Engine Front Cover: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

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: Identifying Area For Applying Sealant

Courtesy of FORD MOTOR CO.

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.
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: Identifying Engine Front Cover And Alignment Dowels
Courtesy of FORD MOTOR CO.

Tighten the engine front cover fasteners in sequence 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).

COMPONENTS DESCRIPTION CHART

Item	Part Number	Description
1	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
2	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
3	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
4	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
5	N806177	Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
6	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
7	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
8	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
9	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
10	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
11	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
12	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
13	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
14	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
15	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 56

Fig 3: Identifying Tightening Sequence For Engine Front Cover Bolts

Courtesy of FORD MOTOR CO.

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 Tightening Sequence Of Front Oil Pan Bolts
  Courtesy of FORD MOTOR CO.
Using a new O-ring seal, install the CKP sensor and the bolt.
- Lubricate the new O-ring seal with clean engine oil prior to installation.
- Tighten to 10 Nm (89 lb-in).
Connect the CKP sensor electrical connector.
Position the A/C compressor and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 5: Locating A/C Compressor Bolts
  Courtesy of FORD MOTOR CO.
Position the power steering pump and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 6: Identifying Power Steering Pump Bolts
  Courtesy of FORD MOTOR CO.
Position the starter electrical harness support bracket and install the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 7: Identifying Cooler Tube/Electrical Harness Support Bracket Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Using a new O-ring seal, install the CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
Connect the CMP sensor electrical connector.
Install the LH radio ignition interference capacitor and the nut.
- Tighten to 10 Nm (89 lb-in).
Install the RH radio ignition interference capacitor and the nut.
- Tighten to 10 Nm (89 lb-in).

NOTE: LH shown, RH similar.

Fig 8: Locating Radio Interference Capacitor Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the radio ignition interference capacitor electrical connectors.
Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
Install the coolant pump pulley and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
Install the accessory drive idler pulley and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

Fig 9: Locating Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
Using the special tools, install a new crankshaft seal into the engine front cover.

Fig 10: Installing Crankshaft Front Seal Using Special Tools
Courtesy of FORD MOTOR CO.

NOTE: If 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. 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 11: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
Use the special tool to install the crankshaft pulley.

Fig 12: Installing Crankshaft Pulley Using Special Tool
Courtesy of FORD MOTOR CO.
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 13: Locating Crankshaft Pulley Bolt
  Courtesy of FORD MOTOR CO.
Rotate the tensioner clockwise and install the accessory drive belt.

Fig 14: Rotating Accessory Drive Belt Tensioner Clockwise
Courtesy of FORD MOTOR CO.
Install the RH valve cover. For additional information, refer to VALVE COVER - RH .
Install the LH valve cover. For additional information, refer to VALVE COVER - LH .
Install the engine cooling fan. For additional information, refer to ENGINE COOLING .
Fill the crankcase with clean engine oil.