Engine Front Cover: Installation

1.

NOTE: Use Spindle Bearing Installer 205-149 to install the seal.

If removed, using the Spindle Bearing Installer, install a new front cover radial seal from the rear side of the front cover.

GFD135116

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2.

Install the Special Tools(s): Alignment Pins 307-399.

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3.

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: 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 procedure can cause engine oil leakage.

NOTE: The engine front cover and bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 must be installed within 10 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 on the inside edge of the engine front cover to the engine front cover sealing surfaces including the 2 engine front cover bolt 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.

GFD135118

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4.

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

Install the engine front cover and the bolts.
- Stage 1: Tighten bolts 1, 2, 7, 8, 15, 17, 18, 19, 20 and 21 in sequence to 10 Nm (89 lb-in).
- Stage 2: Tighten bolts 1, 2, 7, 8, 15, 17, 18, 19 and 20 in sequence to 20 Nm (177 lb-in) then an additional 45 degrees.
- Stage 3: Tighten bolt 21 to 20 Nm (177 lb-in) then an additional 90 degrees.

Fig 1: Engine Front Cover Tightening Sequence (1 of 2)

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5.

Remove the Special Tool(s): Alignment Pins 307-399.

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6.

Install the remaining engine front cover bolts. Tighten in the sequence in 6 stages:
- Stage 1: Tighten bolts 1 thru 21 to 10 Nm (89 lb-in).
- Stage 2: Tighten bolts 1 thru 20 to 24 Nm (18 lb-ft).
- Stage 3: Tighten bolt 21 to 20 Nm (177 lb-in) then an additional 45 degrees.
- Stage 4: Tighten 21 an additional 90 degrees.
- Stage 5: Tighten bolt 22 to 10 Nm (89 lb-in) then an additional 45 degrees.
- Stage 5: Tighten bolt 22 an additional 45 degrees.

Fig 2: Engine Front Cover Tightening Sequence (2 of 2)

GFD135121

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7.

Position the generator wiring harness on the stud bolt and clip the engine harness on the engine front cover.

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8.

Install the transmission cooler tube bracket and the nut on the engine front cover stud bolt.
- Tighten to 12 Nm (106 lb-in).

GFD135109

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9.

Install the pushpin retainer into the oil pan.

GFD135108

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10.

Install the crankshaft front seal. Refer to: Crankshaft Front Seal .

11.

Install the accessory drive belt tensioner and 2 bolts.
- Tighten to 25 Nm (18 lb-ft).

GFD135107

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12.

Install the generator stud.
- Tighten to 8 Nm (71 lb-in).

GFD135106

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13.

Position back the generator and install the bolt.
- Tighten to 48 Nm (35 lb-ft).

GFD135105

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14.

Install the coolant pump. Refer to: Engine Cooling .

15.

Install the LH and RH valve covers. Refer to: Valve Cover - LH and Valve Cover - RH .

16.

Install the intake manifold. Refer to: Intake Manifold .

17.
- Connect the Charge Air Cooler (CAC) -to-Throttle Body (TB) pipe to the CAC.
- Connect the retainer and electrical connector.

GFD135122

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18.

Install the CAC -to-TB pipe. Refer to: Intake Air System Components - Exploded View, 3.5L in Intake Air Distribution and Filtering .

19.

If equipped, install the skid plate and the bolts.
- Tighten to 40 Nm (30 lb-ft).

GFD135102

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20.

If equipped, install the lower air deflector and the pushpins. Turn the quarter-turn retainers.

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21.

If equipped, install the splash shield and the fasteners.

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22.

Connect the battery ground cable. Refer to: Battery, Mounting and Cables .

23.

Fill the engine with clean engine oil.

GFD135083

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