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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2010 Lincoln MKX and 2010 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.
  1. Raise the engine to the installed position.
    2. NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean front cover.
  2. Clean the engine front cover using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
    • Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
    3. NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces of engine block, cylinder heads, and oil pan. These tools can cause contamination that will cause premature engine failure. Remove all traces of the gasket.
  3. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.
    1. Remove any large deposits of silicone or gasket material.
    2. Apply silicone gasket remover and allow to set for several minutes.
    3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
    5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  4. Install the Alignment Pins.
    Fig 1: Identifying Alignment Pins
    G06074606Courtesy of FORD MOTOR CO.
    5. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
    NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
  5. Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
    • Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
      Fig 2: Identifying RTV Silicone Applying Area
      G06061993Courtesy of FORD MOTOR CO.
    6. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  6. Install the engine front cover and bolts 17, 18, 19 and 20.
    • Tighten in sequence to 3 Nm (27 lb-in).
      Fig 3: Identifying Engine Front Cover Bolts Tightening Sequence
      G06062616Courtesy of FORD MOTOR CO.
  7. Remove the Alignment Pins.
    Fig 4: Identifying Alignment Pins
    G06501064Courtesy of FORD MOTOR CO.
    8. NOTE: Do not tighten the bolt at this time.
  8. Lower the engine to allow installation of the engine mount bracket and lower bolt.
    • Install the engine mount bracket and lower bolt as an assembly.
      Fig 5: Locating Lower Engine Mount Bracket Bolt
      G06061986Courtesy of FORD MOTOR CO.
    9. NOTE: Do not tighten the bolts at this time.
  9. Raise the engine to the installed position.
    • Install the 2 upper engine mount bracket bolts.
      Fig 6: Locating Upper Engine Mount Bracket Bolts
      G06061985Courtesy of FORD MOTOR CO.
    10. NOTE: Do not expose the Motorcraft® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
  10. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in illustration in 2 stages:
    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in).
    • Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
      Fig 7: Identifying Engine Front Cover Bolts Tightening Sequence
      G06061998Courtesy of FORD MOTOR CO.
    11. NOTE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.
  11. Install the engine mount studs in the following sequence.
    1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.
    2. Clean all the thread sealer from the engine mount studs (old and new studs).
    3. Apply new Threadlock and Sealer to the engine mount stud threads.
    4. Install the 2 engine mount studs.
      • Tighten to 20 Nm (177 lb-in).
        Fig 8: Locating Engine Mount Studs
        G06061984Courtesy of FORD MOTOR CO.
  12. Install the engine mount bracket and the 2 bolts.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 9: Locating Engine Mount Bracket Bolts
      G06061983Courtesy of FORD MOTOR CO.
  13. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 10: Locating Engine Mount Bolts
      G06501054Courtesy of FORD MOTOR CO.
  14. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 11: Locating Engine Mount Nuts
      G06501053Courtesy of FORD MOTOR CO.
  15. Install the engine mount brace, nut and bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 12: Locating Engine Mount Brace Nut And Bolt
      G06501052Courtesy of FORD MOTOR CO.
  16. Tighten the transaxle mount through bolt to 175 Nm (129 lb-ft).
    Fig 13: Locating Transaxle Mount Through Bolt
    G06501051Courtesy of FORD MOTOR CO.
    17. NOTE: LH shown in illustration, RH similar.
  17. Install the LH and RH VCT  solenoids and bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 14: Locating Variable Camshaft Timing Solenoids Bolts
      G06501049Courtesy of FORD MOTOR CO.
  18. Install the power steering pump and the 3 bolts.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 15: Locating Power Steering Pump Bolts
      G06269976Courtesy of FORD MOTOR CO.
  19. Install the power steering reservoir and the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
      Fig 16: Locating Power Steering Reservoir Nuts
      G06501047Courtesy of FORD MOTOR CO.
  20. Install the degas bottle and the 3 bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 17: Locating Degas Bottle Bolts
      G06501046Courtesy of FORD MOTOR CO.
  21. Connect the 3 PCM electrical connectors.
    Fig 18: Locating PCM Electrical Connectors
    G06505104Courtesy of FORD MOTOR CO.
  22. Connect the purge valve electrical connector.
    Fig 19: Locating Purge Valve Electrical Connector
    G06505103Courtesy of FORD MOTOR CO.
  23. Install the radio interference capacitor, the ground wire and the nut to the cowl stud.
    • Tighten to 10 Nm (89 lb-in).
      Fig 20: Locating Ground Wire Nut
      G06501043Courtesy of FORD MOTOR CO.
  24. Install the radio interference capacitor wire, the ground wire and the nut to the engine front cover stud.
    • Tighten to 10 Nm (89 lb-in).
      Fig 21: Locating Ground Wire Nut
      G06501042Courtesy of FORD MOTOR CO.
  25. Install the ground wire and bolt on the engine front cover.
    • Tighten to 10 Nm (89 lb-in).
      Fig 22: Locating Ground Wire Bolt
      G06501041Courtesy of FORD MOTOR CO.
  26. Connect the 2 engine wiring harness connectors.
    Fig 23: Locating Engine Wiring Harness Connectors
    G06501040Courtesy of FORD MOTOR CO.
  27. Using a new O-ring seal, connect the A/C pressure tube fitting and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 24: Locating A/C Pressure Tube Fitting Nut
      G06501039Courtesy of FORD MOTOR CO.
  28. Install the A/C pressure tube bracket and bolt.
    • Tighten to 8 Nm (71 lb-in).
      Fig 25: Locating A/C Pressure Tube Bracket Bolt
      G06501038Courtesy of FORD MOTOR CO.
  29. Connect the A/C suction tube fitting.
    • Install the safety clip onto the fitting.
      Fig 26: Locating A/C Suction Tube Safety Clip
      G06501037Courtesy of FORD MOTOR CO.
  30. Install the LH and RH valve covers. For additional information, refer to VALVE COVER - LH  and VALVE COVER - RH .
  31. Install the engine Air Cleaner (ACL) and ACL  outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  32. If equipped, attach the engine block heater harness to the radiator support, the A/C suction tube and the engine wiring harness.
    Fig 27: Locating Engine Block Heater Harness And A/C Suction Tube
    G06501036Courtesy of FORD MOTOR CO.
  33. Install the RH front halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
  34. Install and the transaxle bracket and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 28: Locating Transaxle Bracket Bolts
      G06501035Courtesy of FORD MOTOR CO.
  35. Install the engine roll restrictor, transaxle bracket and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 29: Locating Transaxle Bracket Bolts
      G06501033Courtesy of FORD MOTOR CO.
  36. Tighten the engine roll restrictor-to-subframe through bolt to 103 Nm (76 lb-ft).
    Fig 30: Locating Engine Roll Restrictor-To-Subframe Through Bolt
    G06501034Courtesy of FORD MOTOR CO.
  37. Install the roll restrictor heat shield and the 2 nuts.
    • Tighten to 11 Nm (97 lb-in).
      Fig 31: Locating Roll Restrictor Heat Shield Nuts
      G06501032Courtesy of FORD MOTOR CO.
  38. Position the Y-pipe assembly in place and install the 4 nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 32: Locating Exhaust Flexible Pipe Nuts
      G06067902Courtesy of FORD MOTOR CO.
  39. Install the 2 exhaust hangers and tighten the exhaust clamp.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 33: Locating Exhaust Flexible Pipe Clamp
      G06501030Courtesy of FORD MOTOR CO.
    40. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
    Fig 34: Identifying Crankshaft Vibration Damper Installer And Front Crankshaft Installer
    G06061945Courtesy of FORD MOTOR CO.
  40. Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
    41. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
    Fig 35: Identifying Crankshaft Vibration Damper Installer And Front Cover Oil Seal Installer
    G06061939Courtesy of FORD MOTOR CO.
  41. Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.
  42. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
      Fig 36: Locating Crankshaft Pulley Washer And Bolt
      G06062017Courtesy of FORD MOTOR CO.
  43. Install the accessory drive belt, tensioner and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
    44. NOTE: Do not expose the Motorcraft® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
  44. Fill the engine with clean engine oil.
  45. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  46. Evacuate and recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
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