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Engine Front Cover: Installation

    CAUTION: In order to prevent foreign material from contaminating the engine block or the engine front cover, it is necessary to seal the coolant and oil passages of both components. Failure to follow these directions will result in engine damage.
    CAUTION: Do not use a surface conditioning pad or any other type of fibrous abrasive disc to clean the gasket surfaces. Failure to follow these directions will result in engine damage.
  1. Clean and inspect the engine block and front cover as follows:
    • Pack the exposed portion of the oil pan with clean shop towels.
    • Plug the oil and coolant passages.
    • Clean the gasket surfaces.
    • Clean all surfaces requiring gasket sealant with metal surface cleaner.
    • Using compressed air remove any remaining foreign material from the engine block and engine front cover.
    • Remove the shop towels from the oil pan.
    • Remove the plugs or seals from the oil and coolant passages.
  2. Apply a small amount of silicone gasket and sealant as shown.
    Fig 1: Identifying Sealant Area
    G01307722Courtesy of FORD MOTOR CO.
  3. Install the engine front cover gasket and apply a small amount of silicone gasket and sealant as shown.
    Fig 2: Identifying Silicone Gasket & Sealant
    G01307723Courtesy of FORD MOTOR CO.
    4. NOTE: Use pipe sealant with Teflon® on studs No. 4 and No. 6, and bolt No. 12.
  4. Install the engine front cover.
    • Install a 135.5 mm (5.42 in) stud at location No. 5 and tighten to 7 Nm (62 lb-in).
    • Install a 137 mm (5.48 in) stud at locations No. 4, 6, 7 and 10, and tighten to 7 Nm (62 lb-in).
    • Using a new gasket, install the water pump.
    • Tighten bolt No. 12 to 10 Nm (89 lb-in). All other nuts and bolts are to be tightened to 28 Nm (21 lb-ft).
    • Tighten the nuts and bolts in the sequence shown.
      Fig 3: Engine Front Cover Bolt Tightening Sequence
      G01307724Courtesy of FORD MOTOR CO.
  5. Install the water pump pulley.
    Fig 4: Water Pump Pulley Bolt Tightening Torque
    G01307725Courtesy of FORD MOTOR CO.
  6. Lower the engine into position and remove the special tools.
    Fig 5: Identifying Special Tools (303-D095)
    G01307726Courtesy of FORD MOTOR CO.
  7. Raise and support the vehicle. For additional information, refer to JACKING & LIFTING .
  8. Install the engine mount nuts.
    Fig 6: Identifying Tightening Torque Of Engine Mount Nuts
    G01307727Courtesy of FORD MOTOR CO.
  9. Connect the radiator lower hose.
    Fig 7: Connecting Radiator Lower Hose
    G01307728Courtesy of FORD MOTOR CO.
  10. Install the belt tensioner. For additional information, refer to ACCESSORY DRIVE .
  11. Install the catalyst monitor sensor mounting bracket.
    Fig 8: Identifying Tightening Torque Of Catalyst Monitor Sensor Mounting Bracket Nut
    G01307729Courtesy of FORD MOTOR CO.
  12. Connect the catalyst monitor sensor electrical connector.
    Fig 9: Locating Catalyst Monitor Sensor Electrical Connector
    G01307730Courtesy of FORD MOTOR CO.
  13. Install the CKP sensor. For additional information, refer to CAMSHAFT POSITION SENSOR .
  14. Install the crankshaft pulley. For additional information, refer to CRANKSHAFT PULLEY .
  15. Lower the vehicle.
  16. Install the power steering pump mounting bracket and the bolts.
    Fig 10: Identifying Tightening Torque Of Power Steering Pump Mounting Bracket Bolts
    G01307731Courtesy of FORD MOTOR CO.
  17. Install the camshaft synchronizer. .
  18. Install the water pump outlet tube.
    Fig 11: Identifying Tightening Torque Of Water Pump Outlet Tube Bolt
    G01307732Courtesy of FORD MOTOR CO.
  19. Connect the hoses to the water pump outlet tube.
    Fig 12: Connecting Hoses To Water Pump Outlet Tube
    G01307733Courtesy of FORD MOTOR CO.
  20. Install the power steering pump. For additional information, refer to POWER STEERING .
  21. Connect the camshaft position (CMP) sensor electrical connector.
    Fig 13: Connecting Camshaft Position (CMP) Sensor Electrical Connector
    G01307734Courtesy of FORD MOTOR CO.
  22. Connect the IMRC actuator electrical connector.
    Fig 14: Connecting IMRC Actuator Electrical Connector
    G01307735Courtesy of FORD MOTOR CO.
  23. Connect the A/C compressor electrical connector.
    Fig 15: Connecting A/C Compressor Electrical Connector
    G01307736Courtesy of FORD MOTOR CO.
  24. Connect the oil pressure sender electrical connector.
    Fig 16: Connecting Oil Pressure Sender Electrical Connector
    G01307737Courtesy of FORD MOTOR CO.
  25. Install the generator bracket, bracket brace and bolts as an assembly.
    Fig 17: Generator Bracket Brace Bolt Tightening Torque
    G01307738Courtesy of FORD MOTOR CO.
  26. Clip the A/C wiring harness to the generator bracket brace.
    Fig 18: Clipping A/C Wiring Harness To Generator Bracket Brace
    G01307739Courtesy of FORD MOTOR CO.
  27. Install the idler pulley.
    28. Fig 19: Idler Pulley Bolt Tightening Torque
    G01307740Courtesy of FORD MOTOR CO.
  28. Install the generator. For additional information, refer to GENERATOR .
  29. Connect the degas bottle hose.
    30. Fig 20: Connecting Degas Bottle Hose
    G01307741Courtesy of FORD MOTOR CO.
  30. Raise and support the vehicle. For additional information, refer to JACKING & LIFTING .
  31. Drain the engine oil.
  32. Install a new oil filter.
    Fig 21: Installing Oil Filter
    G01307742Courtesy of FORD MOTOR CO.
  33. Fill the engine with clean engine oil.
  34. Fill the engine cooling system. For additional information, refer to ENGINE COOLING .
  35. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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