Engine Front Cover: Installation

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.

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 of the engine block, cylinder heads, and oil pan. These tools cause contamination that can cause premature engine failure. Remove all traces of sealant, including any sealant from the inner surface of the cylinder block and cylinder head.

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.
Install the Alignment Pins.

Fig 1: Installing Alignment 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.

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: Identifying Bead Of Motorcraft® High Performance Engine RTV Silicone Applying Dimension
  Courtesy of FORD MOTOR CO.

NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and bolts 17, 18, 19 and 20.
- Tighten in sequence to 3 Nm (27 lb-in).
  
  Fig 3: Identifying Engine Front Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Remove the Alignment Pins.

Fig 4: Removing Alignment Pins
Courtesy of FORD MOTOR CO.
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.
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.
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 illustration 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 Tightening Sequence
  Courtesy of FORD MOTOR CO.
Using the floor jack, lower the engine to the installed position.
Install the new O-ring seals and the A/C tubes-to-evaporator and the bolt.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 8: Locating A/C Tube-To-Evaporator Bolt And A/C Tubes
  Courtesy of FORD MOTOR CO.
Install the A/C tube retaining clamp bolt.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 9: Locating A/C Tube Retaining Clamp Bolt
  Courtesy of FORD MOTOR CO.
Install the A/C tube bracket bolt.
- Tighten to 15 Nm (133 lb-in).
  
  Fig 10: Locating A/C Tube Bracket Bolt
  Courtesy of FORD MOTOR CO.
Attach the A/C tube and wiring harness to the retainers.

Fig 11: Locating A/C Tube Clamp And Wiring Harness Retainers
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 Threadlock and 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.

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 Threadlock and Sealer to the engine mount stud threads.
4. Install the 2 engine mount studs.
  - Tighten to 20 Nm (177 lb-in).
    
    Fig 12: Locating Engine Mount Studs
    Courtesy of FORD MOTOR CO.
Install the engine mount bracket and the 2 bolts.
- Tighten to 30 Nm (22 lb-ft).
  
  Fig 13: Locating Engine Mount Bracket And Bolts
  Courtesy of FORD MOTOR CO.
Install the engine mount and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).
  
  Fig 14: Locating Engine Mount And Bolts
  Courtesy of FORD MOTOR CO.
Install the 4 engine mount nuts.
- Tighten to 63 Nm (46 lb-ft).
  
  Fig 15: Locating Engine Mount Nuts
  Courtesy of FORD MOTOR CO.
Install the engine mount brace, nut and bolt.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 16: Locating Engine Mount Brace, Nut And Bolt
  Courtesy of FORD MOTOR CO.
Position the power steering pump and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 17: Locating Power Steering Pump Bolts
  Courtesy of FORD MOTOR CO.
Install the Power Steering Pressure (PSP) tube bracket-to-power steering pump bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 18: Locating PSP Tube Bracket-To-Power Steering Pump Bolt
  Courtesy of FORD MOTOR CO.
Connect the PSP switch electrical connector.

Fig 19: Locating PSP Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Install the ground cable bolt.
- Tighten to 12 Nm (106 lb-in).
  
  Fig 20: Locating Bolt And Ground Cable
  Courtesy of FORD MOTOR CO.
Install the RH and LH valve covers. For additional information, refer to VALVE COVER - LH and VALVE COVER - RH .
Connect the hose to the power steering reservoir.

Fig 21: Locating Power Steering Reservoir Hose Clamp
Courtesy of FORD MOTOR CO.

NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

Fig 22: Installing Crankshaft Front Seal

Courtesy of FORD MOTOR CO.

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 23: Installing Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.
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 24: Installing Crankshaft Pulley Washer And Bolt Using Strap Wrench
  Courtesy of FORD MOTOR CO.
Install the RH inner fender splash shield. For additional information, refer to FRONT END BODY PANELS .
Connect the power steering cooler tube.

Fig 25: Locating Power Steering Cooler Tube Clamp
Courtesy of FORD MOTOR CO.
Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
- Tighten to 15 Nm (133 lb-in).
  
  Fig 26: Locating A/C Tube And Nut
  Courtesy of FORD MOTOR CO.
Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut.
- Tighten to 15 Nm (133 lb-in).
  
  Fig 27: Locating A/C Tube Nut
  Courtesy of FORD MOTOR CO.
Install the EVAP canister purge valve. For additional information, refer to EVAPORATIVE EMISSIONS .
Install the degas bottle. For additional information, refer to ENGINE COOLING .
Install the accessory drive belt, tensioner and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
Install the front wheels and tires. For additional information, refer to WHEELS AND TIRES .
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.

Fill the engine with clean engine oil.
Fill the power steering system. For additional information, refer to STEERING SYSTEM - HYDRAULIC POWER ASSIST STEERING (HPAS) .
Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .