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.
- Apply beads of silicone sealant that are 2 mm (0.078 in) around the inner bolt holes.
  Material
  
  : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Apply a bead of silicone sealant that are 3 mm (0.00 in) on the edge of the engine front cover.
  Material
  
  : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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NOTE: The engine front cover must be secured within 10 minutes of silicone sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned.

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

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Install the engine front cover and the bolts in 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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- Position the vacuum valve and install the nuts.
  Torque: 89 lb.in (10 Nm)
- Attach the wiring harness retainer.
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Finger-tight. Install the coolant pump pulley and the bolts finger-tight.

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Install the accessory drive belt tensioner and the bolts.
Torque: 18 lb.ft (25 Nm)

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

NOTE: Lubricate the crankshaft front seal with clean engine oil.

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

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NOTE: Lubricate the crankshaft with clean engine oil.

Lubricate the crankshaft pulley with clean engine oil.

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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. 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: 180°

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Remove. Remove the M6 bolt.

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- Connect the CKP sensor electrical connector.
- NOTE: Do not tighten the CKP sensor bolts at this time.
  
  Install the CKP sensor and the bolts finger tight.
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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.
- Tighten the bolts.
  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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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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Position the A/C compressor and install the bolts.
Torque: 18 lb.ft (25 Nm)

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Connect the A/C compressor electrical connectors and the wire harness retainers.

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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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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: Brake Vacuum Pump - 2.3L EcoBoost (231kW/314PS)/2.3L EcoBoost (257kW/350PS) - MI4 .
2. Refer to: Valve Cover .
3. Refer to: ACCESSORY DRIVE BELT .
Tighten the coolant pump pulley bolts.
Torque: 177 lb.in (20 Nm)

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Install the air cleaner outlet pipe. Refer to: AIR CLEANER OUTLET PIPE .
Drain engine oil and install drain plug. Use the General Equipment: Oil Drain Equipment
Torque: 20 lb.ft (27 Nm)

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Remove and discard the engine oil filter. Use the General Equipment: Oil Drain Equipment

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NOTE: Lubricate the engine oil filter seal with clean engine oil.

Install a new engine oil filter.

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

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Fill the engine with clean engine oil. Refer to: SPECIFICATIONS .

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Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.