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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. 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.
    CAUTION: Do not damage the oil pan gasket while cleaning the sealant from the cylinder block-to-oil pan joint.
  1. Use a plastic scraping tool to remove all traces of sealant.
    • Clean all sealing surfaces with silicone gasket remover and metal surface prep.
    2. NOTE: Install 3 new gaskets in the front cover.
    NOTE: The engine front cover must be installed and the bolts tightened within 4 minutes of applying sealant.
    Fig 1: Installing Gaskets Front Cover
    G03898292Courtesy of FORD MOTOR CO.
  2. Apply a 6 mm (0.23 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder block, cylinder head and oil pan mating surfaces.
  3. Position the engine front cover and install the 15 bolts and stud bolt.
    • Tighten in the sequence shown to 25 Nm (18 lb-ft).
      Fig 2: Installing Bolts And Stud Bolt
      G03990118Courtesy of FORD MOTOR CO.
  4. Install the 2 oil pan-to-front cover bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 3: Installing Oil Pan-To-Front Cover Bolts
      G03990116Courtesy of FORD MOTOR CO.
  5. Remove the oil pan plug and drain the engine oil.
    • Install the plug and tighten to 26 Nm (19 lb-ft).
  6. Attach the ground wire to the engine front cover stud bolt and install the nut.
    • Tighten to 20 Nm (15 lb-ft).
  7. Install the 2 A/C compressor bracket-to-engine front cover bolts.
    • Tighten to 25 Nm (18 lb-ft).
  8. Position the A/C compressor and install the 2 bolts and 2 nuts.
    • Tighten to 25 Nm (18 lb-ft).
  9. Position the radiator splash shield and install the 3 pin-type retainers.
  10. Install the 2 generator-to-engine front cover studs.
    • Tighten to 8 Nm (71 lb-in).
  11. Install the 2 generator-to-engine front cover stud nuts.
    • Tighten to 48 Nm (35 lb-ft).
  12. Connect the camshaft position (CMP) sensor electrical connector.
  13. Connect the crankshaft position (CKP) sensor electrical connector.
  14. Position the power steering pump and fluid reservoir. Install the 3 power steering pump nuts.
    • Tighten to 25 Nm (18 lb-ft).
  15. Install the accessory drive belt tensioner and the bolt.
    • Tighten to 45 Nm (33 lb-ft).
  16. Install the LH and RH valve covers. For additional information, refer to VALVE COVER - LH  and VALVE COVER - RH .
  17. Install the crankshaft front seal. For additional information, refer to LOWER END COMPONENTS - EXPLODED VIEW  and CRANKSHAFT FRONT SEAL .
  18. Fill the engine with clean engine oil.
  19. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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