Engine Front Cover: Installation

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 sealant.

Fig 1: Cleaning Sealing Surfaces With Metal Surface Cleaner

Courtesy of FORD MOTOR CO.

Clean the sealing surfaces with metal surface cleaner.
Install new gaskets.

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

NOTE: If the front cover is not secured within 4 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal surface cleaner. 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 3: Locating Silicone Gasket And Sealant Application Points

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant in the 8 places shown.
Install the engine front cover.
- Position the engine front cover on the cylinder block.
- Loosely install the bolts.
- Tighten the bolts in 2 stages in the sequence shown.
  - Stage 1: Tighten to 5 Nm (44 lb-in).
  - Stage 2: Tighten to 10 Nm (89 lb-in).
    
    Fig 4: Identifying Front Cover Bolt Tightening Sequence
    Courtesy of FORD MOTOR CO.
Attach the wiring harness clips.

Fig 5: Attaching Wiring Harness Clips
Courtesy of FORD MOTOR CO.
Install the coolant pump pulley and bolts and tighten in 2 stages:
- Stage 1: Tighten to 10 Nm (90 lb-in).
- Stage 2: Tighten an additional 45 degrees.
  
  Fig 6: Installing Coolant Pump Pulley And Bolts
  Courtesy of FORD MOTOR CO.

NOTE: The wiring harness is positioned behind the bracket.

Install the power steering pump bracket and the 5 bolts.
- Tighten to 25 Nm (18 lb-ft).

NOTE: One bolt is blocked by the power steering pressure line and must be installed with the power steering pump.

Position the power steering pump and install 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
Connect the 2 oil cooler hoses, if equipped.

Fig 7: Connecting Oil Cooler Hoses
Courtesy of FORD MOTOR CO.
Connect the lower radiator, upper radiator and heater hose.

Fig 8: Locating Lower Radiator, Upper Radiator And Heater Hoses
Courtesy of FORD MOTOR CO.
Install the lower radiator hose bracket nut.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 9: Identifying Lower Radiator Hose Bracket Nut
  Courtesy of FORD MOTOR CO.
Install the A/C compressor. For additional information, refer to AIR CONDITIONING .
Install the crankshaft front seal. For additional information, refer to LOWER END COMPONENTS - EXPLODED VIEW, CRANKSHAFT PULLEY AND CRANKSHAFT FRONT OIL SEAL and CRANKSHAFT FRONT SEAL in this article.
Install the accessory drive belt idler pulley. For additional information, refer to ACCESSORY DRIVE .
Install the engine cooling fan assembly. For additional information, refer to ENGINE COOLING .
Install the RH valve cover. For additional information, refer to VALVE COVER - RH in this article.
Install the LH valve cover. For additional information, refer to VALVE COVER - LH in this article.
Fill the engine with clean engine oil.
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION

CAUTION: The cooling system filling and bleeding procedure must be followed exactly or damage to the engine can occur.

Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
Evacuate and recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .