Engine Front Cover: Installation

WARNING: This page is about a different variant/trim than selected.

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.
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 silicone gasket remover and allow to set for several minutes.
3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply 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.
5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the Alignment Pins.
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 silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

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 4 inner bolt bosses.
- 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 5 places as indicated.
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 to 3 Nm (27 lb-in).
Remove the Alignment Pins.
NOTE: Do not tighten the bolt at this time.

Install the M6 engine front cover bolt.
NOTE: Do not tighten the bolts at this time.

Install the 2 upper M10 engine front cover bolts.
NOTE: Do not allow the A/C compressor to contact the subframe. Failure to follow this direction may result in damage to the A/C compressor.

NOTE: Do not tighten the bolt at this time.

Using the floor jack, lower the engine to allow installation of the lower M10 engine front cover bolt.
- Install the lower M10 engine front cover bolt.
NOTE: Do not expose the Motorcraft® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown below in 7 stages:
- Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in).
- Stage 2: Tighten bolts 23, 24 and 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, 24 and 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.
Install the engine mount bracket and the 2 bolts.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 1: Locating Engine Mount Bracket Bolts
  Courtesy of FORD MOTOR CO.
Use the floor jack to raise the engine to the installed position and install the engine mount and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).
Install the 4 engine mount nuts.
- Tighten to 63 Nm (46 lb-ft).
Install the engine mount brace, nut and bolt.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 2: Locating Engine Mount Brace Nut And Bolt
  Courtesy of FORD MOTOR CO.
Tighten the transaxle mount through bolt to 175 Nm (129 lb-ft).

Fig 3: Locating Transaxle Mount Bolt
Courtesy of FORD MOTOR CO.
Install the power steering pump and the 2 lower bolts.
- Tighten to 25 Nm (18 lb-ft).
Install the upper power steering pump bolt.
- Tighten to 25 Nm (18 lb-ft).
Install the power steering reservoir and the 2 nuts.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 4: Locating Power Steering Reservoir Nut
  Courtesy of FORD MOTOR CO.
Install the degas bottle and the 3 bolts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 5: Locating Degas Bottle Bolts
  Courtesy of FORD MOTOR CO.
Position the generator and install the stud and nut.
- Tighten the stud to 8 Nm (71 lb-in).
- Tighten the nut to 47 Nm (35 lb-ft).
- Tighten the bolt to 47 Nm (35 lb-ft).
Connect the PCM electrical connector.
Install the radio interference capacitor wire and the nut to the engine front cover stud.
- Tighten to 10 Nm (89 lb-in).
Install the ground wire and bolt on the engine front cover.
- Tighten to 10 Nm (89 lb-in).
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 6: Locating A/C Pressure Tube Nut
  Courtesy of FORD MOTOR CO.
Install the A/C pressure tube bracket and bolt.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 7: Locating A/C Pressure Tube Bracket And Bolt
  Courtesy of FORD MOTOR CO.
Install the A/C suction tube and connect the fitting.
- Install the safety clip onto the fitting.
  
  Fig 8: Locating A/C Suction Tube Fitting Safety Clip
  Courtesy of FORD MOTOR CO.
Using a new O-ring seal, install the A/C suction tube and bolt.
- Tighten to 9 Nm (80 lb-in).
Install the LH and RH valve covers. For additional information, refer to VALVE COVER - LH and VALVE COVER - RH .
Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM .
If equipped, attach the engine block heater harness to the radiator support, the A/C suction tube and the engine wiring harness.

Fig 9: Locating Engine Block Heater Harness Retainers
Courtesy of FORD MOTOR CO.
Install the RH front halfshaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
Tighten the 2 engine roll restrictor through bolts to 115 Nm (85 lb-ft).
Install the roll restrictor heat shield and the 2 nuts.
- Tighten to 9 Nm (80 lb-in).
NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.

Fig 10: Locating Crankshaft Front Seal Installer
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.

Fig 11: Installing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
- Stage 1: Tighten to 120 Nm (89 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
  
  Fig 12: Installing Crankshaft Pulley Washer And Bolt Using Strap Wrench
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt, tensioner and the power steering belt. For additional information, refer to ACCESSORY DRIVE BELT .
Install the engine appearance cover. For additional information, refer to ENGINE APPEARANCE COVER - EXPLODED VIEW .
NOTE: Do not expose the Motorcraft® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

Fill the engine with clean engine oil.
Connect the battery ground cable. For additional information, refer to BATTERY, BATTERY MOUNTING & BATTERY CABLES .
Evacuate and recharge the A/C system. For additional information, refer to HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.