Engine Front Cover: Installation

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

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 2 mm (0.078 in) and 3 mm (0.118 in) bead of silicone sealant as location shown.

Material

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

Material

: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

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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 beads of silicone gasket and sealant that are 2 mm (0.078 in) in diameter and 5 mm (0.19 in) in length across the cylinder head and cylinder block joint areas.

Material

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

Material

: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

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Install the engine front cover and the fasteners and tighten in the sequence shown.
Torque

:Bolts 1 - 3: 35 lb.ft (48 Nm) Bolts 4 - 22: 89 lb.in (10 Nm)

Fig 1: Engine Front Cover Bolts Tightening Sequence
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Attach the wiring harness retainers.

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Install the coolant pump pulley and the bolts.
Torque

: 177 lb.in (20 Nm)

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Remove the engine mount. Refer to: Engine Mount .
NOTE: If equipped, the diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.

NOTE: Early build engines are equipped with a diamond washers on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

If equipped, install the diamond washer onto the crankshaft.

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NOTE: Make sure a new component is installed.

NOTE: Component must be lubricated with clean engine oil.

Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal.

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Lubricate the crankshaft pulley with clean engine oil.
Material

: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

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Position the crankshaft pulley onto the crankshaft with the access hole at the 6 o'clock position.

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NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

Install an M6 bolt.

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NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Crank Damper Holding Tool and the bolt should be installed using hand tools only.

Using the special tool, install the new crankshaft bolt and washer and tighten. Use Special Service Tool: 303-1689 Holding Tool, Crank Damper.

Torque

:Stage 1: 74 lb.ft (100 Nm) Stage 2: 90°

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Remove the M6 bolt.

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NOTE: Do not tighten the CKP sensor bolts at this time.

Install the CKP sensor and the bolts.

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Install the Special Tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel. Use Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.
Torque

: 62 lb.in (7 Nm)

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Remove Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.

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Connect the CKP sensor electrical connector.

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Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.

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Install the engine plug bolt.
Torque

: 177 lb.in (20 Nm)

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Remove Special Service Tool: 303-1565 Alignment Tool, Camshaft.

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Using a wrench on the flats of the intake camshaft to prevent cam rotation, install the brake vacuum pump adapter.
Torque

: 46 lb.ft (63 Nm)

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Clean the rear intake camshaft cap.

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NOTE: The intake camshaft rear bearing cap must be secured within 10 minutes of gasket maker application. If the bearing cap is not secured within 10 minutes, the gasket maker must be removed.

Apply 1 mm (0.039 in) beads of gasket maker to the intake rear camshaft bearing cap mating surface as shown.

Material

: Motorcraft® Gasket Maker / TA-16 (WSK-M2G348-A5)

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NOTE: Wipe off any excess gasket maker from the vacuum pump sealing surface of the cylinder head and camshaft cap.

Install the rear intake camshaft cap and the bolts.

Torque

:Stage 1: 62 lb.in (7 Nm) Stage 2: 142 lb.in (16 Nm)

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Install the following items:
1. Refer to: Valve Cover .
2. Refer to: Brake Vacuum Pump - 2.0L EcoBoost (184kW/250PS) - MI4 .
3. Refer to: Accessory Drive Belt Tensioner .
4. Refer to: ACCESSORY DRIVE BELT
5. RH fender splash shield. Refer to: FENDER SPLASH SHIELD .
1. Install the underbody shield and the retainers.
2. Install the underbody shield reinforcement and the retainers.
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Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.