Engine Front Cover: Installation

WARNING: This page is about a different car, the 2021 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.

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 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 mm (0.12 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover inner bolt bosses.
  
  Material
  
  : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Apply a 5 mm (0.19 in) bead of Motorcraft® High Performance Engine RTV Silicone on the chamfer, as shown.
  Material
  
  : Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Apply a 9 mm (0.35 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: 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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Install the remaining engine front cover bolts.
Torque:Stage 1: Tighten bolts 1 through 21 to: 89 lb.in (10 Nm); Stage 2: Tighten bolts 1 through 20 and 23 to: 177 lb.in (20 Nm); Stage 3: Tighten bolts 1 through 20 and 23 an additional: 45 deg.; Stage 4: Tighten bolt 21 to: 177 lb.in (20 Nm); Stage 5: Tighten bolt 21 an additional: 90 deg.; Stage 6: Tighten bolt 22 to: 89 lb.in (10 Nm); Stage 7: Tighten bolt 22 an additional: 45 deg.

Fig 1: Engine Front Cover Bolts Tightening Sequence
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Using the special tool and a hammer, install the oil pump electrical connector seal. Use Special Service Tool: 303-1663 Installer, VDOP Seal.

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Make sure the oil pump electrical connector seal is below the top of the oil pump electrical connector or the oil pump electrical connector seal may leak oil.

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Install the upper intake manifold support bracket and the bolt finger-tight.

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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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Connect the generator wiring to the engine front cover.

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Position the wiring harness and transmission cooler tube bracket and install the nut.
Torque: 106 lb.in (12 Nm)

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- Connect the oil pressure control solenoid wiring harness electrical connector.
- Attach the wiring harness retainers to the engine front cover.
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Position the cabin heater coolant pump and coolant hoses and install the bolts.
Torque: 62 lb.in (7 Nm)

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Connect the cabin heater coolant pump wiring harness electrical connector.

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Install the following items:
1. Install the coolant pump. Refer to: Coolant Pump .
2. Install the degas bottle. Refer to: Degas Bottle .
3. Install the crankshaft front seal. Refer to: Crankshaft Front Seal .
Connect the A/C compressor wiring harness electrical connectors and retainer.

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Position the wiring harness and install the wiring harness retainer in the oil pan.

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Position the ground wire and install the starter motor bolt.
Torque: 35 lb.ft (48 Nm)

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- Lubricate the oil filter seal with clean engine oil and install and tighten in 2 stages.
- Stage 1: Install to initial gasket contact.
- Stage 2: Tighten 3/4 to 1 turn.
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If equipped, install the skid plate and the bolts.
Torque: 30 lb.ft (40 Nm)

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- If equipped, remove the bolts and the skid plate.
  Torque: 30 lb.ft (40 Nm)
- If equipped, install the underbody shield and bolts.
  Torque: 30 lb.ft (40 Nm)
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If equipped, install the transmission housing cover and the bolts
Torque: 71 lb.in (8 Nm)

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Install the following items:
1. Install the RH valve cover. Refer to: Valve Cover RH .
2. Install the LH valve cover. Refer to: Valve Cover LH .
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 .

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Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
Pressurize the fuel system pressure. Refer to: Fuel System Pressure Release .
Fill the 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.