Engine Front Cover: Installation

Install new gaskets on the engine front cover.

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NOTE: The VCT variable force solenoid pins must be fully depressed to avoid interference with the VCT valve tips when installing the engine front cover. Failure to follow these instructions can result in damage to the engine.

NOTE: RH shown, LH similar.

Fully depress the VCT variable force solenoid pins.

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NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage.

Apply a 15 mm (0.59 in) diameter drop of silicone gasket and sealant to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints.

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

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NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before installation.

NOTE: Timing drive components removed from view for clarity.

Position the engine front cover onto the dowels.

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NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. Failure to follow this procedure can cause future oil leakage.

Install the bolts and stud bolts.

Torque: Stage 1: Fasteners 1-15 : 18 lb.ft (25 Nm) Stage 2: Fasteners 16-19 : 89 lb.in (10 Nm) Stage 3: Fasteners 1-15 : 60 deg. Stage 4: Fasteners 16-19 : 45 deg.

Fig 1: Engine Front Cover Bolts Tightening Sequence
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Install the wiring harness retainer and the nut.
Torque: 71 lb.in (8 Nm)

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Clean and inspect the coolant pump and cylinder block sealing surface.

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Install a new coolant pump O-ring seal and lubricate with clean engine coolant.

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Install the coolant pump and bolts.
Torque: Stage 1: 177 lb.in (20 Nm) Stage 2: 60 deg.

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1. Install the coolant pump pulley and the bolts.
  Torque: 18 lb.ft (25 Nm)
2. Install the accessory drive belt tensioner and the bolt.
  Torque: 35 lb.ft (48 Nm)
3. Install the generator and the fasteners.
  Torque: Stud: 71 lb.in (8 Nm) Bolt: 35 lb.ft (48 Nm) Nut: 35 lb.ft (48 Nm)
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Install a new thermostat housing O-ring seal and lubricate with clean engine coolant.

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1. Install the upper radiator hose T-connector/thermostat housing assembly and the clamp.
2. Install the thermostat housing bolts.
  Torque: 89 lb.in (10 Nm)
3. Install the degas bottle coolant hose and the clamp.
4. Connect the heater hose.
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Connect the lower radiator hose to the thermostat housing assembly.

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Connect the upper radiator hose to the radiator assembly.

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Install the following items:
1. Refer to: Crankshaft Front Seal
2. Refer to: Valve Cover LH
3. Refer to: Valve Cover RH
4. Refer to: Air Cleaner
5. Refer to: Air Cleaner Outlet Pipe
6. Refer to: Degas Bottle
NOTE: The drain plug should be removed and installed by hand, do not use tools.
1. Turn the oil drain plug by hand counterclockwise 120 degrees. Use the General Equipment: Oil Drain Equipment
2. Pull the oil drain plug out of the oil pan.
3. After the oil has drained, push the oil drain plug into the oil pan.
4. NOTE: Overtightening will damage the oil drain plug and possibly the oil pan.
  
  Turn the oil drain plug by hand clockwise 120 degrees.
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NOTE: GT vehicle shown, Mach 1 similar.

Remove and discard the engine oil filter.

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NOTE: GT vehicle shown, Mach 1 similar.

NOTE: Do not lubricate the O-ring seal.

Install a new oil filter.

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

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If equipped, install the subframe bracket and underbody shield assembly and the bolts.
Torque: Bracket bolts: 46 lb.ft (63 Nm) Underbody shield bolt: 18 lb.in (2 Nm)

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Fill the engine with clean engine oil. Refer to: Specifications
Connect the battery positive and ground cables. Refer to: Battery Disconnect and Connect
Pressurize the fuel system. Refer to: Fuel System Pressure Release
Fill and bleed the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding
Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
Road test the vehicle.