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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1179 (Engine Mechanical - 2.5L (Hybrid)) >> In-Vehicle Repair >> Engine Front Cover >> Installation

Engine Front Cover: Installation

WARNING: This page is about a different car, the 2010 Mercury Milan and 2010 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean and inspect the mounting surfaces of the engine and the front cover.
    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.
  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.
    NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
    Fig 1: Applying Silicone Gasket & Sealant On Engine Front Cover
    G06094885Courtesy of FORD MOTOR CO.
  3. Install the engine front cover. Tighten the bolts in the sequence shown below, 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 Bolt Tightening Sequence
    G06271752Courtesy 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. Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal.
    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 Seal
    G06271753Courtesy of FORD MOTOR CO.
  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 Removal and Installation .
  9. Install the crankshaft pulley. For additional information, refer to Installation .
  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.
    NOTE: Only hand-tighten the bolt or damage to the front cover can occur.
    Fig 4: Locating Crankshaft Pulley Bolt
    G06271722Courtesy of FORD MOTOR CO.
  11. Install the CKP  sensor and the 2 bolts.
    • Do not tighten the bolts at this time.
    Fig 5: Locating CKP Sensor & Bolts
    G06262156Courtesy 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
    G06271756Courtesy 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 Bolt
    G06271722Courtesy of FORD MOTOR CO.
  15. Install the accessory drive belt and tensioner. For additional information, refer to REMOVAL AND INSTALLATION .
  16. Repower the vehicle high voltage electrical system. For additional information, refer to HIGH-VOLTAGE TRACTION BATTERY SYSTEMS DEPOWERING .
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