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Engine Front Cover: Installation

WARNING: This page is about a different car, the 2004 Ford Ranger. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: This step is needed only if a new front cover is being installed.
    Fig 1: Installing Fan Drive Pulley
    G03273590Courtesy of FORD MOTOR CO.
  1. Install the fan drive pulley, using a nut and bolt with flat washers.
    2. NOTE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  2. Clean and inspect the mounting surfaces of the engine and the front cover.
    3. NOTE: The engine front cover must be installed and the bolts tightened within four minutes of applying the silicone gasket and sealant.
    Fig 2: Applying Sealant To Front Cover
    G03273591Courtesy of FORD MOTOR CO.
  3. Apply a 2.5 mm (0.1-in) bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 -mm (0.1 in) bead of silicone gasket and sealant to the front cover.
  4. Install the front cover. Tighten the bolts in the sequence shown, to the following specifications:
    • Tighten the 8 mm bolts to 10 N.m (89 lb-in).
    • Tighten the 10 mm bolts to 25 N.m (18 lb-ft).
    • Tighten the 13 mm bolts to 48 N.m (35 lb-ft).
      Fig 3: Front Cover Bolt Tightening Sequence
      G03273592Courtesy of FORD MOTOR CO.
  5. Position the power steering pump and install the lower retaining bolt.
    Fig 4: Installing Power Steering Bolt Lower Retaining Bolt
    G03273593Courtesy of FORD MOTOR CO.
  6. Connect the power steering pressure (PSP) switch electrical connector.
    Fig 5: Connecting Power Steering Pressure (PSP) Switch Electrical Connector
    G03273594Courtesy of FORD MOTOR CO.
  7. Install the water pump pulley.
    Fig 6: Installing Water Pump Pulley
    G03273595Courtesy of FORD MOTOR CO.
  8. Install the belt tensioner.
    Fig 7: Installing Belt Tensioner
    G03273596Courtesy of FORD MOTOR CO.
    9. CAUTION: The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, with diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore, the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.
  9. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
  10. Install a new crankshaft position (CKP) sensor. Do not tighten the bolts at this time.
    Fig 8: Installing New Crankshaft Position (CKP) Sensor
    G03273597Courtesy of FORD MOTOR CO.
  11. Adjust the CKP with the alignment tool supplied with the new sensor and tighten the CKP mounting bolt.
    Fig 9: Adjusting/Tightening CKP Sensor
    G03273598Courtesy of FORD MOTOR CO.
  12. Connect the CKP sensor electrical connector and the wiring harness pin -type retainers.
    Fig 10: Connecting CKP Sensor Electrical Connector
    G03273599Courtesy of FORD MOTOR CO.
  13. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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