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Home >> Ford >> 2021 >> Explorer Limited Hybrid, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 16 (Engine - 2.3L ECOBOOST (201KW/273PS)) >> Removal And Installation >> Engine Front Cover >> Installation

Engine Front Cover: Installation

WARNING: This page is about a different variant/trim than selected.
  1. 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.

    • Apply a 3 mm (0.12 in) bead of silicone sealant on the 3 upper bosses, as shown.

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

    • Apply a 4 mm (0.16 in) bead of silicone sealant on the chamfer on the 2 lower bosses, as shown.

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

    • Apply a 5 mm (0.19 in) bead of silicone sealant on the chamfer, as shown.

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

    GFD510533Courtesy of FORD MOTOR COMPANY
  2. 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.

    Apply a 15 mm (0.59 in) drop of silicone sealant at the cylinder head-to-cylinder block and cylinder block-to-oil pan joint areas.

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

    GFD510534Courtesy of FORD MOTOR COMPANY
  3. 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: 97 lb.in (11 Nm)

    Fig 1: Engine Front Cover Tightening Sequence
    GFD510535Courtesy of FORD MOTOR COMPANY
  4. Attach wiring harness retainers to the engine front cover and stud bolts.
    GFD510529Courtesy of FORD MOTOR COMPANY
  5. Install the coolant pump pulley and bolts finger-tight.
    GFD510528Courtesy of FORD MOTOR COMPANY
    • Lubricate the crankshaft front seal with clean engine oil.

    • NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.

      Using the special tools, install the crankshaft front seal. Use Special Service Tool: 303-096 (T74P-6150-A) Installer, Camshaft Front Oil Seal.

    GFD510462Courtesy of FORD MOTOR COMPANY
  7. Lubricate the crankshaft pulley with clean engine oil.
    GFD510479Courtesy of FORD MOTOR COMPANY
  8. Position the crankshaft pulley onto the crankshaft with the access hole at the 6 o'clock position.
    GFD510480Courtesy of FORD MOTOR COMPANY
  9. NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

    Install an M6 bolt.

    GFD510481Courtesy of FORD MOTOR COMPANY
  10. 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.

    With the aid of an assistant and 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°

    GFD510536Courtesy of FORD MOTOR COMPANY
  11. Remove the M6 bolt.
    GFD510483Courtesy of FORD MOTOR COMPANY
  12. NOTE: Do not tighten the CKP sensor bolts at this time.

    Install the CKP sensor and the bolts finger tight.

    GFD510484Courtesy of FORD MOTOR COMPANY
  13. Install the special tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel and tighten the bolts. Use Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.

    Torque: 97 lb.in (11 Nm)

    GFD510485Courtesy of FORD MOTOR COMPANY
  14. Remove Special Service Tool: 303-1521 Alignment Tool, Crankshaft Position Sensor.
    GFD510486Courtesy of FORD MOTOR COMPANY
  15. Connect the CKP sensor electrical connector.
    GFD510487Courtesy of FORD MOTOR COMPANY
  16. Remove Special Service Tool: 303-507 Timing Peg, Crankshaft TDC.
    GFD510488Courtesy of FORD MOTOR COMPANY
  17. Install the engine plug bolt.

    Torque: 177 lb.in (20 Nm)

    GFD510489Courtesy of FORD MOTOR COMPANY
  18. Remove Special Service Tool: 303-1685 Alignment Tool, Camshaft.
    GFD510526Courtesy of FORD MOTOR COMPANY
    • Remove the oil pan drain plug and drain the engine oil. Use the General Equipment: Oil Drain Equipment

    • Install the oil drain plug.

      Torque: 20 lb.ft (27 Nm)

    GFD510436Courtesy of FORD MOTOR COMPANY
  20. Remove and discard the engine oil filter. Use the General Equipment: Oil Drain Equipment
    GFD510437Courtesy of FORD MOTOR COMPANY
  21. Lubricate the new engine oil filter sealing surface with clean engine oil and install.

    Torque: Stage 1: 71 lb.in (8 Nm) - - Stage 2: 180°

    GFD510438Courtesy of FORD MOTOR COMPANY
  22. Install the rear underbody shield, bolts and the pin-type retainers.

    Torque: 22 lb.in (2.5 Nm)

    GFD510498Courtesy of FORD MOTOR COMPANY
    • Install the underbody shield and the bolts.

      Torque: 22 lb.in (2.5 Nm)

    • Install pin-type retainer.

    GFD510470Courtesy of FORD MOTOR COMPANY
  24. Install the following items:

    1. Install the high-pressure fuel pump drive unit. Refer to: High-Pressure Fuel Pump Drive Unit .
    2. Install the accessory drive belt tensioner. Refer to: Accessory Drive Belt Tensioner .
    3. Install the accessory drive belt. Refer to: Accessory Drive Belt .

  25. Tighten the coolant pump pulley bolts.

    Torque: 18 lb.ft (25 Nm)

    GFD510525Courtesy of FORD MOTOR COMPANY
    • Install the air cleaner bracket and the bolts.

      Torque: 59 lb.ft (80 Nm)

    • Attach the wiring harness retainer.

    • Attach the coolant hose retainer.

    GFD510524Courtesy of FORD MOTOR COMPANY
  27. Install the air cleaner inlet tube.
    GFD510468Courtesy of FORD MOTOR COMPANY
  28. Install the EVAP canister tube and connect the quick release coupling and the retainer. Refer to: QUICK RELEASE COUPLING - 2.3L .
    GFD510523Courtesy of FORD MOTOR COMPANY
  29. Install the following items:

    1. Install the EVAP canister purge valve. Refer to: Evaporative Emission Canister Purge Valve .
    2. Install the air cleaner outlet. Refer to: Air Cleaner Outlet Pipe .
    3. Install the air cleaner. Refer to: Air Cleaner .

  30. Connect the battery ground cable. Refer to: BATTERY CABLES - 2.3L ECOBOOST (201KW 273PS) .
    1. NOTE: Lubricating the grommets with silicone grease will aid in the installation of the engine appearance cover, and any future removal and installation of the cover.

      Lubricate each grommet with silicone grease.

      Material: Motorcraft® Silicone Brake Caliper Grease and Dielectric Compound / XG-3-A (ESE-M1C171-A)

    2. Position the engine appearance cover onto engine with the grommet aligned with the stud.
    3. Press down on the engine appearance cover at the grommet location to attach the grommet onto the stud and install the nuts.

      Torque: 44 lb.in (5 Nm)

    GFD510490Courtesy of FORD MOTOR COMPANY
  32. Install the suspension support bar and the bolts.

    Torque: 22 lb.ft (30 Nm)

    GFD510466Courtesy of FORD MOTOR COMPANY
  33. Fill the engine with clean engine oil. Refer to: Specifications .
    GFD510439Courtesy of FORD MOTOR COMPANY
  34. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
  35. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
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