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. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.
Make sure that the mating faces of the engine block are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper
Material
: Motorcraft ® Silicone Gasket Remover / ZC-30-A
Material
: Metal Brake Parts Cleaner / PM-4-A, PM-4-B
Material
: Motorcraft ® Metal Surface Prep / ZC-31-B
- 3.
Using the special tools, install the engine front cover to coolant pipe seal. Use Special Service Tool: 205-149 (T80T-4000-R) Installer, Spindle Bearing., 205-153 (T80T-4000-W) Handle.
- 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 inner bolt bosses.
Material
: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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 the 6 bolts 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 silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.- 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 places as indicated.
Material
: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- 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 inner bolt bosses.
- 6.NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and the bolts.
Torque
: 27 lb.in (3 Nm)
- 8.
Install the remaining engine front cover bolts. Tighten in the sequence shown below in 6 stages:Torque
: Stage 1: Tighten bolts 1 thru 21 to:: 89 lb.in (10 Nm) Stage 2: Tighten bolts 1 thru 20 to:: 18 lb.ft (24 Nm) Stage 3: Tighten bolt 21 to:: 177 lb.in (20 Nm) Stage 4: Tighten bolt 21 an additional:: 90 ° Stage 5: Tighten bolt 22 to:: 89 lb.in (10 Nm) Stage 6: Tighten bolt 22 an additional:: 45 °
- 10.
Position back the engine wiring harness. Position back the transmission cooler tube bracket and install the nut.Torque
: 106 lb.in (12 Nm)
- 15.
Install the following items:- Install the crankshaft front seal. Refer to: Crankshaft Front Seal .
- Install the coolant pump. Refer to: COOLANT PUMP .
- Install the RH valve cover. Refer to: Valve Cover RH .
- Install the LH valve cover. Refer to: Valve Cover LH .
- Install the intake manifold. Refer to: Intake Manifold .
- 16.NOTE: Do not lubricate the engine oil filter seal.
Install a new engine oil filter.
Torque
: Stage 1: 44 lb.in (5 Nm) Stage 2: 180 °
- 17.
- Install the turbocharger outlet tube and connect turbocharger outlet tube into the grommet. Tighten the clamps.
- Connect the turbocharger outlet tube hose.
Torque
: 44 lb.in (5 Nm)
- 18.
Install the turbocharger inlet tube and connect the turbocharger inlet tube into the grommet. Tighten the clamp at the turbocharger.Torque
: 44 lb.in (5 Nm)
- 20.
Connect the battery positive cable. Refer to: Battery Disconnect and Connect .
- 21.
Install the turbocharger outlet tube and connect turbocharger outlet tube into the grommet. Tighten the clamps.Torque
: 44 lb.in (5 Nm)
- 23.
Install the turbocharger inlet tube and connect the turbocharger inlet tube into the grommet. Tighten the clamp at the turbocharger.Torque
: 44 lb.in (5 Nm)
- 24.
Connect the quick connect couplings and the turbocharger bypass tube. Refer to: QUICK RELEASE COUPLING
- 25.
- 1.
Install the PCV tube. Refer to: QUICK RELEASE COUPLING .
- 2.
Connect the PCV pressure sensor electrical connector.
- 1.
- 27.
Connect the electrical connector and the wire retainer. Connect the quick connect coupling. Refer to: QUICK RELEASE COUPLING
- 28.
Install the air cleaner outlet pipe. Refer to: AIR CLEANER OUTLET PIPE .
- 30.
Fill the engine with clean engine oil. Refer to: Specifications .Material
: Motorcraft ® SAE 5W-30 Premium Synthetic Blend Motor Oil / XO-5W30-QSP (WSS-M2C946-A)
- 31.
Connect the battery ground cable. Refer to: Battery Disconnect and Connect .