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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

All engines 

  1. If installing a new engine front cover, install the CKP sensor and the bolt onto the engine front cover.
    • Lubricate the CKP O-ring seal with clean engine oil prior to installation.
    • 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 clean sealing surfaces.
    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: Identifying Area For Silicone Gasket Application
    G03886057Courtesy of FORD MOTOR CO.
  3. Install the engine front cover with the engine front cover gasket on the front cover-to-cylinder block dowel and loosely install the bolts.
    4. Fig 2: Installing Engine Front Cover With Engine Front Cover Gasket On Front Cover-To-Cylinder Block Dowel
    GF0002613Courtesy of FORD MOTOR CO.

    4.6L (2V) engine 

  4. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
    Item Part Number Description
    1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    6 W706508 Stud, Hex Shldr Pilot, M8 x 1.25 x 50 - M6 x 1 x 10
    7 N808586 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 50 - M6 x 1 x 24
    8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    11 N808294 Hex HD Pilot, M8 x 1.25 x 53
    12 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 - M6 x 1.25 x 26
    13 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 - M6 x 1.25 x 26
    14 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 - M6 x 1.25 x26
    15 N806300 Stud, Hex Shldr Pilot, M8 x 1.25 x 65 - M6 x 1.25 x 26
    5. Fig 3: Front Cover Fastener Torque Sequence - 4.6L
    GF0011641Courtesy of FORD MOTOR CO.

    5.4L (2V) engine 

  5. Tighten the engine front cover fasteners in sequence in 3 stages.

    Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).

    Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

    Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).

    Item Part Number Description
    1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30
    7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30
    8 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5
    9 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5
    10 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5
    11 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
    12 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
    13 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
    14 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
    15 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
    6. Fig 4: Engine Front Cover Torque Sequence
    GF0011642Courtesy of FORD MOTOR CO.

    All engines 

  6. Loosely install the bolts, then tighten the bolts in 2 stages following the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
    7. Fig 5: Identifying Tightening Sequence Of Front Oil Pan Bolts
    G03920544Courtesy of FORD MOTOR CO.
  7. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
    8. Fig 6: Locating Crankshaft Front Seal
    G03881970Courtesy of FORD MOTOR CO.
  8. Using the special tools, install a new crankshaft front seal.
    9. Fig 7: 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.
  9. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
    10. Fig 8: Identifying Woodruff Key Slot On Crankshaft Pulley
    G03948080Courtesy of FORD MOTOR CO.
  10. Using the special tool, install the crankshaft pulley.
    11. Fig 9: Installing Crankshaft Pulley Using Special Tool
    G03919878Courtesy of FORD MOTOR CO.

    4.6L (2V) engine 

  11. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt 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 without exceeding 200 Nm (148 lb-ft).
    12. Fig 10: Holding Crankshaft Pulley Using Special Tool (303-D055)
    G04613240Courtesy of FORD MOTOR CO.

    5.4L (2V) engine 

  12. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages:
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    13. Fig 11: Holding Crankshaft Pulley Using Special Tool (303-D055)
    G04613240Courtesy of FORD MOTOR CO.

    All engines 

    NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
  13. Install the CMP sensor and bolt.
    • Tighten to 10 Nm (89 lb-in).
    14. Fig 12: Locating LH CMP Sensor Bolt
    G03919989Courtesy of FORD MOTOR CO.
  14. Connect the CMP electrical connector.
    15. Fig 13: Locating Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  15. Position the bracket, connect the tubes and install the nut.
    • Tighten to 10 Nm (89 lb-in) for the 4.6L engine.
    • Tighten to 30 Nm (22 lb-ft) for the 5.4L engine.
    16. Fig 14: Bracket & Nut
    GF0011639Courtesy of FORD MOTOR CO.
  16. Position the power steering pump and install the 5 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    17. Fig 15: Identifying Power Steering Pump Bolts
    G03886436Courtesy of FORD MOTOR CO.
  17. Connect the wire harness to the bracket.
    18. Fig 16: Wiring Harness Bracket
    GF0011638Courtesy of FORD MOTOR CO.
  18. Connect the A/C compressor electrical connector.
    19. Fig 17: A/C Compressor Electrical Connector
    G03888356Courtesy of FORD MOTOR CO.
  19. Connect the CKP sensor electrical connector.
    20. Fig 18: Identifying Crankshaft Position Sensor Electrical Connector
    G03888354Courtesy of FORD MOTOR CO.
  20. Position the belt idler pulley and install the bolt.
    • Tighten to 25 Nm (18 lb-ft).
    21. Fig 19: Accessory Drive Belt Idler Pulley And Retaining Bolt
    G04613548Courtesy of FORD MOTOR CO.
  21. Position the coolant pump pulley and install the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  22. Rotate the tensioner clockwise and install the accessory drive belt.
    23. Fig 20: Rotating Tensioner Clockwise
    GF0000336Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  23. Install the 2 radio interference capacitors and the 2 nuts.
    • Tighten to 25 Nm (18 lb-ft).
    24. Fig 21: Radio Interference Capacitor And Retaining Nut
    G04612142Courtesy of FORD MOTOR CO.
  24. Install the drain plug.
    • Tighten to 23 Nm (17 lb-ft).
    25. Fig 22: Engine Oil Drain Plug
    GF0002670Courtesy of FORD MOTOR CO.
  25. Install the RH and LH valve covers. For additional information, refer to Valve Cover - LH , Valve Cover - RH, 4.6L  or Valve Cover - RH, 5.4L .
  26. Fill the engine with clean engine oil.
  27. Install the radiator. For additional information, refer to ENGINE COOLING article.
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