Engine Front Cover: Installation
- 2.NOTE: If the engine front cover is not secured within 5 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 3 mm bead of silicone sealant to the new engine front cover.
Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 3.NOTE: The component must be installed within 5 minutes of applying the sealant.
Install a 5 mm bead of silicone sealant to the T-joints.
Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- 4.
Using the special tool to align the engine front cover. Install the engine front cover, nuts and bolts. Tighten in the sequence shown in illustration in 3 stages.Use Special Service Tool: 303-682 Aligner, Engine Front Cover.
Torque:
Stage 1: 44 lb.in (5 Nm)
Stage 2: 89 lb.in (10 Nm)
Stage 3: 89 lb.in (10 Nm)
- 6.
Install the idler assembly. Install the accessory drive idler assembly and the bolts.Torque: 35 lb.ft (48 Nm)
- 7.
Position back the thermostat assembly and install the bolt. Release the coolant hose clamp.Use the General Equipment: Hose Clamp Remover/Installer
Torque: 17 lb.ft (23 Nm)
- 8.
Position back the engine wire harness and install the nut. Connect the electrical connectors.Torque: 89 lb.in (10 Nm)
- 9.
Connect the coolant hoses and hose retainer.Use the General Equipment: Hose Clamp Remover/Installer
- 13.
Install the generator bracket, lifting bracket and the bolts. Tighten the bolts in the sequence shown in illustration in 3 stages.Torque:
M8 bolts:
Stage 1: 133 lb.in (15 Nm)
Stage 2: 17 lb.ft (23 Nm)
Stage 3: 17 lb.ft (23 Nm)
M10 bolts:
Stage 4: 177 lb.in (20 Nm)
Stage 5: 35 lb.ft (48 Nm)
Stage 6: 35 lb.ft (48 Nm)
- 16.
Install the following items:- Install the generator. Refer to: Generator - 3.2L Duratorq-TDCi (148kW/200PS) - Puma .
- Install the crankshaft front seal. Refer to: Crankshaft Front Seal .
- Install the cooling fan motor and shroud. Refer to: Cooling Fan Motor and Shroud .
- 17.
Fill the cooling system. Refer to: Cooling System Draining, Vacuum Filling and Bleeding .
- 18.
Connect the battery ground cable. Refer to: Battery Disconnect and Connect - Vehicles With: Dual Batteries .