Engine Front Cover: Installation

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

Install new engine front cover gaskets.

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Lubricate and install a new oil gallery seal (6G068).
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

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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 must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

Apply a 9 mm (0. 35 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the cylinder block skirt-to-cylinder block joint and the cylinder head-to-cylinder block joint areas as indicated.

Material: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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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 must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

Apply a 4. 5 mm (0. 18 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)

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Install the engine front cover and the fasteners.
Torque:

Stage 1: Tighten bolts 1 thru 11 to: 18 lb. ft (24 Nm)

Stage 2: Tighten bolts 12 thru 13 to: 35 lb. ft (48 Nm)

Stage 3: Tighten bolts 14 thru 21 to: 18 lb. ft (24 Nm)

Fig 1: Engine Front Cover Tightening Sequence
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Release the coolant hoses and wiring harness.

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Install the insulator and the fasteners.
Torque: 89 lb. in (10 Nm)

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Lubricate the engine front cover bore with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

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Using the special tools, install the new crankshaft front oil seal. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal., 303-1531 Installer, Front Crank Seal and Damper.

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Lubricate the crankshaft front seal inner lip with clean engine oil.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

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Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
Material: Engine Oil - SAE 5W-30 - Synthetic Blend Motor Oil / XO-5W30-Q1SP (WSS-M2C946-B1)

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Using the special tools, install the crankshaft pulley. Use Special Service Tool: 303-335 (T88T-6701-A) Installer, Front Cover Oil Seal., 303-1531 Installer, Front Crank Seal and Damper.

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Install a new crankshaft pulley bolt finger tight.

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Using the floor jack, raise the engine to the installed position. Use the General Equipment: Wooden Block Use the General Equipment: Trolley Jack

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- Lubricate the inside and the outside diameter of the grommet with clean engine coolant.
  Material: Motorcraft ® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)
- Install the grommet so it is flush with the rear of the coolant pump housing.
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NOTE: Verify the front cover dowel pins are aligned to the coolant pump and that the coolant pump is fully seated prior to installing the fasteners.
- Using a new gasket, install the coolant pump and the fasteners.
  Torque:
  
  Fasteners 1-7:Stage 1: 89 lb. in (10 Nm)
  
  Stage 2: 45 °
- Torque: Fastener 8: 18 lb. ft (24 Nm)
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Install the coolant pump pulley and the bolts.
Torque: 89 lb. in (10 Nm)

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NOTE: Hand tighten fasteners only at this time.
1. Position the engine mount.
2. Install the engine mount-to-engine nuts and hand tighten.
3. Install the engine mount-to-frame bolts and hand tighten.
4. Install the engine mount-to-frame nut and hand tighten.
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Tighten the engine mount-to-engine nuts.
Torque: 59 lb. ft (80 Nm)

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Remove. Use the General Equipment: Wooden Block Use the General Equipment: Trolley Jack

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1. Tighten the engine mount-to-frame bolts.
  Torque: 81 lb. ft (110 Nm)
2. Tighten the engine mount-to-frame nut.
  Torque: 81 lb. ft (110 Nm)
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NOTE: Use a universal pulley holder (such as an OTC 4754, or equivalent).

Using a universal pulley holder, tighten the new crankshaft pulley bolt.

Torque:

Stage 1: 166 lb. ft (225 Nm)

Stage 2: Loosen: 360 °

Stage 3: 26 lb. ft (35 Nm)

Stage 4: 270 °

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1. Connect the lower radiator hose. Use the General Equipment: Hose Clamp Remover/Installer
2. Connect the heater hose. Use the General Equipment: Hose Clamp Remover/Installer
3. Attach the heater hose retainer.
4. Install the bolt.
  Torque: 80 lb. in (9 Nm)
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Attach the wiring harness retainers.

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Install the splash shield and the retainers.

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Install the stands. Install the General Equipment: Vehicle/Axle Stands

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1. Remove and discard the subframe bolts.
2. Remove the bolts and the subframe brackets.
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Remove and discard the subframe bolts.

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Using the adjustable stands lower the LH side of the subframe 20 mm (0. 75 in) and lower the RH 65 mm (2. 5 in). Use the General Equipment: Vehicle/Axle Stands

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Install a new oil pump seal.

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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 oil pan must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.
1. Apply a 4. 5 mm (0. 18 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the new oil pan.
  Material: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
2. Apply a 9 mm (0. 35 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-cylinder block joint areas on the new oil pan.
  Material: Motorcraft ® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
3. Inspect the crankcase ventilation passages to make sure they are not blocked by any sealer applied.
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Install the oil pan and the bolts.
Torque:

Stage 1: 31 lb. in (3. 5 Nm)

Stage 2: 89 lb. in (10 Nm)

Fig 2: Oil Pan Tightening Sequence
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Using the adjustable stands raise the subframe into the installed position. Use the General Equipment: Vehicle/Axle Stands

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NOTE: Align the reference marks made during removal.

NOTE: Only tighten the bolts finger tight at this stage.

Install the new subframe bolts.

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NOTE: Align the reference marks made during removal.

NOTE: Only tighten the bolts finger tight at this stage.
1. Install the subframe brackets and the new subframe bolts.
2. Install the subframe bracket bolts.
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NOTE: While tightening the subframe bolts, make sure the front subframe does not move.

Tighten the subframe bolts.

Torque: 173 lb. ft (235 Nm)

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1. Tighten.
  Torque:
  
  Stage 1: 76 lb. ft (103 Nm)
  
  Stage 2: 270 °
2. Tighten.
  Torque: 35 lb. ft (48 Nm)
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Remove. Use the General Equipment: Vehicle/Axle Stands

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Install the cooling module support panel and the fasteners.
Torque: 177 lb. in (20 Nm)

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Install the subframe support bracket and the nuts.
Torque: 33 lb. ft (45 Nm)

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NOTE: Use the internal or external hex-holding feature to prevent the ball and stud from turning while removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while tightening the link nuts or damage to the boot seal will occur.

Position the RH sway bar link and install the new nut.

Torque: 85 lb. ft (115 Nm)

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Install the RH ride height sensor. Refer to : Front Suspension Height Sensor .
Install the underbody shields and the retainers.

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If equipped, install the front underbody straps and the retainers.

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Remove the cooling module support.

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Install the oil level indicator.

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Position the generator and install the stud and bolt.
Torque:

Stud: 71 lb. in (8 Nm)

Bolt: 35 lb. ft (47 Nm)

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Install the idler pulley and the bolt.
Torque: 35 lb. ft (48 Nm)

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1. Install the M8 x 50 mm bolt.
  Torque: 18 lb. ft (25 Nm)
2. Install the M10 x 43 mm bolt.
  Torque: 35 lb. ft (47 Nm)
3. Install the M8 x 30 mm bolt and the A/C compressor mounting bracket.
  Torque: 18 lb. ft (25 Nm)
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1. Remove the support, position the A/C compressor and install the stud bolt.
  Torque: 18 lb. ft (25 Nm)
2. Install the bolt.
  Torque: 18 lb. ft (25 Nm)
3. Install the stud.
  Torque: 89 lb. in (10 Nm)
4. Install the nut.
  Torque: 18 lb. ft (25 Nm)
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Attach the wiring harness retainers, connect the A/C compressor electrical connectors and slide down the insulator.

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Position the A/C line bracket onto the generator stud.

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Install the generator nut.
Torque: 35 lb. ft (47 Nm)

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Install the following items:
1. Refer to: Oil Pressure Control Solenoid .
2. Refer to: Accessory Drive Belt Tensioner .
3. RH fender splash shield. Refer to : Fender Splash Shield .
4. Refer to: Valve Cover RH .
5. Refer to: Valve Cover LH .
6. Refer to: Powertrain Control Module (PCM) .
7. Refer to: Degas Bottle .
Install a new engine oil filter and fill the engine with clean engine oil. Refer to : Engine Oil Draining and Filling .
Connect the battery ground cable. Refer to : Battery Disconnect and Connect .
Fill and bleed the engine cooling system. Refer to : Cooling System Draining, Vacuum Filling and Bleeding .
Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.