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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. 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 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 Silicone Gasket
    G03897744Courtesy 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 Tightening Sequence Of Engine Front Cover Bolts
      G04679989Courtesy of FORD MOTOR CO.
  4. Position the power steering pump and install the 3 bolts.
    5. NOTE: The coolant pump pulley bolts should be tightened after the accessory drive belt is installed.
  5. Install the coolant pump pulley and bolts.
    • Tighten to 20 Nm (15 lb-ft).
    6. NOTE: Remove the through-bolt from the special tool.
    NOTE: Lubricate the oil seal with clean engine oil.
    Fig 3: Installing Crankshaft Front Oil Seal Using Special Tool
    G03897717Courtesy of FORD MOTOR CO.
  6. Using the special tool, install the crankshaft front oil seal.
  7. Install the engine mount. For additional information, refer to ENGINE MOUNT .
  8. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
    9. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
    Fig 4: Aligning Crankshaft Pulley Bolt Holes
    G03897704Courtesy of FORD MOTOR CO.
  9. 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.
    10. NOTE: Whenever the crankshaft position (CKP) sensor is removed, a new one must be installed using the alignment tool supplied with the new part.
  10. Install a new CKP sensor.
    • Do not tighten the bolts at this time.
      Fig 5: Locating CKP Sensor Bolts
      G04679992Courtesy of FORD MOTOR CO.
    11. NOTE: The CKP sensor alignment tool is supplied with the new sensor and is not available separately.
  11. Adjust the new CKP sensor with the alignment tool.
    • Tighten the bolts to 7 Nm (62 lb-in).
      Fig 6: Locating CKP Sensor Bolts And Alignment Tool
      G04679993Courtesy of FORD MOTOR CO.
  12. Connect the CKP sensor electrical connector.
  13. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 7: Aligning Crankshaft Pulley Bolt Holes
    G03897704Courtesy of FORD MOTOR CO.
  14. If equipped, install the underbody cover and the 7 screws.
    Fig 8: Locating Underbody Cover Screws
    G04679995Courtesy of FORD MOTOR CO.
  15. Install the accessory drive belt and idler pulley. For additional information, refer to ACCESSORY DRIVE - 2.3L .
  16. Tighten the 3 coolant pump pulley bolts to 20 Nm (15 lb-ft).
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