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Home >> Mercury >> 2009 >> Mariner Base, 2.5 7, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 20 (Engine Mechanical - 2.5L - (Hybrid)) >> In-Vehicle Repair >> Engine Front Cover >> Installation

Engine Front Cover: Installation

WARNING: This page is about a different variant/trim than selected.
    NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  1. Clean and inspect the mounting surfaces of the engine and the front cover.
    2. NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying the silicone gasket and sealant.
    Fig 1: Locating Front Cover Silicone Gasket And Sealant Bead
    G06094885Courtesy of FORD MOTOR CO.
  2. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm (0.09 in) bead of silicone gasket and sealant to the front cover.
  3. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
    • Tighten the 8-mm bolts to 10 Nm (89 lb-in).
    • Tighten the 13-mm bolts to 48 Nm (35 lb-ft).
      Fig 2: Identifying Engine Front Cover Bolts Tightening Sequence
      G06094886Courtesy of FORD MOTOR CO.
    4. NOTE: Remove the through bolt from the Camshaft Front Oil Seal Installer.
    NOTE: Lubricate the oil seal with clean engine oil.
    Fig 3: Installing Crankshaft Front Oil Seal
    G06094868Courtesy of FORD MOTOR CO.
  4. Using the Camshaft Front Oil Seal Installer, install the crankshaft front seal.
  5. Install the coolant pump pulley and the 3 bolts.
    • Tighten to 20 Nm (177 lb-in).
  6. Install the engine mount. For additional information, refer to ENGINE MOUNT .
  7. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
    8. NOTE: Only hand-tighten the bolt or damage to the front cover can occur.
    Fig 4: Locating Crankshaft Pulley Through Bolt (6 mm x 18 mm)
    G06094854Courtesy of FORD MOTOR CO.
  8. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
  9. Install the CKP sensor and the 2 bolts.
    • Do not tighten the bolts at this time.
      Fig 5: Locating Bolts And CKP Sensor
      G06096795Courtesy of FORD MOTOR CO.
  10. Using the Crankshaft Sensor Aligner, adjust the CKP sensor.
    • Tighten the 2 CKP bolts to 7 Nm (62 lb-in).
      Fig 6: Identifying Crankshaft Sensor Aligner
      G06094890Courtesy of FORD MOTOR CO.
  11. Connect the CKP sensor electrical connector.
  12. Remove the 6 mm x 18 mm bolt.
    Fig 7: Locating Crankshaft Pulley Through Bolt (6 mm x 18 mm)
    G06094854Courtesy of FORD MOTOR CO.
  13. Install the accessory drive belt and tensioner. For additional information, refer to ACCESSORY DRIVE - HYBRID .
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