Engine Front Cover: Installation

WARNING: This page is about a different car, the 2004 Ford Focus. 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 disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean and inspect the mounting surfaces of the engine and the front cover.

NOTE: The engine front cover must be installed and the bolts tightened within four minutes of applying the silicone gasket and sealant.

Fig 1: Locating Silicone Gasket

Courtesy of FORD MOTOR CO.

Apply a 2.5-mm bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5-mm bead of silicone gasket and sealant to the front cover.
Install the 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: Tightening Front Cover Bolts In Sequence
Courtesy of FORD MOTOR CO.
Position the power steering pump and install the four retaining bolts.

Fig 3: Installing Power Steering Pump Retaining Bolts
Courtesy of FORD MOTOR CO.
Using the special tool, install a new O-ring on the PSP tube fitting.

Fig 4: Installing Teflon Seal On Power Steering Pressure Hose Fitting
Courtesy of FORD MOTOR CO.
Connect the power steering PSP tube fitting.

Fig 5: Connecting Power Steering PSP Tube Fitting
Courtesy of FORD MOTOR CO.

NOTE: Make sure the pulley is flush with the end of the power steering pump shaft.

Fig 6: Installing Power Steering Pump Pulley

Courtesy of FORD MOTOR CO.

Using the special tool, install the power steering pump pulley.
Attach the PSP tube bracket and install the nut.

Fig 7: Attaching PSP Tube Bracket
Courtesy of FORD MOTOR CO.
Connect the PSP switch electrical connector.

Fig 8: Connecting PSP Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Install the coolant pump pulley.

Fig 9: Installing Coolant Pump Pulley
Courtesy of FORD MOTOR CO.
Install the accessory drive belt idler pulley.

Fig 10: Installing Accessory Drive Belt Idler Pulley
Courtesy of FORD MOTOR CO.
Install the accessory drive belt tensioner.
1. Position the tensioner.
2. Install the tensioner belts.
Fig 11: Installing Accessory Drive Belt Tensioner
Courtesy of FORD MOTOR CO.
Install the RH motor mount. For additional information, refer to ENGINE MOUNT - RH .

NOTE: If the crankshaft position (CKP) sensor is damaged during engine front cover installation a new CKP sensor must be installed.

Fig 12: Connecting CKP Sensor Electrical Connector And Wiring Harness Pin-Type Retainers

Courtesy of FORD MOTOR CO.

Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.

CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.

Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Fill and purge the power steering fluid. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .