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Engine Front Cover: Installation

    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 engine front cover. These tools cause scratches and gouges that make leak paths.
  1. 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.
    2. 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 sealant, including any sealant from the inner surface of the cylinder block and cylinder head.
  2. 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.
  3. Install the special tools.
    4. Fig 1: Identifying Special Tool (307-399)
    GF0029329Courtesy 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 tighten 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.
  4. 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.
    5. Fig 2: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Engine Front Cover Sealing Surfaces
    GF0029330Courtesy of FORD MOTOR CO.
    NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  5. Install the engine front cover and bolts 17, 18, 19 and 20.
    • Tighten in sequence to 3 Nm (27 lb-in).
    6. Fig 3: Installing Engine Front Cover & Bolts In Sequence
    GF0029331Courtesy of FORD MOTOR CO.
  6. Remove the special tools (alignment pins).
  7. Install the engine mount bracket and lower bolt.
    • Do not tighten at this time.
    8. Fig 4: Locating Lower Engine Mount Bracket Bolt
    GF0031370Courtesy of FORD MOTOR CO.
  8. Install the 2 upper engine mount bracket bolts.
    • Do not tighten at this time.
    9. Fig 5: Locating Upper Engine Mount Bracket Bolts
    GF0031369Courtesy 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.
  9. 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).
    10. Fig 6: Identifying Tightening Of Engine Front Cover Bolts & Engine Mount Bracket Bolts In Sequence
    GF0029332Courtesy of FORD MOTOR CO.
  10. Using the floor jack, lower the engine to the installed position.
  11. Install the new O-ring seals and the A/C tubes-to-evaporator and the bolt.
    • Tighten to 15 Nm (11 lb-ft).
    12. Fig 7: Identifying Bolt And A/C Tubes
    GF0045641Courtesy of FORD MOTOR CO.
  12. Install the A/C tube retaining clamp bolt.
    • Tighten to 10 Nm (89 lb-in).
    13. Fig 8: Identifying A/C Tube Retaining Clamp Bolt
    GF0045640Courtesy of FORD MOTOR CO.
  13. Install the A/C tube bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
    14. Fig 9: Identifying A/C Tube Bracket Bolt
    GF0045639Courtesy of FORD MOTOR CO.
  14. Install the 2 engine mount studs.
    • Tighten to 18 Nm (13 lb-ft).
    15. Fig 10: Locating Engine Mount Studs
    GF0029187Courtesy of FORD MOTOR CO.
  15. Install the engine mount bracket and the 2 bolts.
    • Tighten to 24 Nm (18 lb-ft).
    16. Fig 11: Locating Engine Mount Bracket & Bolts
    GF0029186Courtesy of FORD MOTOR CO.
  16. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    17. Fig 12: Identifying Engine Mount And Bolts
    GF0045638Courtesy of FORD MOTOR CO.
  17. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
    18. Fig 13: Identifying Mounting Nuts
    GF0045637Courtesy of FORD MOTOR CO.
  18. Install the engine mount brace, nut and bolt.
    • Tighten to 20 Nm (15 lb-ft).
    19. Fig 14: Identifying Nut, Bolt And Brace
    GF0045636Courtesy of FORD MOTOR CO.
  19. Position the power steering pump and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    20. Fig 15: Identifying Bolts
    GF0045635Courtesy of FORD MOTOR CO.
  20. Install the power steering pressure (PSP) tube bracket-to-power steering pump bolt.
    • Tighten to 10 Nm (89 lb-in).
    21. Fig 16: Identifying Bracket-To-Power Steering Pump Bolt
    GF0045634Courtesy of FORD MOTOR CO.
  21. Connect the PSP switch electrical connector.
    22. Fig 17: Identifying PSP Connector
    GF0045633Courtesy of FORD MOTOR CO.
  22. Connect the fuel efficient power steering system solenoid electrical connector.
    23. Fig 18: Identifying Connector
    GF0045632Courtesy of FORD MOTOR CO.
  23. Install the ground cable bolt.
    • Tighten to 12 Nm (9 lb-ft).
    24. Fig 19: Identifying Bolt And Ground Cable
    GF0045631Courtesy of FORD MOTOR CO.
  24. Install the RH and LH valve covers. For additional information, refer to Valve Cover - LH  and Valve Cover - RH .
  25. Connect the hose to the power steering reservoir.
    26. Fig 20: Disconnecting Hose From Power Steering Reservoir
    GF0031386Courtesy of FORD MOTOR CO.
  26. Using a new gasket, install the exhaust Y-pipe and install the 2 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    • Attach the exhaust hanger.
    27. Fig 21: Identifying Nuts And Exhaust Hanger
    GF0045630Courtesy of FORD MOTOR CO.
  27. Install the exhaust Y-pipe assembly and 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    28. Fig 22: Identifying Nuts
    GF0045629Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
  28. Using the special tools, install a new crankshaft front seal.
    29. Fig 23: Installing Crankshaft Front Seal Using Special Tools (303-102) & (303-1251)
    GF0029107Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
  29. Using the special tools, install the crankshaft pulley.
    30. Fig 24: Installing Crankshaft Pulley
    GF0017018Courtesy of FORD MOTOR CO.
  30. 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.
    31. Fig 25: Installing Crankshaft Pulley Washer & Bolt Using Special Tools (303-D055)
    GF0029104Courtesy of FORD MOTOR CO.
  31. Install the RH inner fender splash shield. For additional information, refer to FRONT END BODY PANELS article.
  32. Connect the power steering cooler tube.
    33. Fig 26: Identifying Power Steering Cooler Tube
    GF0045628Courtesy of FORD MOTOR CO.
  33. Install a new O-ring seal and the A/C tube-to-receiver/drier and the nut.
    • Tighten to 15 Nm (11 lb-ft).
    34. Fig 27: Identifying Nut
    GF0045627Courtesy of FORD MOTOR CO.
  34. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
    • Tighten to 15 Nm (11 lb-ft).
    35. Fig 28: Identifying Nuts
    GF0045626Courtesy of FORD MOTOR CO.
  35. Install the degas bottle. For additional information, refer to ENGINE COOLING article.
  36. Install the accessory drive belt, tensioner and the power steering belt. For additional information, refer to ACCESSORY DRIVE article.
  37. Install the front wheels and tires. For additional information, refer to WHEELS AND TIRES article.
  38. Install the engine air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
    39. 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.
  39. Fill the engine with clean engine oil.
  40. Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION article.
  41. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
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