Engine Front Cover: Installation

Using the special tools, install the engine front cover to coolant pipe seal. Use Special Service Tool: 205-149 (T80T-4000-R) Installer, Spindle Bearing, 205-153 (T80T-4000-W) Handle.

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NOTE: The use of alignment pins will aid in the installation of the engine front cover.

Install Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

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- NOTE: 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 the 6 bolts must be installed within 10 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 60 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 inner bolt boss.
  
  Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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- NOTE: 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 the 6 bolts must be installed within 10 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 60 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 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 places as indicated.
  
  Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and the bolts.

Torque: 27 lb.in (3 Nm)

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Remove Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

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Install the remaining engine front cover bolts and tighten in the sequence shown in 3 stages.
Torque: Stage 1: Tighten bolts 1 through 24 to: 89 lb.in (10 Nm) | Stage 2: Tighten bolts 1 through 24 to: 177 lb.in (20 Nm) | Stage 3: Tighten bolts 1 through 24 an additional: 45°

Fig 1: Engine Front Cover Bolts Tightening Sequence
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Install the coolant hose retainer bracket and the nuts.
Torque: 177 lb.in (20 Nm)

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Install the coolant pump belt idler pulley bracket and the bolts.
Torque: 18 lb.ft (25 Nm)

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Install the coolant pump belt idler pulley and bolt.
Torque: 18 lb.ft (25 Nm)

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- Install a new coolant pump gasket.
- Lubricate the coolant pump O-ring seal with clean engine coolant and install.
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Install the coolant pump and tighten in sequence shown.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45°

Fig 2: Coolant Pump Bolts Tightening Sequence
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- Install a new thermostat housing gasket.
- Lubricate the thermostat housing O-ring seal with clean engine coolant and install.
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Position the thermostat housing and install the bolts and tighten in sequence shown.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45°

Fig 3: Thermostat Housing Bolts Tightening Sequence
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Position the coolant hoses and install the nut.
Torque: 89 lb.in (10 Nm)

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1. Position the coolant hoses and tighten the coolant hose clamp.
  Torque: 44 lb.in (5 Nm)
2. Install the coolant hose retainer nut.
  Torque: 97 lb.in (11 Nm)
3. Attach the coolant hose retainer.
4. Install the coolant hose retainer nut and bolt.
  Torque: 97 lb.in (11 Nm)
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- Install the coolant hoses and tighten the coolant hose clamps.
  Torque: 44 lb.in (5 Nm)
- Install and tighten the coolant hose fitting.
  Torque: 97 lb.in (11 Nm)
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Install the following items:
1. Install the crankshaft front seal. Refer to: Crankshaft Front Seal .
2. Install the RH valve cover. Refer to: Valve Cover RH .
3. Install the LH valve cover. Refer to: Valve Cover LH .
1. Prefill a new oil filter with clean engine oil.
  Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)
2. Lubricate the oil filter gasket with clean engine oil.
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- Install a new oil filter and tighten in 2 stages.
- Stage 1: Install to initial gasket contact.
- Stage 2: Tighten 3/4 to 1 turn.
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NOTE: The total volume of oil required to properly refill the engine oil system can vary depending on the volume of oil drained from the system components.

Add 10.0 quarts (9.5 liters) of clean engine oil to the oil tank as an initial fill.

Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)

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- Continue idling until the coolant temperature reaches 190 degrees Fahrenheit (88 degrees Celsius).
- Turn the engine off.
- Wait 2 to 3 minutes.
NOTE: Do not exceed the specified engine oil system capacity of 13.7 quarts (13 liters).

Check the oil level by screwing dipstick in until fully seated and add as necessary to place the level between the minimum and maximum oil level marks on the dipstick.

Material: Castrol® EDGE® Supercar 5W-50 (WSS-M2C931-C)

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Lower the vehicle and position the hoist using the front and mid lift points. Refer to: Jacking and Lifting - Overview .
NOTE: Apply threadlock to the bolts before installation.

Install the engine underbody cover and the bolts.

Material: Motorcraft® Threadlock and Sealer / TA-25-B

Torque: 60 lb.in (6.8 Nm)

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Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.