Engine Front Cover: Installation

WARNING: This page is about a different car, the 2008 Ford Pickup and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

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

Install the CKP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).

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 Motorcraft 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.

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.

Fig 1: Applying A Bead Of Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

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

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).

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	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
12	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
13	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
14	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
15	W709573	Bolt, Hex Head Pilot, M8 x 1.25 x 56

Fig 3: Tightening Engine Front Cover In 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: Identifying Tightening Sequence Of Front Oil Pan Bolts

Courtesy of FORD MOTOR CO.

Connect the CKP sensor electrical connector.
Position the starter wiring harness and transmission fluid cooler tubes support brackets and install the nut.
- Tighten to 25 Nm (18 lb-ft).
Position the power steering pump assembly and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).

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

Install the RH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
Connect the RH CMP sensor electrical connector.

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

Install the LH CMP sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).
Connect the LH CMP sensor electrical connector.
Install the RH and LH radio ignition interference capacitors and the 2 nuts.
- Tighten to 10 Nm (89 lb-in).
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 finger tight.
Install the accessory drive idler pulley and the bolt.
- Tighten to 25 Nm (18 lb-ft).
Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.

Fig 5: Locating Crankshaft Front Seal

Courtesy of FORD MOTOR CO.

Using the special tools, install a new crankshaft front seal into the engine front cover.

Fig 6: Installing Crankshaft Front Seal Using Special Tools (303-102, 303-335, 303-635)

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 Motorcraft 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.

Apply Silicone Gasket and Sealant to the Woodruff key slot on the crankshaft pulley.

Fig 7: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Use the special tool to install the crankshaft pulley.

Fig 8: Installing Crankshaft Pulley Using Special Tool (303-102)

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.
Rotate the tensioner clockwise and install the accessory drive belt.

Fig 9: Rotating Tensioner Clockwise

Courtesy of FORD MOTOR CO.

Tighten the 4 coolant pump pulley bolts.
- Tighten to 25 Nm (18 lb-ft).
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 ENGINE COOLING article.
Install the engine cooling fan shroud. For additional information, refer to ENGINE COOLING article.
Fill the crankcase with clean engine oil.