LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 689 (Engine - 4.6L (2V) - F-150) >> In-Vehicle Servicing >> Engine Front Cover >> Installation

Engine Front Cover: Installation

WARNING: This page is about a different car, the 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the CKP sensor and the CKP sensor bolt.
    • Tighten to 10 Nm (89 lb-in).
    2. 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 with 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.
    NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
  2. 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.
    3. Fig 1: Identifying Area For Silicone Gasket Application
    G03886057Courtesy of FORD MOTOR CO.
  3. Install the engine front cover with the engine front cover gasket on the front cover-to-cylinder block dowel and loosely install the bolts.
    4. Fig 2: Installing Engine Front Cover With Engine Front Cover Gasket On Front Cover-To-Cylinder Block Dowel
    GF0002613Courtesy of FORD MOTOR CO.
  4. Tighten the engine front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
    Item Part Number Description
    1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 53
    6 W706508 Stud Hex Shoulder Pilot, M8 x 1.25 x 50- M6 x 1 x 10
    7 N808586 Stud and Washer, Hex Head Pilot, M8 x 1.25 - M6 x 1 x 86.35
    8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    11 N808294 Bolt, Hex Head Pilot, M8 x 1.25 x 53
    12 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
    13 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
    14 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
    15 N806300 Stud Hex Shoulder Pilot, M8 x 1.25 x 1.25 x 91.1
    5. Fig 3: Identifying Tightening Sequence Of Engine Front Cover
    GF0002614Courtesy of FORD MOTOR CO.
  5. 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.
    6. Fig 4: Identifying Tightening Sequence Of Front Oil Pan Bolts
    G03920544Courtesy of FORD MOTOR CO.
  6. If equipped, install the transmission cooler tube support bracket and nut.
    • Tighten to 10 Nm (89 lb-in).
    7. Fig 5: Locating Transmission Cooler Tube Support Bracket
    GF0002611Courtesy of FORD MOTOR CO.
  7. Install the A/C manifold and tube assembly support bracket and nut.
    • Tighten to 10 Nm (89 lb-in).
    8. Fig 6: Locating A/C Manifold And Tube Assembly Support Bracket
    GF0002610Courtesy of FORD MOTOR CO.
  8. Connect the CKP sensor electrical connector.
  9. Position the RH radio interference capacitor and install the nut.
    • Tighten to 25 Nm (18 lb-ft).
  10. Position the upper radiator hose bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    11. Fig 7: Locating Upper Radiator Hose Bracket
    GF0002609Courtesy of FORD MOTOR CO.
  11. Position the LH radio interference capacitor and install the nut.
    • Tighten to 25 Nm (18 lb-ft).
  12. Install the CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
  13. Connect the CMP sensor electrical connector.
  14. Position the power steering pump and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    15. Fig 8: Locating Power Steering Pump Bolts
    GF0002608Courtesy of FORD MOTOR CO.
  15. Using the special tool, install a new O-ring seal on the pressure line fitting.
    16. Fig 9: Locating O-Ring Seal On Pressure Line Fitting
    GF0002615Courtesy of FORD MOTOR CO.
  16. Connect the power steering pressure tube.
    • Tighten to 65 Nm (48 lb-ft).
    17. Fig 10: Locating Power Steering Pressure Tube
    GF0002606Courtesy of FORD MOTOR CO.
  17. Position the power steering pressure tube support bracket and install the nut.
    • Tighten to 12 Nm (9 lb-ft).
    18. Fig 11: Locating Power Steering Pressure Tube Support Bracket
    GF0002607Courtesy of FORD MOTOR CO.
    CAUTION: If the pulley has been removed and installed twice, install a new power steering pump pulley.
  18. Using the special tool, install the power steering pump pulley.
    • Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint marks, install a new pulley. If there is one paint mark or none at all, use a pencil to mark the web area of the pulley near the hub.
    19. Fig 12: Installing Power Steering Pump Pulley Using Special Tool
    GF0002616Courtesy of FORD MOTOR CO.
  19. Install the 3 accessory drive belt idler pulleys and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  20. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  21. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    22. Fig 13: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  22. Using the special tools, install a new crankshaft front seal.
    23. Fig 14: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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.
  23. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
    24. Fig 15: Identifying Woodruff Key Slot On Crankshaft Pulley
    G03948080Courtesy of FORD MOTOR CO.
  24. Using the special tool, install the crankshaft pulley.
    25. Fig 16: Installing Crankshaft Pulley Using Special Tool
    G03919878Courtesy of FORD MOTOR CO.
  25. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages:
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees without exceeding 200 N.m (148 lb-ft).
    26. Fig 17: Locating Crankshaft Pulley Bolt
    GF0002598Courtesy of FORD MOTOR CO.
  26. Rotate the tensioner clockwise and install the drive belt.
    27. Fig 18: Rotating Tensioner Clockwise
    GF0000336Courtesy of FORD MOTOR CO.
  27. Install the LH valve cover. For additional information, refer to Valve Cover - LH  in this article.
  28. Install the RH valve cover. For additional information, refer to Valve Cover - RH  in this article.
  29. Install the cooling fan. For additional information, refer to ENGINE COOLING article.
  30. Fill the engine with clean engine oil.
scientia non olet · About LEMON Manuals