Engine Front Cover: Installation

Raise the engine to the installed position.

CAUTION: Only use a 3M Roloc® Bristle Disk, (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.

Clean the engine front cover using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
- Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.

CAUTION: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

CAUTION: Do not use wire brushes, power abrasive discs or 3M Roloc® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.

Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.
1. Remove any large deposits of silicone or gasket material.
2. Apply silicone gasket remover and allow to set for several minutes.
3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the special tools.

Fig 1: Identifying Special Tool (307-399)

Courtesy of FORD MOTOR CO.

CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
- Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.

Fig 2: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Engine Front Cover Sealing Surfaces

Courtesy of FORD MOTOR CO.

NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and bolts 17, 18, 19 and 20.
- Tighten in sequence to 3 Nm (27 lb-in).

Fig 3: Installing Engine Front Cover & Bolts In Sequence

Courtesy of FORD MOTOR CO.

Remove the special tools (alignment pins).

NOTE: Do not tighten the bolt at this time.

Lower the engine to allow installation of the engine mount bracket and lower bolt.
- Install the engine mount bracket and lower bolt as an assembly.

Fig 4: Locating Lower Engine Mount Bracket Bolt

Courtesy of FORD MOTOR CO.

NOTE: Do not tighten the bolts at this time.

Raise the engine to the installed position.
- Install the 2 upper engine mount bracket bolts.

Fig 5: Locating Upper Engine Mount Bracket Bolts

Courtesy of FORD MOTOR CO.

CAUTION: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:
- Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft).
- Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).

Fig 6: Identifying Tightening Of Engine Front Cover Bolts & Engine Mount Bracket Bolts In Sequence

Courtesy of FORD MOTOR CO.

Install the 2 engine mount studs.
- Tighten to 18 Nm (13 lb-ft).

Fig 7: Locating Engine Mount Studs

Courtesy of FORD MOTOR CO.

Install the engine mount bracket and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).

Fig 8: Locating Engine Mount Bracket & Bolts

Courtesy of FORD MOTOR CO.

Install the engine mount and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).

Fig 9: Locating Engine Mount Bolts

Courtesy of FORD MOTOR CO.

Install the 4 engine mount nuts.
- Tighten to 63 Nm (46 lb-ft).

Fig 10: Locating Engine Mount Nuts

Courtesy of FORD MOTOR CO.

Install the engine mount brace, nut and bolt.
- Tighten to 20 Nm (15 lb-ft).

Fig 11: Locating Nut, Bolt & Engine Mount Brace

Courtesy of FORD MOTOR CO.

Tighten the transaxle mount through bolt to 175 Nm (129 lb-ft).

Fig 12: Identifying Transaxle Mount Bolt

Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Install the LH and RH VCT solenoids and bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 13: Locating LH & RH VCT Solenoids Bolts

Courtesy of FORD MOTOR CO.

Install the power steering pump and the 3 bolts.
- Tighten to 24 Nm (18 lb-ft).

Fig 14: Locating Power Steering Pump Bolts

Courtesy of FORD MOTOR CO.

Install the power steering reservoir and the 2 nuts.
- Tighten to 8 Nm (71 lb-in).

Fig 15: Locating Power Steering Reservoir Nuts

Courtesy of FORD MOTOR CO.

Install the degas bottle and the 3 bolts.
- Tighten to 9 Nm (80 lb-in).

Fig 16: Identifying Bolts & Position Degas Bottle Aside

Courtesy of FORD MOTOR CO.

Connect the 3 PCM electrical connectors.

Fig 17: Identifying PCM Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the purge valve electrical connector.

Fig 18: Locating Purge Valve Electrical Connector

Courtesy of FORD MOTOR CO.

Install the radio interference capacitor, the ground wire and the nut to the cowl stud.
- Tighten to 10 Nm (89 lb-in).

Fig 19: Removing Nut, Ground Wire & Radio Interference Capacitor Wire From Cowl Stud

Courtesy of FORD MOTOR CO.

Install the radio interference capacitor wire, the ground wire and the nut to the engine front cover stud.
- Tighten to 10 Nm (89 lb-in).

Fig 20: Removing Nut, Ground Wire & Radio Interference Capacitor Wire From Engine Front Cover Stud

Courtesy of FORD MOTOR CO.

Install the ground wire and bolt on the engine front cover.
- Tighten to 10 Nm (89 lb-in).

Fig 21: Removing Bolt & Ground Wire From Engine Front Cover

Courtesy of FORD MOTOR CO.

Connect the 2 engine wiring harness connectors.

Fig 22: Locating Engine Wiring Harness Connectors

Courtesy of FORD MOTOR CO.

Using a new O-ring seal, connect the A/C pressure tube fitting and install the nut.
- Tighten to 8 Nm (71 lb-in).

Fig 23: Locating A/C Pressure Tube Fitting Nut

Courtesy of FORD MOTOR CO.

Install the A/C pressure tube bracket and bolt.
- Tighten to 8 Nm (71 lb-in).

Fig 24: Locating A/C Pressure Tube Bracket Bolt

Courtesy of FORD MOTOR CO.

Connect the A/C suction tube fitting.
- Install the safety clip onto the fitting.

Fig 25: Identifying Safety Clip On A/C Suction Tube Fitting

Courtesy of FORD MOTOR CO.

Install the LH and RH valve covers. For additional information, refer to Valve Cover - LH and Valve Cover - RH .
Install the engine air cleaner and air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
If equipped, attach the engine block heater harness to the radiator support, the A/C suction tube and the engine wiring harness.

Fig 26: Identifying Engine Block Heater Harness, Radiator Support, A/C Suction Tube & Engine Wiring Harness

Courtesy of FORD MOTOR CO.

Align the RH halfshaft splines with the intermediate shaft and push the halfshaft on until the circlip locks the shafts together.
- Pull the inboard halfshaft outward to make sure the circlip is locked.

Fig 27: Pushing Halfshaft On Until Circlip Locks Shafts Together

Courtesy of FORD MOTOR CO.

NOTE: Do not tighten the halfshaft nut at this time.

Install the RH halfshaft into the hub and install a new halfshaft nut.

Fig 28: Locating RH Front Halfshaft Nut

Courtesy of FORD MOTOR CO.

Install the RH lower ball joint into the steering knuckle and install the pinch bolt.
- Tighten to 55 Nm (41 lb-ft).

Fig 29: Locating Ball Joint Pinch Bolt

Courtesy of FORD MOTOR CO.

Install the RH stabilizer bar link into the lower control arm and install the nut.
- Tighten to 90 Nm (66 lb-ft).

Fig 30: Locating Stabilizer Bar Link Nut

Courtesy of FORD MOTOR CO.

NOTE: Apply the brake to keep the halfshaft from rotating.

Tighten the RH halfshaft nut to 350 Nm (258 lb-ft).

Fig 31: Locating RH Front Halfshaft Nut

Courtesy of FORD MOTOR CO.

Install and the transaxle bracket and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).

Fig 32: Locating Transaxle Bracket Bolts

Courtesy of FORD MOTOR CO.

Position the roll restrictor and transaxle bracket plate and install the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).

Fig 33: Locating Roll Restrictor-To-Transaxle Bracket Plate Bolts

Courtesy of FORD MOTOR CO.

Tighten the engine roll restrictor-to-subframe through bolt to 103 Nm (76 lb-ft).

Fig 34: Locating Roll Restrictor-To-Subframe Bolt

Courtesy of FORD MOTOR CO.

Install the roll restrictor heat shield and the 2 nuts.
- Tighten to 11 Nm (8 lb-ft).

Fig 35: Locating Roll Restrictor Heat Shield Nuts

Courtesy of FORD MOTOR CO.

Position the Y-pipe assembly in place and install the 4 nuts.
- Tighten to 40 Nm (30 lb-ft).

Fig 36: Locating Exhaust Flexible Pipe, Y-Pipe & Nuts

Courtesy of FORD MOTOR CO.

Install the 2 exhaust hangers and tighten the exhaust clamp.
- Tighten to 40 Nm (30 lb-ft).

Fig 37: Locating Exhaust Flexible Pipe Clamp & Exhaust Hangers

Courtesy of FORD MOTOR CO.

NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

Using the special tools, install a new crankshaft front seal.

Fig 38: Installing Crankshaft Front Seal Using Special Tools (303-102) & (303-1251)

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

Using the special tools, install the crankshaft pulley.

Fig 39: Installing Crankshaft Pulley Using Special Tools (303-102) & (303-335)

Courtesy of FORD MOTOR CO.

Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
- Stage 1: Tighten to 120 Nm (89 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.

Fig 40: Installing Crankshaft Pulley Washer & Bolt Using Special Tools (303-D055)

Courtesy of FORD MOTOR CO.

Install the accessory drive belt, tensioner and the power steering belt. For additional information, refer to ACCESSORY DRIVE .

Fill the engine with clean engine oil.
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Evacuate and recharge the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .