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Engine Front Cover: Installation

    CAUTION: In order to prevent foreign material from contaminating the engine block or the engine front cover, it is necessary to seal the coolant and oil passages of both components. Failure to follow these directions will result in engine damage.
    CAUTION: Do not use a surface conditioning pad or any other type of fibrous abrasive disc to clean the gasket surfaces. Failure to follow these directions will result in engine damage.
  1. Clean and inspect the engine block and front cover as follows:
    • Pack the exposed portion of the oil pan with clean shop towels.
    • Plug the oil and coolant passages.
    • Clean the gasket surfaces.
    • Clean all surfaces requiring gasket sealant with metal surface cleaner.
    • Using compressed air, remove any remaining foreign material from the engine block and front cover.
    • Remove the shop towels from the oil pan.
    • Remove the plugs or seals from the oil and coolant passages.
  2. Apply a small amount of silicone gasket and sealer as shown.
    3. Fig 1: Applying Silicone Sealer
    GF0002393Courtesy of FORD MOTOR CO.
  3. Install the engine front cover gasket and apply a small amount of silicone gasket and sealer as shown.
    4. Fig 2: Applying Silicone Sealer To Pan
    GF0002394Courtesy of FORD MOTOR CO.
    CAUTION: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence.
    NOTE: Use Thread Sealant with PTFE on studs No. 4, 6 and bolt No. 12.
  4. Install the engine front cover with the engine front cover studs in their original locations.
    • Tighten the engine front cover studs to 7 Nm (62 lb-in).
    • Using a new gasket, install the coolant pump.
    • Tighten the fasteners in the sequence shown.
      • Tighten bolt No. 12 to 10 Nm (89 lb-in).
      • Tighten all other fasteners to 28 Nm (21 lb-ft).
    5. Fig 3: Identifying Front Cover Bolt Tightening Sequence
    GF0002395Courtesy of FORD MOTOR CO.
  5. Install the 2 oil pan-to-engine front cover bolts.
    • Tighten to 10 Nm (89 lb-in).
  6. Install the catalyst monitor sensor electrical connector bracket and the nut.
    • Tighten to 28 Nm (21 lb-ft).
    7. Fig 4: Locating Catalyst Monitor Sensor Electrical Connector Bracket Nut
    GF0033037Courtesy of FORD MOTOR CO.
  7. Connect the catalyst monitor sensor electrical connector.
    8. Fig 5: Locating Catalyst Monitor Sensor Electrical Connector
    GF0033036Courtesy of FORD MOTOR CO.
  8. Clean and inspect the engine front cover-to-crankshaft front seal mating surface.
    9. NOTE: Lubricate the new crankshaft front seal lips with clean engine oil prior to installation.
  9. Assemble the special tools, then place the crankshaft front seal onto the special tools.
    10. Fig 6: Identifying Special Tools (303--335) And (303--474)
    GF0033032Courtesy of FORD MOTOR CO.
  10. Using the special tools, install the crankshaft front seal.
    11. Fig 7: Installing Crankshaft Front Seal Using Special Tools (303--335) And (303--474)
    GF0033033Courtesy of FORD MOTOR CO.
  11. Remove the bolts lower the RH side of the subframe 50.8 mm (2 in).
    12. Fig 8: Right Subframe Bolts
    GF0033029Courtesy of FORD MOTOR CO.
    NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. 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.
  12. Apply silicone gasket and sealer to the Woodruff key slot in the crankshaft pulley.
    13. Fig 9: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley
    G03919877Courtesy of FORD MOTOR CO.
  13. Lubricate the crankshaft pulley sealing surface with clean engine oil.
    14. Fig 10: Lubricating Crankshaft Pulley Sealing Area With Clean Engine Oil
    GF0002599Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the crankshaft front seal inner lip with clean engine oil prior to installation.
  14. Using the special tool, install the crankshaft pulley.
    15. Fig 11: Installing Crankshaft Pulley Using Special Tool (303--175)
    GF0033031Courtesy of FORD MOTOR CO.
  15. Install the crankshaft pulley washer and the bolt.
    • Tighten to 160 Nm (118 lb-ft).
  16. Raise the subframe into position, then install the bolts.
    • Tighten to 175 Nm (129 lb-ft).
    17. Fig 12: Right Subframe Bolts
    GF0033029Courtesy of FORD MOTOR CO.
  17. Connect the RH front anti-lock brake wheel sensor electrical connector.
    18. Fig 13: Right Front Anti-Lock Brake Wheel Sensor Electrical Connector
    GF0033027Courtesy of FORD MOTOR CO.
  18. Drain the engine oil.
    • Install the drain plug and tighten to 26 Nm (19 lb-ft).
    19. Fig 14: Identifying Engine Oil Drain Plug
    GF0033020Courtesy of FORD MOTOR CO.
  19. If equipped, install the oil cooler. For additional information, refer to Oil Cooler .
    20. NOTE: Lubricate the new engine oil filter seal with clean engine oil prior to installation.
  20. Install a new engine oil filter.
    • Tighten one half turn after the gasket makes contact with the oil filter housing.
  21. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  22. Install the generator mounting bracket and the generator brace bolt.
    • Tighten to 47 Nm (35 lb-ft).
  23. Install the camshaft synchronizer. For additional information, refer to ELECTRONIC ENGINE CONTROLS article.
  24. Install the coolant pump. For additional information, refer to ENGINE COOLING article.
  25. Install the generator. For additional information, refer to GENERATOR AND REGULATOR article.
  26. Fill the engine with clean engine oil.
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