Engine Front Cover: Installation

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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 mm (0.12 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover inner bolt bosses.
  
  Material: RTV Silicone Sealant (WSE-M4G323-A6)
- Apply a 5 mm (0.19 in) bead of Motorcraft® High Performance Engine RTV Silicone on the chamfer, as shown.
  Material: RTV Silicone Sealant (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: RTV Silicone Sealant (WSE-M4G323-A6)
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NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

NOTE: It will be necessary to obtain 2 W503297 (10mm HEX) M8 X 1.25 X 35 bolts and washers to replace the dual generator bracket bolts during the front cover tightening process.

Install the engine front cover and the bolts.

Torque: 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: 10 Nm Stage 2: Tighten bolts 1 through 20 and 23 to: 20 Nm Stage 3: Tighten bolts 1 through 20 and 23 an additional: 45deg. Stage 4: Tighten bolt 21 to: 20 Nm Stage 5: Tighten bolt 21 an additional: 90deg. Stage 6: Tighten bolt 22 to: 10 Nm Stage 7: Tighten bolt 22 an additional: 45deg.

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

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If equipped with dual generators, remove the 2 engine front cover bolts.

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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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- 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: 26 Nm
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Remove and discard the engine oil filter.

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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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1. Position the generator.
2. Install the generator stud.
  Torque: 8 Nm
3. Install the bolt.
  Torque: 47 Nm
4. Install the nut.
  Torque: 47 Nm
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Install the accessory drive belt tensioner and the bolts.
Torque: 25 Nm

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Install the following items:
1. Install the coolant pump. Refer to: Coolant Pump .
2. Install the crankshaft front seal. Refer to: Crankshaft Front Seal .
If equipped with dual generators, install the generator bracket and the bolts finger tight.
- Tighten the bolts and stud bolt in sequence shown.
  Torque: Stage 1: Tighten bolts 1 and 2 to: 35 Nm Stage 2: Tighten bolt 3 to: 48 Nm Stage 3: Tighten stud bolt 4 to: 35 Nm
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If equipped with dual generators, install the secondary generator. Refer to: Generator - 3.5L Duratec (202kW/275PS) .
If equipped with dual generators, install the A/C compressor. Refer to: AIR CONDITIONING (A C) COMPRESSOR - 3.5L DURATEC (202KW 275PS)
Install the following items:
1. Install theRH 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: 10 Nm

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Fill the engine with clean engine oil. Refer to: Engine Oil Draining and Filling

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Connect the battery ground cable. Refer to: BATTERY DISCONNECT AND CONNECT - VEHICLES WITH: SINGLE BATTERY . Refer to: BATTERY DISCONNECT AND CONNECT - VEHICLES WITH: DUAL BATTERIES
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.