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Home >> Ford >> 2002 >> Focus ZX5, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1884 (Engine - 6.8L (3V) -- F250-F550 Super Duty) >> In-Vehicle Servicing >> Engine Front Cover >> Installation

Engine Front Cover: Installation

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 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: Applying Bead of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface And Oil Pan-To-Cylinder Block Surface
    GF0005574Courtesy 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.
  2. 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 Engine Front Cover Gasket
    GF0000367Courtesy of FORD MOTOR CO.
  3. 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).

    Fig 3: Identifying Tightening Sequence For Engine Front Cover Bolts
    GF0005575Courtesy of FORD MOTOR CO.
    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
  4. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 20 N.m (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
    Fig 4: Identifying Tightening Sequence Of Front Oil Pan Bolts
    G03920544Courtesy of FORD MOTOR CO.
  5. 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 N.m (89 lb-in).
  6. Connect the CKP sensor electrical connector.
  7. Position the A/C compressor and install the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 5: Locating Bolt Access Holes For A/C Compressor
    G03919912Courtesy of FORD MOTOR CO.
  8. Position the power steering pump and install the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
    Fig 6: Identifying Power Steering Pump Bolts
    G03886436Courtesy of FORD MOTOR CO.
  9. Position the starter electrical harness support bracket and install the bolt.
    • Tighten to 10 N.m (89 lb-in).
    Fig 7: Identifying Cooler Tube/Electrical Harness Support Bracket Bolt
    G03919905Courtesy of FORD MOTOR CO.
    10. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
  10. Using a new O-ring seal, install the CMP sensor and the bolt.
    • Tighten to 10 N.m (89 lb-in).
  11. Connect the CMP sensor electrical connector.
  12. Install the LH radio ignition interference capacitor and the nut.
    • Tighten to 10 N.m (89 lb-in).
  13. Install the RH radio ignition interference capacitor and the nut.
    • Tighten to 10 N.m (89 lb-in).
    14. NOTE: LH shown, RH similar.
    Fig 8: Locating Radio Interference Capacitor Electrical Connectors
    G03885209Courtesy of FORD MOTOR CO.
  14. Connect the radio ignition interference capacitor electrical connectors.
  15. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
  16. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 25 N.m (18 lb-ft).
  17. Install the accessory drive idler pulley and the 3 bolts.
    • Tighten to 25 N.m (18 lb-ft).
  18. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
    Fig 9: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  19. Using the special tools, install a new crankshaft seal into the engine front cover.
    Fig 10: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    20. 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
    G03919877Courtesy of FORD MOTOR CO.
  20. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  21. Use the special tool to install the crankshaft pulley.
    Fig 12: Installing Crankshaft Pulley Using Special Tool
    G03919878Courtesy of FORD MOTOR CO.
  22. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 N.m (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 N.m (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 13: Identifying Crankshaft Pulley Bolt Tightening Sequence
    GF0002723Courtesy of FORD MOTOR CO.
  23. Rotate the tensioner clockwise and install the accessory drive belt.
    Fig 14: Rotating Tensioner Clockwise And Installing Accessory Drive Belt
    GF0000336Courtesy of FORD MOTOR CO.
  24. Install the RH valve cover. For additional information, refer to Valve Cover - RH  in this article.
  25. Install the LH valve cover. For additional information, refer to Valve Cover - LH  in this article.
  26. Install the engine cooling fan. For additional information, refer to ENGINE COOLING article.
  27. Fill the crankcase with clean engine oil.
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