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Engine Front Cover: Installation

    NOTE: Lubricate the O-ring with clean engine oil prior to 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.
  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. Fig 1: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface And Oil Pan-To-Cylinder Block Surface
    GF0002753Courtesy of FORD MOTOR CO.
  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.
    4. Fig 2: Installing Engine Front Cover Gasket
    GF0000367Courtesy 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).

    Item Part Number Description
    1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
    6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
    8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    11 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
    12 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    13 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    14 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
    15 W706605 Bolt, Hex Head Pilot, M8 x 1.25 x 56
    5. Fig 3: Identifying Engine Front Cover Fasteners Tightening Sequence
    GF0002754Courtesy 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.
    6. Fig 4: Identifying Tightening Sequence Of Front Oil Pan Bolts
    G03920544Courtesy of FORD MOTOR CO.
  6. Position the power steering pump assembly and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
  7. Position the power steering pressure (PSP) hose support bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    8. Fig 5: Locating Power Steering Pressure Hose Support Bracket Nut
    GF0002607Courtesy of FORD MOTOR CO.
  8. Position the transmission cooler tube support bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
    9. Fig 6: Locating Transmission Cooler Tube Support Bracket Nut
    GF0002750Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
  9. Install the RH CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
  10. Connect the RH CMP sensor electrical connector.
  11. Connect the wiring harness retainer from the cylinder head.
  12. Connect the A/C compressor electrical connector.
  13. Connect the CKP sensor electrical connector.
  14. Install the LH radio ignition interference capacitor and the nut.
    • Tighten to 25 Nm (18 lb-ft).
    15. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
  15. Install the LH CMP sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
  16. Connect the LH CMP sensor electrical connector.
  17. Install the RH radio ignition interference capacitor and the nut.
    • Tighten to 25 Nm (18 lb-ft).
    18. NOTE: LH shown, RH similar.
  18. Connect the radio ignition interference capacitor electrical connectors.
    19. Fig 7: Locating Radio Interference Capacitor Electrical Connectors
    G03885209Courtesy of FORD MOTOR CO.
  19. Connect the wiring harness position retainer to the power steering pump stud bolt.
    20. Fig 8: Wiring Harness Position Retainer
    GF0022019Courtesy of FORD MOTOR CO.
  20. Connect the wiring harness position retainer and the EOP switch electrical connector.
    21. Fig 9: Engine Oil Pressure (EOP) Switch Electrical Connector & Wiring Harness Position Retainer
    GF0022020Courtesy of FORD MOTOR CO.
  21. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  22. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  23. Install the 3 accessory drive idler pulleys and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  24. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    25. Fig 10: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  25. Using the special tools, install the crankshaft front seal into the engine front cover.
    26. Fig 11: Installing Crankshaft Front Seal Using Special Tools
    G03919891Courtesy of FORD MOTOR CO.
    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.
  26. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
    27. Fig 12: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03919877Courtesy of FORD MOTOR CO.
  27. Use the special tool to install the crankshaft pulley.
    28. Fig 13: Installing Crankshaft Pulley Using Special Tool
    G03919878Courtesy of FORD MOTOR CO.
  28. 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.
    29. Fig 14: Installing Crankshaft Pulley Bolt
    GF0002723Courtesy of FORD MOTOR CO.
  29. Rotate the tensioner clockwise and install the accessory drive belt.
    30. Fig 15: Rotating Tensioner Clockwise
    GF0000336Courtesy of FORD MOTOR CO.
  30. Install the RH valve cover. For additional information, refer to Valve Cover - RH .
  31. Install the LH valve cover. For additional information, refer to Valve Cover - LH .
  32. Install the cooling fan shroud. For additional information, refer to ENGINE COOLING article.
  33. Install the engine cooling fan. For additional information, refer to ENGINE COOLING article.
  34. Fill the crankcase with clean engine oil.
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