Engine Front Cover: Installation

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Follow the directions on the packaging. 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 Gasket And Sealant Applying Areas On Cylinder Head-To-Cylinder Block Surface And Oil Pan-To-Cylinder Block Surface

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 in illustration.
Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.

Fig 2: Installing Engine Front Cover Gasket On Engine Front Cover
Courtesy of FORD MOTOR CO.

Tighten the engine front cover fasteners in sequence in 3 stages.

Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).

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

Stage 3: Tighten fasteners 8 through 15 to 25 Nm (18 lb-ft).

PARTS DESCRIPTION CHART

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 and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
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	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 56

Fig 3: Engine Front Cover Fasteners Tightening Sequence

Courtesy of FORD MOTOR CO.

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 Front Oil Pan/Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Connect the CKP sensor electrical connector.
Position the power steering pump and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
Position the transmission cooler tube and starter electrical harness support brackets and install the nut.
- Tighten to 25 Nm (18 lb-ft).
Connect the CMP sensor electrical connector.
Install the LH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).
Install the RH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).
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 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

Fig 5: Locating Engine Front Cover And Crankshaft Front Seal Inner Lip
Courtesy of FORD MOTOR CO.
Using the Crankshaft Vibration Damper Installer, Front Cover Oil Seal Installer and Crankshaft Front Oil Seal Installer, install a new crankshaft front seal.

Fig 6: Installing Crankshaft Front Seal
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. 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.

Fig 7: Identifying 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.
Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.

Fig 8: Installing Crankshaft Pulley Using Crankshaft Vibration Damper Installer
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 9: Installing Crankshaft Pulley Bolt And Washer
  Courtesy of FORD MOTOR CO.
Rotate the tensioner clockwise and install the accessory drive belt.

Fig 10: Rotating 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 ENGINE COOLING .
Install the engine cooling fan shroud. For additional information, refer to ENGINE COOLING .
Fill the crankcase with clean engine oil.