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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2003 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.
  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 four minutes of applying the silicone gasket and sealant.
    Fig 1: Applying A Bead Of Silicone To Gasket Front Cover
    G01611349Courtesy of FORD MOTOR CO.
  2. 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.
  3. 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: Front Cover Bolts Tightening Sequence
      G01611350Courtesy of FORD MOTOR CO.
  4. Position the power steering pump and install the four retaining bolts.
    Fig 3: Installing Power Steering Pump Retaining Bolts
    G01611351Courtesy of FORD MOTOR CO.
  5. Using the special tool, install a new O-ring on the PSP tube fitting.
    Fig 4: Installing O-Ring On PSP Tube Fitting
    G01611352Courtesy of FORD MOTOR CO.
  6. Connect the power steering PSP tube fitting.
    Fig 5: Connecting Power Steering PSP Tube Fitting
    G01611353Courtesy of FORD MOTOR CO.
  7. Attach the PSP tube bracket and install the nut.
    Fig 6: Attaching PSP Tube Bracket And Install Nut
    G01611354Courtesy of FORD MOTOR CO.
  8. Connect the PSP switch electrical connector.
    Fig 7: Connecting PSP Switch Electrical Connector
    G01611355Courtesy of FORD MOTOR CO.
  9. Install the coolant pump pulley.
    Fig 8: Installing Coolant Pump Pulley
    G01611356Courtesy of FORD MOTOR CO.
  10. Install the accessory drive belt idler pulley.
    Fig 9: Installing Accessory Drive Belt Idler Pulley
    G01611357Courtesy of FORD MOTOR CO.
  11. Install the accessory belt tensioner.
    1. Position the tensioner.
    2. Install the tensioner belts.
      Fig 10: Installing Accessory Belt Tensioner
      G01611358Courtesy of FORD MOTOR CO.
    12. CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction 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.
  12. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
    13. NOTE: If the crankshaft position (CKP) sensor is damaged during engine front cover installation a new CKP sensor must be installed. Refer to the manufacturer instructions for sensor installation.
    Fig 11: Connecting CKP Sensor Electrical Connector And Wiring Harness Pin-Type Retainers
    G01611359Courtesy of FORD MOTOR CO.
  13. Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.
  14. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
  15. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  16. Fill and purge the power steering fluid. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
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