Engine Front Cover: Installation

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

Using the special tools, install the engine front cover to coolant pipe seal. Use Special Service Tool: 205-149 (T80T-4000-R) Installer, Spindle Bearing, 205-153 (T80T-4000-W) Handle.

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Install Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

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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 and the 6 bolts 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. 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 inner bolt bosses.
  
  Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- 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 places as indicated.
  Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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NOTE: It will be necessary to obtain 2 W503297 (10mm HEX) M8 X 1.25 X 35 bolts and washers to replace the power steering bracket bolts during the front cover tightening process.

NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and the bolts.

Torque: 27 lb.in (3 Nm)

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Remove Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

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NOTE: After the tightening sequence is completed, bolts 10 and 18 will be removed to accommodate installation of the power steering pump assembly and bolts.

Install the remaining engine front cover bolts.

Torque: Stage 1: Tighten bolts 1 thru 21 to: 89 lb.in (10 Nm) Stage 2: Tighten bolts 1 thru 20 to: 18 lb.ft (24 Nm) Stage 3: Tighten bolt 21 to: 177 lb.in (20 Nm) Stage 4: Tighten bolt 21 an additional: 90 deg. Stage 5: Tighten bolt 22 to: 89 lb.in (10 Nm) Stage 6: Tighten bolt 22 an additional: 45 deg.

Fig 1: Engine Front Cover Tightening Sequence
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Install the upper intake manifold support bracket and the bolt finger-tight.

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Remove the bolts.

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NOTE: Do not tighten the bolts at this time.

Position the power steering pump and hoses and install the bolts by hand.

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Install the power steering pump bracket stud bolt.
Torque: 27 lb.in (3 Nm)

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1. Tighten the bolt.
  Torque: 26 lb.ft (35 Nm)
2. Tighten the bolt.
  Torque: 26 lb.ft (35 Nm)
3. Tighten the stud bolt.
  Torque: 19 lb.ft (26 Nm)
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Install the wiring harness conduit and nut.
Torque: 71 lb.in (8 Nm)

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Install the wiring harness conduit bolt.
Torque: 106 lb.in (12 Nm)

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Attach the wiring harness retainer to the accessory drive belt tensioner.

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- Remove the oil pan drain plug and drain the engine oil. Use the General Equipment: Oil Drain Equipment
- Install the oil pan drain plug.
  Torque: 20 lb.ft (27 Nm)
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Remove and discard the engine oil filter.

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NOTE: Do not lubricate the engine oil filter seal.

Install a new engine oil filter.

Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 180 deg.

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1. Install the stud bolt.
  Torque: 71 lb.in (8 Nm)
2. Install the generator.
3. Install the bolt.
  Torque: 35 lb.ft (47 Nm)
4. Install the nut.
  Torque: 35 lb.ft (47 Nm)
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Install the accessory drive belt tensioner and the bolts.
Torque: 18 lb.ft (25 Nm)

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Install the following items:
1. Refer to: Coolant Pump .
2. Refer to: Crankshaft Front Seal .
3. Refer to: Valve Cover RH .
4. Refer to: Valve Cover LH .
Tighten the coolant pump pulley bolts.
Torque: 18 lb.ft (24 Nm)

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Tighten the bolt for the upper intake manifold support bracket.
Torque: 89 lb.in (10 Nm)

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Fill the engine with clean engine oil. Refer to: Specifications .
Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

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Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure using a diagnostic scan tool.