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Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine Mechanical - 3.5L-Ti-VCT >> Removal And Installation >> Engine Front Cover >> Installation

Engine Front Cover: Installation

  1. 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.

    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.

  2. 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.

    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 Motorcraft® Silicone Gasket Remover and allow to set for several minutes.
    3. Remove the Motorcraft® Silicone Gasket Remover. A second application of Motorcraft® Silicone Gasket Remover may be required if residual traces of silicone or gasket material remain.
    4. Apply Motorcraft® 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.
  3. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

    Install 307-399  .

    Fig 1: Identifying Cylinder Block Dowel Pins
    G08028972Courtesy of FORD MOTOR CO.
  4. 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 7, 8, 15, 17, 18, 21 and 22 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover 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 Motorcraft® Silicone Gasket Remover and Motorcraft® Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.

    Apply a 3 mm (0.1181 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the front cover.

    • Apply a 5.5 mm (0.22 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: Locating RTV Silicone Applying Area On Engine Front Cover Sealing Surfaces
    G08028973Courtesy of FORD MOTOR CO.
  5. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

    Install the engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22.

    • Tighten in sequence shown in illustration to 3 Nm (27 lb-in).
    Fig 3: Identifying Tightening Sequence Of Engine Front Cover Mounting Bolts
    G08028974Courtesy of FORD MOTOR CO.
  6. Remove 307-399  .
    Fig 4: Identifying Cylinder Block Dowel Pins
    G08028975Courtesy of FORD MOTOR CO.
  7. Install the M6 engine front cover bolt. Do not tighten at this time.
    Fig 5: Locating M6 Engine Front Cover Bolt
    G08028970Courtesy of FORD MOTOR CO.
  8. Install the 2 upper M10 engine front cover bolts. Do not tighten the bolts at this time.
    Fig 6: Locating Engine Front Cover Bolts (M10)
    G08028968Courtesy of FORD MOTOR CO.
  9. NOTE: It may be necessary to use the floor jack and lower the engine slightly to gain enough access to install the bolt.

    Install the lower M10 bolt. Do not tighten at this time.

    Fig 7: Locating Lower M10 Engine Front Cover Bolt
    G08028967Courtesy of FORD MOTOR CO.
  10. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts in the sequence shown in illustration in 7 stages.
    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in).
    • Stage 2: Tighten bolts 23 thru 25 to 15 Nm (133 lb-in).
    • Stage 3: Tighten bolt 26 to 10 Nm (89 lb-in).
    • Stage 4: Loosen bolt 26 one full turn.
    • Stage 5: Tighten bolts 23 thru 25 to 30 Nm (22 lb-ft) plus an additional 90 degrees.
    • Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lb-in) plus an additional 45 degrees.
    • Stage 7: Tighten bolt 26 to 10 Nm (89 lb-in) plus an additional 45 degrees.
    Fig 8: Identifying Tightening Sequence Of Engine Front Cover Bolts
    G08028979Courtesy of FORD MOTOR CO.
  11. Install the engine mount, 4 engine mount nuts and 3 engine mount bolts hand tight.
    Fig 9: View Of Engine Mount And Fasteners
    G08028966Courtesy of FORD MOTOR CO.
  12. Tighten the 3 engine mount bolts.
    • Tighten to 90 Nm (66 lb-ft).
  13. Tighten the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
  14. Connect the fuel supply tube to the fuel rail. REFER to QUICK CONNECT COUPLING .
    Fig 10: Locating Fuel Supply Tube Quick Connect Coupling
    G07417510Courtesy of FORD MOTOR CO.
  15. Install the bolt from the fuel supply tube to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).
    Fig 11: Locating Engine Front Cover Fuel Supply Tube Bracket Bolt
    G07417509Courtesy of FORD MOTOR CO.
  16. If equipped, connect the degas bottle coolant hose to the engine coolant tube.
    Fig 12: View Of Degas Bottle Coolant Hose Connected -To- Engine Coolant Tube
    G08028962Courtesy of FORD MOTOR CO.
  17. Install the vent hose to the degas bottle.
    Fig 13: Locating Degas Bottle Vent Hose Clamp
    G08028961Courtesy of FORD MOTOR CO.
  18. 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 14: Locating A/C Tube And Mounting Nut
    G08028960Courtesy of FORD MOTOR CO.
  19. Install the LH and RH valve covers. REFER to Valve Cover - LH  and Valve Cover - RH .
  20. If equipped, attach the engine block heater harness to the radiator support, the A/C  suction tube and the engine wiring harness.
  21. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 11 Nm (97 lb-in).
    Fig 15: Locating Drive Belt Tensioner Mounting Bolts
    G08028959Courtesy of FORD MOTOR CO.
  22. Install the crankshaft pulley and seal. REFER to Crankshaft Front Seal .
  23. Install the underbody air duct and the 3 twist lock retainers.
    Fig 16: Locating Underbody Air Duct And Twist Lock Retainers
    G07430766Courtesy of FORD MOTOR CO.
  24. Install the RH fender splash shield. REFER to FENDER SPLASH SHIELD .
  25. Connect the battery ground cable. REFER to BATTERY DISCONNECT .
  26. Install the engine appearance cover.
  27. Evacuate and recharge the A/C system. REFER to AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION, AND CHARGING .
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