Engine Front Cover: Installation

All vehicles 

NOTE: 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.
NOTE: 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.
NOTE: 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 Alignment Pins.
   Fig 1: Identifying Dowel Pins

   Courtesy of FORD MOTOR CO.
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 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 tightened 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.
     Fig 2: Applying Bead Of Motorcraft High Performance Engine RTV Silicone

     Courtesy 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).
     Fig 3: Identifying Dowel Pins

     Courtesy of FORD MOTOR CO.
6. Remove the Alignment Pins.
   Fig 4: Identifying Alignment Pins

   Courtesy of FORD MOTOR CO.
7. Install the engine mount bracket and lower bolt.
   • Do not tighten at this time.
     Fig 5: Locating Engine Mount Bracket And Lower Bolt

     Courtesy of FORD MOTOR CO.
8. Install the 2 upper engine mount bracket bolts.
   • Do not tighten at this time.
     Fig 6: Locating Upper Engine Mount Bracket Bolts

     Courtesy of FORD MOTOR CO.
NOTE: 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 (133 lb-in).
   • 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).
     Fig 7: Identifying Engine Front Cover Bolts In Sequence

     Courtesy 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 (133 lb-in).
      Fig 8: Locating A/C Tube Bracket Bolt

      Courtesy of FORD MOTOR CO.
12. Install the A/C tube retaining clamp bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 9: Locating A/C Tube Retaining Clamp Bolt

      Courtesy of FORD MOTOR CO.
13. Install the A/C tube bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 10: Locating A/C Tube Bracket Bolt

      Courtesy of FORD MOTOR CO.
NOTE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new thread sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.
14. Install the engine mount studs in the following sequence.
    1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.
    2. Clean all the thread sealer from the engine mount studs (old and new studs).
    3. Apply new thread sealer to the engine mount stud threads.
    4. Install the 2 engine mount studs.
       • Tighten to 20 Nm (177 lb-in).
         Fig 11: Locating Engine Mount Studs

         Courtesy of FORD MOTOR CO.
15. Install the engine mount bracket and the 2 bolts.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 12: Locating Bolts And Engine Mount Bracket

      Courtesy of FORD MOTOR CO.
16. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 13: Locating Bolts And Engine Mount

      Courtesy of FORD MOTOR CO.
17. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 14: Locating Engine Mount Nuts

      Courtesy of FORD MOTOR CO.
18. Install the engine mount brace, nut and bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 15: Locating Engine Mount Brace, Nut And Bolt

      Courtesy of FORD MOTOR CO.
19. Position the power steering pump and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 16: Locating Power Steering Pump And Bolts

      Courtesy of FORD MOTOR CO.
20. Install the PSP  tube bracket-to-power steering pump bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 17: Locating PSP Tube Bracket-To-Power Steering Pump Bolt

      Courtesy of FORD MOTOR CO.
21. Connect the PSP  switch electrical connector.
    Fig 18: Locating Power Steering Pressure (PSP) Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
22. Install the ground cable bolt.
    • Tighten to 12 Nm (106 lb-in).
      Fig 19: Locating Bolt And Ground Cable

      Courtesy of FORD MOTOR CO.
23. Attach the wiring harness retainer to the engine mount bracket stud bolt.
    Fig 20: Locating Engine Mount Bracket Stud Bolt

    Courtesy 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.
    Fig 21: Locating Power Steering Reservoir Hose

    Courtesy 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.
      Fig 22: Locating Y-Pipe Flange Nuts

      Courtesy of FORD MOTOR CO.
27. Install the exhaust Y-pipe assembly and 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 23: Locating Y-Pipe-To-Catalytic Converter Nuts

      Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Fig 24: Installing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
28. Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Fig 25: Identifying Front Cover Oil Seal Installer And Crankshaft Vibration Damper
Courtesy of FORD MOTOR CO.
29. Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.
30. Using the Strap Wrench, 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.
      Fig 26: Locating Crankshaft Pulley Washer And Bolt

      Courtesy of FORD MOTOR CO.
31. Install the RH inner fender splash shield. For additional information, refer to FRONT END BODY PANELS .
32. Connect the power steering cooler tube.
    Fig 27: Locating Power Steering Cooler Tube

    Courtesy of FORD MOTOR CO.

Vehicles with rear A/C 

33. Install the new O-ring seal, A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).
      Fig 28: Locating Nut And Rear A/C Tube

      Courtesy of FORD MOTOR CO.
34. Install the new O-ring seal, A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).
      Fig 29: Locating A/C Tube And Nut

      Courtesy of FORD MOTOR CO.

All vehicles 

35. Install a new O-ring seal and the A/C tube-to-receiver/drier and the bolt.
    • Tighten to 15 Nm (133 lb-in).
      Fig 30: Locating A/C Tube-To-Receiver/Drier And Bolt

      Courtesy of FORD MOTOR CO.
36. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
    • Tighten to 15 Nm (133 lb-in).
      Fig 31: Locating A/C Tubes And Nuts

      Courtesy of FORD MOTOR CO.
37. Install the EVAP  canister purge valve. For additional information, refer to EVAPORATIVE EMISSIONS .
38. Install the degas bottle. For additional information, refer to ENGINE COOLING .
39. Install the accessory drive belt, tensioner and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
40. Install the front wheels and tires. For additional information, refer to WHEELS & TIRES .
41. Install the engine ACL  outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
NOTE: 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.
42. Fill the engine with clean engine oil.
43. Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION .
44. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .