Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
    Fig 2: Identifying Engine Front Cover Bolts Tightening Sequence
    G07781943Courtesy of FORD MOTOR CO.
  4. Connect the vehicle high voltage electrical connector to the DC/DC converter and attach the wiring retainer.
  5. Install the A/C tube bracket bolt to the strut tower.
    • Tighten to 6 Nm (53 lb-in).
    6. NOTE: Remove the through bolt from the Camshaft Front Oil Seal Installer.
    NOTE: Lubricate the oil seal with clean engine oil.
    Fig 3: Installing Crankshaft Front Oil Seal Using Camshaft Front Oil Seal Installer
    G07781944Courtesy of FORD MOTOR CO.
  6. Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal.
  7. Install the coolant pump pulley and the 3 bolts.
    • Tighten to 20 Nm (177 lb-in).
  8. Install the engine mount. For additional information, refer to ENGINE MOUNT  in this service information.
  9. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY  in this service information.
    10. NOTE: Only hand-tighten the bolt or damage to the front cover can occur.
    Fig 4: Locating Crankshaft Pulley Mounting Bolt
    G07781945Courtesy of FORD MOTOR CO.
  10. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
  11. Install the CKP sensor and the 2 bolts.
    • Do not tighten the bolts at this time.
    Fig 5: Locating CKP Sensor And Mounting Bolts
    G07781946Courtesy of FORD MOTOR CO.
  12. Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
    • Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
    Fig 6: Adjusting CKP Sensor Using Crankshaft Sensor Aligner
    G07781947Courtesy of FORD MOTOR CO.
  13. Connect the CKP sensor electrical connector.
  14. Remove the 6 mm x 18 mm bolt.
    Fig 7: Locating Crankshaft Pulley Mounting Bolt
    G07781948Courtesy of FORD MOTOR CO.
  15. Install the accessory drive belt and tensioner. For additional information, refer to ACCESSORY DRIVE - FUSION HYBRID, MILAN HYBRID & MKZ HYBRID article.
  16. Repower the vehicle high voltage electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY -- FUSION HYBRID, MILAN HYBRID & MKZ HYBRID article.
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