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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 703 (Engine - 4.2L - 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.
    CAUTION: In order to prevent foreign material from contaminating the engine block or the engine front cover, it is necessary to seal the coolant and oil passages of both components. Failure to follow these directions will result in engine damage.
    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.
  1. Clean and inspect the engine block and engine front cover as follows:
    • Pack the exposed portion of the oil pan with clean shop towels.
    • Plug the oil and coolant passages.
    • Clean the gasket surfaces. Use silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Using compressed air, remove any remaining foreign material from the engine block and front cover.
    • Remove the shop towels from the oil pan.
    • Remove the plugs or seals from the oil and coolant passages.
  2. Apply thread sealant to the threads on the studs and the cap screw.
  3. Install the engine front cover studs.
    • Tighten to 7 Nm (62 lb-in).
    4. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing areas cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 1: Applying Silicone And Gasket
    GF0002393Courtesy of FORD MOTOR CO.
  4. Apply silicone gasket and sealant as shown.
  5. Install the engine front cover gasket.
    6. Fig 2: Identifying Engine Front Cover Gasket
    GF0002394Courtesy of FORD MOTOR CO.
    NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing areas cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  6. Apply silicone gasket and sealant to the oil pan as shown.
    7. CAUTION: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence.
    Fig 3: Installing Engine Front Cover
    GF0002395Courtesy of FORD MOTOR CO.
  7. Install the engine front cover and coolant pump.
    • Position the engine front cover and install the bolt, the stud bolts and the cap screw finger tight.
    • Position a new coolant pump gasket and the coolant pump and install the fasteners finger tight.
    • Tighten the fasteners in the sequence shown.
      • Tighten capscrew No. 12 to 10 Nm (89 lb-in).
      • Tighten all other fasteners to 28 Nm (21 lb-ft).
  8. If equipped, position the transmission cooler tube bracket and install the nut.
    • Tighten to 20 Nm (15 lb-ft).
  9. Install the accessory drive belt tensioner and the bolt.
    • Tighten to 55 Nm (41 lb-ft).
    Fig 4: Installing Accessory Drive Belt Tensioner And Bolt
    GF0002390Courtesy of FORD MOTOR CO.
  10. Install the 2 oil pan-to-engine front cover bolts.
    • Tighten to 10 Nm (89 lb-in).
  11. Install a new oil filter.
    • Tighten to 16 Nm (12 lb-ft).
  12. Connect the CKP sensor electrical connector.
    • Attach the wiring harness retainers to the engine front cover stud bolts.
  13. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal  in this article.
  14. Install the camshaft synchronizer. For additional information, refer to ELECTRONIC ENGINE CONTROLS article.
  15. Position the coolant pump pulley and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 5: Identifying Coolant Pump Pulley Bolts
    GF0002396Courtesy of FORD MOTOR CO.
  16. Position the A/C compressor and power steering pump pulley bracket brace and install the 2 bolts and 2 nuts.
    • Tighten the bolts to 48 Nm (35 lb-ft).
    • Tighten the nuts to 25 Nm (18 lb-ft).
    Fig 6: Identifying Power Steering Pump Pulley Bracket Brace Bolts And Nuts
    GF0002397Courtesy of FORD MOTOR CO.
    17. NOTE: Slide the power steering pump in while tightening the front lower bolt, then tighten the rear lower and 2 upper bolts.
  17. Tighten the power steering pump bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 7: Identifying Power Steering Pump Bolts
      GF0002391Courtesy of FORD MOTOR CO.
  18. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE article.
  19. Install the cooling fan and fan shroud. For additional information, refer to ENGINE COOLING article.
  20. Fill the engine with clean engine oil.
  21. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING article.
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