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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. If removed, install the front cover crankcase dowels into the cylinder block.
    Fig 1: Installing Front Cover Crankcase Dowels Into Cylinder Block
    G03887308Courtesy of FORD MOTOR CO.
    2. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
    Fig 2: Installing Guide Studs
    G03887309Courtesy of FORD MOTOR CO.
  2. Install the guide studs.
  3. Apply a bead of sealant at the seam where the crankcase and the lower crankcase meet.
    Fig 3: Applying Bead Of Sealant
    G03887310Courtesy of FORD MOTOR CO.
  4. Install a new engine front cover gasket.
    Fig 4: Installing Engine Front Cover Gasket
    G03887311Courtesy of FORD MOTOR CO.
  5. Install the engine front cover and bolts.
    Fig 5: Installing Engine Front Cover And Tightening Bolts
    G03921466Courtesy of FORD MOTOR CO.
  6. Install the oil pump. For additional information, refer to OIL PUMP .
  7. Install the battery cable bracket and nut.
    Fig 6: Installing Battery Cable Bracket And Nut
    G03906869Courtesy of FORD MOTOR CO.
    8. NOTE: Install a new O-ring seal on the coolant pump pulley.
    Fig 7: Installing O-Ring Seal On Coolant Pump Pulley
    G03887313Courtesy of FORD MOTOR CO.
  8. If removed, install the coolant pump and bolts.
  9. If removed, install the coolant pump pulley and bolts.
    Fig 8: Installing Coolant Pump Pulley And Bolts
    G03887314Courtesy of FORD MOTOR CO.
  10. If removed, install the drive idler pulleys and bolts.
    Fig 9: Installing Drive Belt Idler Pulley
    G03887719Courtesy of FORD MOTOR CO.
  11. Install the accessory drive belt tensioner and bolts.
    Fig 10: Accessory Drive Belt Tensioner Bolt - With Torque Specification
    G03887315Courtesy of FORD MOTOR CO.
  12. Position back the power steering pump and install the three bolts.
    Fig 11: Installing Power Steering Pump
    G03921472Courtesy of FORD MOTOR CO.
  13. Connect the lower radiator coolant hose.
    Fig 12: Connecting Lower Radiator Coolant Hose
    G03921454Courtesy of FORD MOTOR CO.
  14. Connect the heater hose at the front cover.
    Fig 13: Installing Heater Hose At Front Cover
    G03921453Courtesy of FORD MOTOR CO.
    15. NOTE: Install a new O-ring seal.
    Fig 14: Locating Stud Bolts And Thermostat Assembly - With Torque Specification
    G03887322Courtesy of FORD MOTOR CO.
  15. If removed, install the thermostat housing and stud bolts.

    16. Early build 

  16. Install the exhaust pressure bracket assembly and retaining nuts.
    Fig 15: Locating Retaining Nuts And Exhaust Backpressure Assembly - With Torque Specification
    G03906879Courtesy of FORD MOTOR CO.
  17. Connect the exhaust pressure tube fitting at the exhaust manifold.
    Fig 16: Exhaust Pressure Tube Fitting - With Torque Specification
    G03906880Courtesy of FORD MOTOR CO.

    18. All vehicles 

  18. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
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