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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1493 (Engine Mechanical - 2.5L (Except Hybrid)) >> In-Vehicle Repair >> Engine Front Cover >> Installation

Engine Front Cover: Installation

WARNING: This page is about a different car, the 2011 Mercury Milan 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 discs 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.
    NOTE: If the oil pan is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow these instructions can cause future oil leakage.
    Fig 1: Locating Bead Of Silicone Gasket And Sealant On Front Cover
    G07780585Courtesy 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 the 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
    G07780586Courtesy of FORD MOTOR CO.
  4. Install the accessory drive belt idler pulley and bracket and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    5. NOTE: The coolant pump pulley bolts should be tightened after the accessory drive belt is installed.
  5. Install the coolant pump pulley and bolts.
    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 Special Tool
    G07780587Courtesy of FORD MOTOR CO.
  6. Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.
  7. Install the engine mount. For additional information, refer to ENGINE MOUNT  in this service information.
  8. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY  in this service information.
    9. NOTE: Only hand-tighten the bolt or damage to the front cover can occur.
    Fig 4: Locating Standard 6mm x 18 mm Crankshaft Pulley Bolt
    G07780588Courtesy of FORD MOTOR CO.
  9. Install a standard 6 mm x 18 mm bolt through the crankshaft pulley and thread it into the front cover.
  10. Install the CKP sensor and the 2 bolts.
    • Do not tighten the bolts at this time.
    Fig 5: Locating CKP Sensor And Bolts
    G07780589Courtesy of FORD MOTOR CO.
  11. Using the Crank Alignment Tool, adjust the CKP sensor.
    • Tighten the bolts to 7 Nm (62 lb-in).
    Fig 6: Adjusting Crankshaft Sensor Using Crank Alignment Tool
    G07780590Courtesy of FORD MOTOR CO.
  12. Connect the CKP sensor electrical connector.
  13. Remove the 6 mm x 18 mm bolt.
    Fig 7: Locating Crankshaft Pulley Bolt In Hole
    G07780591Courtesy of FORD MOTOR CO.
  14. If equipped, install the underbody cover and the 7 screws.
    Fig 8: Locating Underbody Cover Screws
    G07780592Courtesy of FORD MOTOR CO.
  15. Install the accessory drive belt and the accessory drive idler pulley. For additional information, refer to ACCESSORY DRIVE - 2.5L -- FUSION & MILAN (EXCEPT HYBRID) article.
  16. Tighten the 3 coolant pump pulley bolts to 20 Nm (177 lb-in).
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