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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2007 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: 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. Use a plastic scraping tool to remove all traces of the old front cover gasket and the silicone sealer.
  1. Clean and inspect the gasket mating surfaces. Use silicone gasket remover and metal surface prep and a plastic scraping tool. Follow the directions on the packaging.
  2. Position the front cover gasket.
    3. CAUTION: If not secured within 4 minutes, the sealant must be removed and the sealing area 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 Gasket And Sealant To Oil Pan And Engine Block Mating Surfaces
    GF0009334Courtesy of FORD MOTOR CO.
  3. Apply silicone gasket and sealant to the oil pan and engine block mating surfaces.
    4. CAUTION: If not secured within 4 minutes, the sealant must be removed and the sealing area 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 2: Applying Silicone Gasket And Sealant To Front Cover In Two Places
    GF0009335Courtesy of FORD MOTOR CO.
  4. Apply silicone gasket and sealant to the front cover in 2 places.
    5. NOTE: Make sure the coolant bypass hose is attached to the coolant pump.
    NOTE: Make sure the stud bolts are installed in their original positions.
  5. Position the engine front cover and install the 5 bolts and 5 stud bolts.
    • Tighten to 19 Nm (14 lb-ft).
  6. Install the 5 cylinder block cradle-to-front cover bolts.
    • Tighten bolts without washers to 14 Nm (10 lb-ft).
  7. Attach the wiring harness to the LH cylinder head and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
  8. Position the bypass hose clamp.
    Fig 3: Locating Bypass Hose Clamp
    GF0009324Courtesy of FORD MOTOR CO.
  9. Connect the lower radiator hose to the coolant pump.
  10. Connect the heater hose to the coolant pump.
  11. Install new wiring harness anchors and position the CKP sensor wiring.
  12. Attach the wiring harness retainer.
  13. Connect the CKP sensor electrical connector.
  14. Position the power steering and A/C compressor bracket and install the bolts.
    • Tighten to 42 Nm (31 lb-ft).
  15. Position the generator bracket and install the bolts.
    • Tighten to 42 Nm (31 lb-ft).
  16. Position the accessory drive belt tensioner and install the bolt.
    • Tighten to 47 Nm (35 lb-ft).
  17. Connect the generator electrical connectors.
  18. Attach the generator terminal and install the nut.
    • Tighten to 8 Nm (71 lb-in).
  19. Position the A/C tube bracket and install the nut.
    • Tighten to 20 Nm (15 lb-ft).
  20. Drain the engine oil. Install the drain plug when finished.
    • Tighten to 26 Nm (19 lb-ft).
  21. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal  in this article.
  22. Fill the engine with clean engine oil.
  23. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  24. Fill the engine cooling system. For additional information, refer to ENGINE COOLING article.
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