Engine Front Cover: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Fig 1: Identifying Silicone Sealant Application Areas

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.

Fig 2: Installing Engine Front Cover
Courtesy of FORD MOTOR CO.
Tighten the engine front cover fasteners in sequence in 2 stages.
Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).

Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

Fig 3: Identifying Engine Front Cover Tightening Sequence
Courtesy of FORD MOTOR CO.
Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
  
  Fig 4: Installing Oil Pan-To-Front Cover Bolts
  Courtesy of FORD MOTOR CO.
Install the crankshaft position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
Connect the CKP sensor electrical connector.
Position the A/C compressor and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 5: Locating Bolt Access Holes For A/C Compressor
  Courtesy of FORD MOTOR CO.
Position the power steering pump assembly and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
Position the air cleaner outlet tube support bracket and install the 2 nuts.
- Tighten to 10 Nm (89 lb-in)
  
  Fig 6: Locating Air Cleaner Outlet Tube Support Bracket Bolt
  Courtesy of FORD MOTOR CO.
Position the starter wiring harness support bracket and install the nut.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 7: Locating Starter Wiring Harness Support Bracket Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Using a new O-ring seal, install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
Connect the RH CMP sensor electrical connector.

Fig 8: Identifying RH CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Using a new O-ring seal, install the LH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
Connect the LH CMP sensor electrical connector.

Fig 9: Identifying LH CMP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Install the RH and LH radio ignition interference capacitors and the 2 nuts.
- Tighten to 10 Nm (89 lb-in).

NOTE: LH shown, RH similar.

Fig 10: Locating Radio Ignition Interference Capacitor Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the radio ignition interference capacitor electrical connectors.
Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
Install the coolant pump pulley and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
Install the accessory drive idler pulley and the bolt.
- Tighten to 25 Nm (18 lb-ft).
Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

Fig 11: Installing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
Using the special tools, install the crankshaft seal into the engine front cover.

Fig 12: Installing Crankshaft Front Seal Using Special Tools
Courtesy of FORD MOTOR CO.

NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Fig 13: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
Use the special tool to install the crankshaft pulley.

Fig 14: Installing Crankshaft Pulley Using Special Tool
Courtesy of FORD MOTOR CO.
Tighten the new crankshaft pulley bolt in 4 stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
  
  Fig 15: Installing Crankshaft Pulley Bolt & Washer
  Courtesy of FORD MOTOR CO.
Rotate the tensioner clockwise and install the accessory drive belt.

Fig 16: Rotating Accessory Drive Belt Tensioner Clockwise
Courtesy of FORD MOTOR CO.
Install the RH valve cover. For additional information, refer to VALVE COVER - RH .
Install the LH valve cover. For additional information, refer to VALVE COVER - LH .
Install the engine cooling fan. For additional information, refer to COOLING FAN -- BLADE, CLUTCH AND SHROUD .
Fill the crankcase with clean engine oil.