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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. 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 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 four 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. Failure to follow this procedure can 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: Applying A Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface
    G02763847Courtesy 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.
  2. Install the engine front cover with the engine front cover gasket on the engine front cover-to-cylinder block dowel and loosely install the bolts.
    Fig 2: Installing Engine Front Cover With Engine Front Cover Gasket
    G02763848Courtesy of FORD MOTOR CO.
  3. Tighten the engine front cover fasteners in sequence in two stages.

    Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 lb-ft).

    Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 lb-ft).

    Fig 3: Engine Front Cover Fastener Tightening Sequence
    G02763849Courtesy of FORD MOTOR CO.
  4. Position the accessory drive belt idler pulley and install the bolt.
    Fig 4: Positioning Accessory Drive Belt Idler Pulley
    G02763850Courtesy of FORD MOTOR CO.
  5. Connect the CMP electrical connector.
    Fig 5: Connecting CMP Electrical Connector
    G02763851Courtesy of FORD MOTOR CO.
  6. Loosely install the bolts, then tighten the bolts in the two stages, in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
    Fig 6: Installing Bolts And Tighten In Two Stages
    G02763852Courtesy of FORD MOTOR CO.
  7. Connect the CKP sensor electrical connector.
    Fig 7: Connecting CKP Sensor Electrical Connector
    G02763853Courtesy of FORD MOTOR CO.
    8. NOTE: The front lower hole in the power steering pump is not used.
    Fig 8: Positioning Power Steering Pump
    G02763854Courtesy of FORD MOTOR CO.
  8. Position the power steering pump and install the bolts.
  9. Install the oil drain plug.
  10. Install a new crankshaft front seal. For additional information, refer to CRANKSHAFT FRONT SEAL .
  11. Install the valve covers. For additional information, refer to VALVE COVER - LH  and VALVE COVER - RH .
  12. Install the water pump. For additional information, refer to ENGINE COOLING .
  13. Install the radiator. For additional information, refer to ENGINE COOLING .
  14. Fill the engine with clean engine oil.
  15. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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