FixVault
Home › Lincoln › 2011 › MKS Base, AWD › Repair and Diagnosis › External Pages › Different car › Section 1848 (Engine Mechanical - 3.5L GTDI) › In-Vehicle Repair › Engine Front Cover › Installation

Engine Front Cover: Installation

WARNING: This page is about a different car, the 2011 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.
    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.
  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.
    2. 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.
    NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
  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 with a plastic scraper.
    2. Apply silicone gasket remover, following package directions and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, 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: Installing Alignment Pins
    G07807691Courtesy of FORD
    4. NOTE: Failure to use the correct RTV Silicone Sealant (TA-357) 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  4. Apply a 3.0 mm (0.11 in) bead of RTV Silicone Sealant (TA-357) to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
    • Apply a 5.5 mm (0.21 in) bead of RTV Silicone Sealant (TA-357) 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 RTV Silicone Applying Area Into Oil Pan-To-Cylinder Block Joint And Cylinder Head-To-Cylinder Block Joint
      G07807692Courtesy of FORD
    5. 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 Engine Front Cover Bolts Tightening Sequence
      G07807693Courtesy of FORD
  6. Remove the Alignment Pins.
    Fig 4: Removing Alignment Pins
    G07807694Courtesy of FORD
  7. Install the engine mount bracket and lower bolt.
    • Do not tighten at this time.
      Fig 5: Locating Lower Engine Mount Bracket And Bolt
      G07807695Courtesy of FORD
  8. Using the floor jack, raise the engine slightly.
  9. Install the 2 upper engine mount bracket bolts.
    • Do not tighten at this time.
      Fig 6: Locating Upper Engine Mount Bracket Bolts
      G07807696Courtesy of FORD
    10. NOTE: Do not expose the RTV Silicone Sealant to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
  10. 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
      G07807697Courtesy of FORD
  11. Install the HO2S connector bracket and stud bolt.
    • Tighten to 10 Nm (89 lb-in).
    • Attach the HO2S electrical connector.
      Fig 8: Locating RH Heated Oxygen Sensor (HO2S) Electrical Connector, Bracket And Bolt
      G07807698Courtesy of FORD
    12. 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.
  12. 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 9: Locating Engine Mount Studs
        G07807699Courtesy of FORD
  13. Install the engine mount. For additional information, refer to ENGINE MOUNT  .
    14. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
    Fig 10: Installing Crankshaft Front Seal
    G07807700Courtesy of FORD
  14. Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
    15. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
    Fig 11: Installing Crankshaft Pulley
    G07807701Courtesy of FORD
  15. Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.
  16. 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 12: Installing Crankshaft Pulley Washer And Bolt Using Strap Wrench
      G07807702Courtesy of FORD
    17. NOTE: The bracket has keyed tabs to orient the roll restrictor.
  17. Position the rear roll restrictor bracket with the keyed tabs aligned to the rear roll restrictor and install the bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 13: Locating Rear Roll Restrictor Bracket And Bolts
      G07807703Courtesy of FORD
  18. Tighten the rear roll restrictor bolt to 90 Nm (66 lb-ft).
    Fig 14: Locating Rear Roll Restrictor Bolt
    G07807704Courtesy of FORD
  19. Install the front roll restrictor bolt.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 15: Locating Front Roll Restrictor Bolt
      G07807705Courtesy of FORD
  20. Install the accessory drive belt tensioner and belt. For additional information, refer to ACCESSORY DRIVE BELT Article.
  21. Install the RH inner fender splash shield. For additional information, refer to BODY PANEL SYSTEM - FRONT END BODY PANELS Article.
  22. Install the underbody shield and the 4 retainers.
    Fig 16: Locating Underbody Shield Retainers
    G07807706Courtesy of FORD
  23. Install the RH and LH valve covers. For additional information, refer to VALVE COVER - RH  and VALVE COVER - LH  .
  24. Connect the LH HO2S electrical connector.
    • Attach the HO2S connector retainer to the bracket.
      Fig 17: Locating LH Heated Oxygen Sensor (HO2S) Electrical Connector
      G07807707Courtesy of FORD
  25. Fill the engine with clean engine oil.
  26. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.
About FixVault