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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 engine front cover.
    • Remove the shop towels from the oil pan.
    • Remove the plugs or seals from the engine block and engine front cover.
  2. Apply a small amount of silicone gasket and sealant as shown.
    Fig 1: Applying Sealant
    G03400760Courtesy of FORD MOTOR CO.
  3. Install the engine front cover gasket and apply silicone gasket and sealant as shown.
    Fig 2: Applying Sealant
    G03400761Courtesy of FORD MOTOR CO.
  4. Install the engine front cover and bolts.
    Fig 3: Installing Engine Front Cover And Bolts
    G03400762Courtesy of FORD MOTOR CO.
  5. Install the water pump. Install the nuts and bolts.
    Fig 4: Installing Water Pump
    G03400763Courtesy of FORD MOTOR CO.
    6. NOTE: The number 12 bolt is not part of the tightening sequence.
    Fig 5: Tightening Fasteners In Sequence
    G03400764Courtesy of FORD MOTOR CO.
  6. Tighten the fasteners in the sequence shown to 26 N.m (19 lb-ft).
  7. Install a new oil filter.
    Fig 6: Installing Oil Filter
    G03400765Courtesy of FORD MOTOR CO.
  8. Install the wiring harness pin-type retainer.
    Fig 7: Installing Wiring Harness Pin-Type Retainer
    G03400766Courtesy of FORD MOTOR CO.
  9. Connect the crankshaft position sensor electrical connector.
    Fig 8: Connecting Crankshaft Position Sensor Electrical Connector
    G03400767Courtesy of FORD MOTOR CO.
  10. Connect the lower radiator hose.
    Fig 9: Connecting Lower Radiator Hose
    G03400768Courtesy of FORD MOTOR CO.
  11. Install the camshaft synchronizer assembly. For additional information, refer to CAMSHAFT SYNCHRONIZER .
  12. Install the heater water outlet tube. For additional information, refer to ENGINE COOLING .
  13. Connect the bypass hose and the upper radiator hose.
    Fig 10: Connecting Bypass Hose And Upper Radiator Hose
    G03400769Courtesy of FORD MOTOR CO.
  14. Connect the EGR tube.
    Fig 11: Connecting EGR Tube
    G03400770Courtesy of FORD MOTOR CO.
  15. Install the power steering pump.
    Fig 12: Installing Power Steering Pump
    G03400771Courtesy of FORD MOTOR CO.
  16. Install the water pump pulley.
    Fig 13: Installing Water Pump Pulley Bolts
    G03400772Courtesy of FORD MOTOR CO.
  17. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
  18. Fill the engine cooling system. For additional information, refer to ENGINE COOLING .
  19. Drain and refill with clean engine oil
  20. Connect the battery ground cable.
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