Engine Front Cover: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

ALL ENGINES

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: Identifying Silicone Gasket And Sealant Application Points

Courtesy of FORD MOTOR CO.

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.
Install the engine front cover with engine front cover gasket on the front cover to cylinder block dowel and loosely install the bolts.

Fig 2: Installing Engine Front Cover
Courtesy of FORD MOTOR CO.

ROMEO ENGINE (4.6L)

Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).

Fig 3: Identifying Front Cover Fasteners Tightening Sequence (Items 1-6)
Courtesy of FORD MOTOR CO.

Fig 4: Identifying Front Cover Fasteners Tightening Sequence (Items 7-15)
Courtesy of FORD MOTOR CO.

WINDSOR ENGINE (5.4L)

Tighten the engine front cover fasteners in sequence in three stages.
Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).

Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).

Fig 5: Engine Front Cover Fasteners Tightening Sequence (Windsor Engine) (Items 1-11)
Courtesy of FORD MOTOR CO.

Fig 6: Identifying Engine Front Cover Fasteners Tightening Sequence (Windsor Engine) (Items 12-15)
Courtesy of FORD MOTOR CO.

ALL ENGINES

Position the belt idler pulley and install the bolt.

Fig 7: Installing Belt Idler Pulley
Courtesy of FORD MOTOR CO.
Connect the CMP sensor electrical connection.

Fig 8: Connecting CMP Sensor Connector
Courtesy of FORD MOTOR CO.
Raise and support the vehicle.
Install a new crankshaft front seal. For additional information, refer to CRANKSHAFT FRONT SEAL .
Loosely install the bolts, then tighten the bolts in the two stages following the sequence shown.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
Fig 9: Installing Bolts
Courtesy of FORD MOTOR CO.
Connect the crankshaft position sensor electrical connector.

Fig 10: Connecting Crankshaft Position Sensor Electrical Connector
Courtesy of FORD MOTOR CO.

NOTE: The front lower hole in the power steering pump is not used.

Fig 11: Installing Power Steering Pump

Courtesy of FORD MOTOR CO.

Position the power steering pump and install the bolts.
Install the drain plug.

Fig 12: Installing Drain Plug
Courtesy of FORD MOTOR CO.
Lower the vehicle.
Install the valve covers. For additional information, refer to VALVE COVER LH , VALVE COVER RH - 4.6L or VALVE COVER RH - 5.4L .
Fill the engine with clean engine oil.
Install the water pump. For additional information, refer to ENGINE COOLING .
Install the radiator. For additional information, refer to ENGINE COOLING .
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .