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Engine Front Cover: Installation

    CAUTION: In order to prevent foreign material from contaminating the engine block or the engine front cover it is necessary to seal the coolant and oil passages of both components. Failure to follow these directions will result in engine damage.
    CAUTION: Do not use a surface conditioning pad or any other type of fibrous abrasive disc to clean the gasket surfaces. Failure to follow these directions will result in engine damage.
  1. Clean and inspect the engine block and front cover as follows:
    • Pack the exposed portion of the oil pan with clean shop towels.
    • Plug the oil and coolant passages.
    • Clean the gasket surfaces.
    • Clean all surfaces requiring gasket sealant with metal surface cleaner.
    • Using compressed air remove any remaining foreign material from the engine block and engine front cover.
    • Remove the shop towels from the oil pan.
    • Remove the plugs or seals from the oil and coolant passages.
  2. Install the timing chain and gears. Refer to TIMING CHAIN .
  3. Apply a small amount of silicone gasket and sealant as shown.
    Fig 1: Identifying Silicone Gasket And Sealant
    G03424913Courtesy of FORD MOTOR CO.
  4. Install the engine front cover gasket and apply a small amount of silicone gasket and sealant as shown.
    Fig 2: Installing Silicone Gasket Sealant
    G03424914Courtesy of FORD MOTOR CO.
    5. NOTE: Use pipe sealer on studs No. 4 and No. 6, and bolt No. 12.
  5. Install the engine front cover.
    • Install a 135.5 mm (5.42 in) stud at location No. 5 and tighten to 7 N.m (62 lb-in).
    • Install a 137 mm (5.48 in) stud at locations No. 4, 6, 7 and 10, and tighten to 7 N.m (62 lb-in).
    • Install the water pump with a new gasket.
    • Tighten bolt No. 12 to 10 N.m (89 lb-in). All other nuts and bolts are to be tightened to 28 N.m (21 lb-ft.).
    • Tighten the nuts and bolts in the sequence shown.
      Fig 3: Engine Front Cover Bolt Tightening Sequence
      G03424915Courtesy of FORD MOTOR CO.
  6. Install the water pump pulley.
    Fig 4: Installing Water Pump Pulley
    G03424916Courtesy of FORD MOTOR CO.
  7. Lower the engine into position and remove the special tools.
    Fig 5: Lower Engine Into Position
    G03424917Courtesy of FORD MOTOR CO.
  8. Raise the vehicle on the hoist.
  9. Install the engine mount nuts.
    Fig 6: Installing Engine Mount Nuts
    G03424918Courtesy of FORD MOTOR CO.
  10. Connect the radiator lower hose.
    Fig 7: Connecting Radiator Lower Hose
    G03424919Courtesy of FORD MOTOR CO.
  11. Install the power steering pump mounting bracket and the lower retainers.
    Fig 8: Installing Power Steering Pump Mounting Bracket
    G03424920Courtesy of FORD MOTOR CO.
  12. Install the belt tensioner. For additional information refer to SPECIFICATIONS & DRIVE BELT ROUTING .
    Fig 9: Installing Belt Tensioner
    G03424921Courtesy of FORD MOTOR CO.
  13. Install the CMS mounting bracket.
    Fig 10: Installing CMS Mounting Bracket
    G03424922Courtesy of FORD MOTOR CO.
  14. Connect the CMS electrical connector.
    Fig 11: Connecting CMS Electrical Connector
    G03424923Courtesy of FORD MOTOR CO.
  15. Install the CKP sensor. Refer to CRANKSHAFT POSITION SENSOR .
  16. Install the crankshaft pulley. Refer to CRANKSHAFT PULLEY .
  17. Lower the hoist.
  18. Install the power steering pump mounting bracket upper bolts.
    Fig 12: Installing Power Steering Pump Mounting Bracket Upper Bolts
    G03424924Courtesy of FORD MOTOR CO.
  19. Install the camshaft synchronizer. Refer to CAMSHAFT POSITION SYNCHRONIZER .
  20. Install the water pump outlet tube.
    Fig 13: Installing Water Pump Outlet Tube
    G03424925Courtesy of FORD MOTOR CO.
  21. Connect the hoses to the water pump outlet tube.
    Fig 14: Connecting Hoses To Water Pump Outlet Tube
    G03424926Courtesy of FORD MOTOR CO.
  22. Install the power steering pump. Refer to PUMP - CIII .
  23. Connect the camshaft position electrical connector.
    Fig 15: Connecting Camshaft Position Electrical Connector
    G03424927Courtesy of FORD MOTOR CO.
  24. Connect the IMRC actuator electrical connector.
    Fig 16: Connecting IMRC Actuator Electrical Connector
    G03424928Courtesy of FORD MOTOR CO.
  25. Connect the A/C compressor electrical connector.
    Fig 17: Connecting A/C Compressor Electrical Connector
    G03424929Courtesy of FORD MOTOR CO.
  26. Connect the oil pressure sender electrical connector.
    Fig 18: Connecting Oil Pressure Sender Electrical Connector
    G03424930Courtesy of FORD MOTOR CO.
  27. Install the generator bracket, bracket brace and bolts as an assembly.
    Fig 19: Installing Generator Bracket
    G03424931Courtesy of FORD MOTOR CO.
  28. Clip the A/C wiring harness to the generator bracket brace.
    Fig 20: Identifying Clip A/C Wiring Harness To Generator Bracket Brace
    G03424932Courtesy of FORD MOTOR CO.
  29. Install the idler pulley.
    Fig 21: Installing Idler Pulley
    G03424933Courtesy of FORD MOTOR CO.
  30. Install the generator. Refer to GENERATOR .
  31. Connect the degas bottle hose.
    Fig 22: Connecting Degas Bottle Hose
    G03424934Courtesy of FORD MOTOR CO.
  32. Raise the vehicle on the hoist.
  33. Drain the engine oil.
  34. Install a new oil filter.
    Fig 23: Installing A New Oil Filter
    G03424935Courtesy of FORD MOTOR CO.
  35. Fill the engine with clean engine oil.
  36. Fill the engine cooling system. Refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
  37. Connect the battery ground cable.
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