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Home >> Ford >> 2002 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2436 (Engine - 6.4L 99R Diesel -- F250-F550 Super Duty) >> In-Vehicle Servicing >> Engine Front Cover >> Installation

Engine Front Cover: Installation

WARNING: This page is about a different car, the 2008 Ford Pickup, 2008 Ford F550 Super Duty, 2008 Ford F450 Super Duty, and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Install a new O-ring seal.
  1. Install the EGR coolant adapter and bolt.
    • Tighten to 13 Nm (115 lb-in).
  2. Apply a dime-sized bead of sealant at the front seam of the upper and lower crankcase.
    3. Fig 1: Applying A Dime-Sized Bead Of Sealant At Front Seam Of Upper & Lower Crankcase
    GF0048517Courtesy of FORD MOTOR CO.
    NOTE: Failure to use guide pins to position the front cover gasket may lead to oil in the coolant.
    NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
  3. Position the new front cover gasket on the engine and install guide pins.
    4. Fig 2: Locating Guide Pins
    GF0048518Courtesy of FORD MOTOR CO.
  4. Position the engine front cover and loosely install the 10 bolts.
    5. NOTE: Install oil pump drive rotors with marks pointing outward.
  5. Lubricate the inner drive rotor with clean engine oil and install onto the crankshaft. Lubricate the outer drive rotor with clean engine oil and mesh with the inner drive rotor.
  6. Install a new press-in-place gasket, the oil pump housing and the 11 bolts.
    • Tighten the 7 long bolts to 31 Nm (23 lb-ft).
    • Tighten the 4 short bolts to 22 Nm (16 lb-ft).
  7. Tighten the 10 engine front cover bolts.
    • Tighten to 31 Nm (23 lb-ft).
    8. NOTE: Install a new O-ring seal on the coolant pump.
  8. If removed, install the coolant pump and the 5 bolts.
    • Tighten to 31 Nm (23 lb-ft).
  9. If removed, install the coolant pump pulley and the 4 bolts.
    • Tighten to 31 Nm (23 lb-ft).
  10. If removed, install a new press-in-place gasket. Install the thermostat housing, collar and 4 bolts.
    • Tighten to 13 Nm (115 lb-in).
    11. NOTE: Do not bend or flex the heater supply tube or damage to the tube may occur.
    NOTE: Install a new O-ring seal.
  11. Position back the heater supply tube.
  12. Install the nut and 2 bolts for the heater supply tube and engine wiring harness.
    • Tighten to 13 Nm (115 lb-in).
  13. Connect the ECT sensor electrical connector and wire retainer.
    14. Fig 3: Locating ECT Sensor Electrical Connector & Wire Retainer
    GF0048472Courtesy of FORD MOTOR CO.
  14. Install the accessory drive belt idler pulley and bolt.
    • Tighten to 47 Nm (35 lb-ft).
  15. If equipped, install the A/C belt tensioner and bolt.
    • Tighten to 47 Nm (35 lb-ft).
  16. Install the accessory drive belt tensioner and bolt.
    • Tighten to 47 Nm (35 lb-ft).
    17. NOTE: Install a new O-ring seal on the tube.
    NOTE: Hand start both bolts prior to tightening the bolts.
  17. Position back the EGR cooler coolant supply tube and install the 2 bolts.
    • Tighten to 13 Nm (115 lb-in).
    18. NOTE: Install a new O-ring seal.
  18. Position back the heater return tube and install the 2 bolts.
    • Tighten to 13 Nm (115 lb-in).
  19. Install the upper radiator hose and retaining clip.
  20. Position back the lower radiator hose and install the retaining clip.
    21. NOTE: Install a new horizontal EGR cooler gasket prior to installing the vertical EGR cooler.
  21. Position the vertical EGR cooler assembly and loosely install the 5 bolts.
  22. Install a new vertical EGR cooler gasket and the stud.
    • Tighten to 31 Nm (23 lb-ft).
  23. Install the nut and bolt for the vertical EGR cooler.
    • Tighten to 31 Nm (23 lb-ft).
  24. Install the retaining clip and nut on the stud.
    • Tighten to 12 Nm (106 lb-in).
  25. Connect the EGRT sensor electrical connector. Connect the cooler hose and connect to the retaining clips.
    26. NOTE: Install a new O-ring seal.
  26. Install the vertical EGR cooler tube and bolt.
    • Tighten to 10 Nm (89 lb-in).
    27. NOTE: Do not bend or twist the EGR cooler bellows or damage to the EGR cooler may occur.
    NOTE: Inspect the corrugation of the vertical EGR cooler inlet to make sure that the corrugation ribs are not touching and are not damaged.
  27. Install the 2 nuts for the vertical EGR cooler.
    • Tighten to 31 Nm (23 lb-ft).
    28. NOTE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps may result in hose joint failure.
    NOTE: Install a new clamp on the vertical EGR cooler coolant hose.
  28. Connect the vertical EGR cooler coolant hose and tighten the clamp.
    • Tighten to 4 Nm (35 lb-in).
  29. Tighten the 5 EGR cooler bolts.
    • Tighten the M8 bolts to 31 Nm (23 lb-ft).
    • Tighten the M10 bolt to 62 Nm (46 lb-ft).
  30. Install the 3 bolts for the power steering pump.
    • Tighten to 25 Nm (18 lb-ft).
  31. Install the retaining nut for the power steering hose and tube.
    • Tighten to 25 Nm (18 lb-ft).
  32. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal .
  33. Install the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
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