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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2010 Ford Pickup and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may 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: Locating Silicone Sealant Application Areas
    G06126231Courtesy of FORD MOTOR CO.
  1. 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 in illustration.
  2. 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 Gasket On Engine Front Cover
    G06396283Courtesy of FORD MOTOR CO.
  3. Tighten the 15 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).
    ITEM DESCRIPTION

    Item Part Number Description
    1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
    6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    11 W709573 Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    12 W709573 Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    13 W709573 Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    14 W709573 Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    15 W709573 Stud, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    Fig 3: Identifying Engine Front Cover Fasteners Tighten Sequence
    G06772613Courtesy of FORD MOTOR CO.
  4. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown in illustration.
    • Stage 1: Tighten to 20 Nm (177 lb-in).
    • Stage 2: Tighten an additional 60 degrees.
      Fig 4: Identifying Tightening Sequence Of Front Oil Pan And Cover Bolts
      G06126234Courtesy of FORD MOTOR CO.
  5. Connect the CKP  sensor electrical connector.
  6. Position the starter wiring harness and transmission fluid cooler tubes support brackets and install the nut.
    • Tighten to 25 Nm (18 lb-ft).
  7. Position the power steering pump assembly and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  8. Connect the RH CMP  sensor electrical connector.
  9. Connect the LH CMP  sensor electrical connector.
  10. Install the RH and LH radio ignition interference capacitors and the 2 nuts.
    • Tighten to 10 Nm (89 lb-in).
  11. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  12. Install the coolant pump pulley and the 4 bolts finger-tight.
  13. Install the accessory drive idler pulley and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
  14. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 5: Lubricating Engine Front Cover And Crankshaft Seal Inner Lip With Clean Engine Oil
    G06126205Courtesy of FORD MOTOR CO.
  15. Using the Crankshaft Front Oil Seal Installer, the Crankshaft Vibration Damper Installer and the Front Cover Oil Seal Installer, install the new crankshaft front seal into the engine front cover.
    Fig 6: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tools
    G06126206Courtesy of FORD MOTOR CO.
    16. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 7: Applying Silicone Gasket And Sealant To Woodruff Key Slot In Crankshaft Pulley
    G06126752Courtesy of FORD MOTOR CO.
  16. Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
  17. Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.
    Fig 8: Installing Crankshaft Pulley
    G06126193Courtesy of FORD MOTOR CO.
  18. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the 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 9: Installing Crankshaft Pulley Bolt And Washer
      G06461362Courtesy of FORD MOTOR CO.
  19. Rotate the tensioner clockwise and install the accessory drive belt.
    Fig 10: Installing Accessory Drive Belt
    G06392440Courtesy of FORD MOTOR CO.
  20. Tighten the 4 coolant pump pulley bolts.
    • Tighten to 25 Nm (18 lb-ft).
  21. Install the RH valve cover. For additional information, refer to VALVE COVER - RH .
  22. Install the LH valve cover. For additional information, refer to VALVE COVER - LH .
  23. Install the engine cooling fan. For additional information, refer to ENGINE COOLING .
  24. Install the engine cooling fan shroud. For additional information, refer to ENGINE COOLING .
  25. Fill the crankcase with clean engine oil.
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