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Engine Front Cover: Installation

  1. Install the CKP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    2. 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 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. 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 Front Cover Silicone Application Points
    G03919915Courtesy of FORD MOTOR CO.
  2. 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.
  3. Install new engine front cover gaskets on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.
    Fig 2: Installing Engine Front Cover
    G03881967Courtesy of FORD MOTOR CO.
  4. Tighten the engine front cover fasteners in 2 stages, in the sequence shown.

    Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).

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

    Fig 3: Identifying Tighten Sequence Of Engine Front Cover Fasteners
    G03933423Courtesy of FORD MOTOR CO.
  5. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
    Fig 4: Identifying Installing Sequence Of Front Oil Pan/Cover Bolts
    G03920544Courtesy of FORD MOTOR CO.
  6. Connect the CKP sensor electrical connector.
  7. Position the power steering pump assembly and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
  8. Position the power steering pressure hose support bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 5: Identifying Power Steering Pressure Tube Support Bracket
    G03933414Courtesy of FORD MOTOR CO.
  9. Position the transmission cooler tube support bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    Fig 6: Identifying Transmission Cooler Tube Support Bracket Nut
    G03933415Courtesy of FORD MOTOR CO.
    10. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
  10. Using a new O-ring seal, install the RH CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
  11. Connect the RH CMP sensor electrical connector.
  12. Install the LH radio ignition interference capacitor and the nut.
    • Tighten to 10 Nm (89 lb-in).
    13. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
  13. Using a new O-ring seal, install the LH CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
  14. Connect the LH CMP sensor electrical connector.
  15. Install the RH radio ignition interference capacitor and the nut.
    • Tighten to 10 Nm (89 lb-in).
    16. NOTE: LH shown, RH similar.
    Fig 7: Locating Radio Ignition Interference Capacitor Electrical Connectors
    G03885209Courtesy of FORD MOTOR CO.
  16. Connect the radio ignition interference capacitor electrical connectors.
  17. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  18. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  19. Install the 3 accessory drive idler pulleys and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  20. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    Fig 8: Lubricating Engine Front Cover & Crankshaft Front Seal Inner Lip
    G03881970Courtesy of FORD MOTOR CO.
  21. Using the special tools, install the crankshaft front seal into the engine front cover.
    Fig 9: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    22. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 10: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03919877Courtesy of FORD MOTOR CO.
  22. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  23. Use the special tool to install the crankshaft pulley.
    Fig 11: Installing Crankshaft Pulley Using Special Tool
    G03919878Courtesy of FORD MOTOR CO.
  24. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen 360 degrees.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    Fig 12: Installing Crankshaft Pulley Bolt & Washer
    G04672695Courtesy of FORD MOTOR CO.
  25. Rotate the tensioner clockwise and install the accessory drive belt.
    Fig 13: Rotating Accessory Drive Belt Tensioner Clockwise
    G03886148Courtesy of FORD MOTOR CO.
  26. Install the RH valve cover. For additional information, refer to VALVE COVER - RH .
  27. Install the LH valve cover. For additional information, refer to VALVE COVER - LH .
  28. Install the engine cooling fan. For additional information, refer to ENGINE COOLING .
  29. Fill the crankcase with clean engine oil.
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