LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2005 >> Freestar Base >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine >> In-Vehicle Repair >> Engine Front Cover >> Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

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 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 in illustration.
    Fig 1: Applying Small Amount Of Silicone Gasket And Sealant
    G03962017Courtesy of FORD MOTOR CO.
  3. Install the engine front cover gasket and apply a small amount of silicone gasket and sealant as shown in illustration.
    Fig 2: Installing Engine Front Cover Gasket
    G03962018Courtesy of FORD MOTOR CO.
    4. CAUTION: The coolant pump and gasket must be installed at this time to correctly tighten all of the engine front cover fasteners in sequence.
    NOTE: Use pipe sealant with Teflon on studs No. 4, 6 and bolt No. 12.
    Fig 3: Installing Engine Front Cover With Engine Front Cover Studs
    G03962019Courtesy of FORD MOTOR CO.
  4. Install the engine front cover with the engine front cover studs in their original locations.
    • Tighten the engine front cover studs to 7 Nm (62 lb-in).
    • Using a new gasket, install the coolant pump.
    • Tighten the fasteners in the sequence shown in illustration.
      • Tighten bolt No. 12 to 10 Nm (89 lb-in).
      • Tighten all other fasteners to 28 Nm (21 lb-ft).
  5. Install the 2 oil pan-to-engine front cover bolts.
    • Tighten to 10 Nm (89 lb-in).
  6. Install the catalyst monitor sensor electrical connector bracket and the nut.
    • Tighten to 28 Nm (21 lb-ft).
    Fig 4: Installing Catalyst Monitor Sensor Electrical Connector Bracket And Nut
    G04003950Courtesy of FORD MOTOR CO.
  7. Connect the catalyst monitor sensor electrical connector.
    Fig 5: Connecting Catalyst Monitor Sensor Electrical Connector
    G04003949Courtesy of FORD MOTOR CO.
  8. Clean and inspect the engine front cover-to-crankshaft front seal mating surface.
    9. NOTE: Lubricate the new crankshaft front seal lips with clean engine oil prior to installation.
    Fig 6: Placing Crankshaft Front Seal Onto Special Tools
    G04003923Courtesy of FORD MOTOR CO.
  9. Assemble the special tools, then place the crankshaft front seal onto the special tools.
  10. Using the special tools, install the crankshaft front seal.
    Fig 7: Installing Crankshaft Front Seal
    G04003924Courtesy of FORD MOTOR CO.
  11. Remove the bolts lower the RH side of the subframe 50.8 mm (2 in).
    Fig 8: Removing Bolts At Lower RH Side Of Subframe
    G04003914Courtesy of FORD MOTOR CO.
    12. NOTE: Apply a bead of sealant to the keyway in the crankshaft pulley.
    Fig 9: Installing Crankshaft Pulley
    G04003916Courtesy of FORD MOTOR CO.
  12. Using the special tool, install the crankshaft pulley.
  13. Install the crankshaft pulley washer and the bolt.
    • Tighten to 160 Nm (118 lb-ft).
  14. Raise the subframe into position, then install the bolts.
    • Tighten to 175 Nm (129 lb-ft).
    Fig 10: Installing Subframe Bolts
    G04003914Courtesy of FORD MOTOR CO.
  15. Connect the RH front anti-lock brake wheel sensor electrical connector.
    Fig 11: Connecting RH Front Anti-Lock Brake Wheel Sensor Electrical Connector
    G04003912Courtesy of FORD MOTOR CO.
  16. Drain the engine oil.
    • Tighten to 26 Nm (19 lb-ft).
    Fig 12: Identifying Drain Plug
    G04003902Courtesy of FORD MOTOR CO.
  17. If equipped, install the oil cooler. For additional information, refer to OIL COOLER .
    18. NOTE: Lubricate the new oil filter seal with clean engine oil prior to installation.
  18. Install a new oil filter.
    • Tighten the oil filter one half turn after the gasket makes contact with the oil filter housing.
  19. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  20. Install the generator mounting bracket and the generator brace bolt.
    • Tighten to 47 Nm (35 lb-ft).
  21. Install the camshaft synchronizer. For additional information, refer to ELECTRONIC ENGINE CONTROLS .
  22. Install the coolant pump. For additional information, refer to ENGINE COOLING .
  23. Install the generator. For additional information, refer to GENERATOR AND REGULATOR .
  24. Fill the engine with clean engine oil.
scientia non olet · About LEMON Manuals