Engine Front Cover - Plug-In Hybrid Electric Vehicle (PHEV): Installation

1.

NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean all mating surfaces with

Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A

Material: Motorcraft ® Metal Surface Prep / ZC-31-A

2.

NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft ® Metal Surface Prep.

Apply a continuous bead of the specified diameter from the specified tube.

Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

GFD70826

Courtesy of FORD MOTOR COMPANY

3.

NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft ® Metal Surface Prep.

Apply a continuous bead of the specified diameter from the specified tube.

Material: Motorcraft ® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)

GFD70827

Courtesy of FORD MOTOR COMPANY

4.

Torque:
Stage 1: bolts 1 - 17: 89 lb.in (10 Nm)

Stage 2: bolts 18-21: 35 lb.ft (48 Nm)

Fig 1: Engine Front Cover (PHEV) Tightening Sequence

GFD70828

Courtesy of FORD MOTOR COMPANY

5.

Torque: 28 lb.ft (38 Nm)

GFD70824

Courtesy of FORD MOTOR COMPANY

6.

Install the following items:
- Refer to: Engine Mount .
- Refer to: Crankshaft Front Seal .

7.

GFD70823

Courtesy of FORD MOTOR COMPANY

8.

NOTE: Only hand-tighten the bolt or damage to the front cover can occur.

M6 Bolt.

GFD70787

Courtesy of FORD MOTOR COMPANY

9.

NOTE: Do not tighten the bolts at this time.

GFD70822

Courtesy of FORD MOTOR COMPANY

10.

Use Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.
Torque: 62 lb.in (7 Nm)

GFD70785

Courtesy of FORD MOTOR COMPANY

11.

Remove the M6 Bolt.

GFD70787

Courtesy of FORD MOTOR COMPANY

12.

Torque: 89 lb.in (10 Nm)

GFD70832

Courtesy of FORD MOTOR COMPANY

13.

Torque:
1: 89 lb.in (10 Nm)

2: 133 lb.in (15 Nm)

GFD70834

Courtesy of FORD MOTOR COMPANY

14.
- Refer to: Cooling System Draining, Filling and Bleeding .
- Refer to: Air Conditioning (A/C) System Recovery, Evacuation And Charging .