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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2009 Ford Mustang. 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 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. 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.
    NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
  1. 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.
    2. Fig 1: Applying A Bead Of Silicone Gasket And Sealant
    GF0002753Courtesy of FORD MOTOR CO.
  2. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.
    3. Fig 2: Installing Engine Front Cover Gasket On Engine Front Cover
    GF0015190Courtesy of FORD MOTOR CO.
  3. 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 Bolt, 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 N806177 Bolt, Hex Flange 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
    4. Fig 3: Identifying Tightening Sequence Of Engine Front Cover Fasteners
    GF0015191Courtesy of FORD MOTOR CO.
  4. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 20 N.m (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
    5. Fig 4: Identifying Tightening Sequence Of Front Oil Pan Bolts
    G03920544Courtesy of FORD MOTOR CO.
  5. Lubricate the engine front cover and the crankshaft front oil seal inner lip with clean engine oil.
    6. Fig 5: Lubricating Engine Front Cover And Crankshaft Front Seal Inner Lip
    GF0000315Courtesy of FORD MOTOR CO.
  6. Using the special tools, install the crankshaft front oil seal.
    7. Fig 6: Installing Crankshaft Front Seal Using Special Tools (303-102, 303-335, 303-635)
    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. 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.
  7. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
    8. Fig 7: Applying Silicone Gasket And Sealant To Woodruff Key Slot In Crankshaft Pulley
    GF0015184Courtesy of FORD MOTOR CO.
  8. Using the special tool, install the crankshaft pulley.
    9. Fig 8: Installing Crankshaft Pulley Using Special Tool (303-102)
    GF0000328Courtesy of FORD MOTOR CO.
  9. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 stages.
    • Stage 1: Tighten to 90 N.m (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 N.m (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
  10. Connect the CKP sensor electrical connector.
  11. Position the power steering pump assembly and install the stud bolts.
    • Tighten to 25 N.m (18 lb-ft).
  12. Install the wiring retainer on the power steering stud bolt.
    13. Fig 9: Locating Power Steering Stud Bolt
    GF0000326Courtesy of FORD MOTOR CO.
  13. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 25 N.m (18 lb-ft).
  14. Connect the LH CMP sensor electrical connector.
  15. Install the LH radio ignition interference capacitor and nut onto the engine front cover stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
  16. Connect the RH CMP sensor electrical connector.
  17. Install the RH radio ignition interference capacitor and the nut.
    • Tighten to 25 Nm (18 lb-ft).
  18. Connect the upper coolant hose to the engine.
  19. Install the RH valve cover. For additional information, refer to Valve Cover - RH .
  20. Install the LH valve cover. For additional information, refer to Valve Cover - LH .
  21. Install the accessory drive belt tensioner and 3 idler pulleys. For additional information, refer to ACCESSORY DRIVE .
  22. Fill the crankcase with clean engine oil.
  23. Install the engine coolant degas bottle. For additional information, refer to ENGINE COOLING .
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