Engine Front Cover
WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOLS
| Alignment Pins 307-399 |
|
| Handle 205-153 (T80T-4000-W) |
|
| Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) |
|
| Installer, Front Cover Oil Seal 303-335 |
|
| Installer, Front Crankshaft Seal 303-1251 |
|
| Installer, VCT Spark Plug Tube Seal 303-1247/2 |
|
| Powertrain Lift 300-OTC1585AE |
|
| Strap Wrench 303-D055 (D85L-6000-A) or equivalent |
|
| Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool |
MATERIAL SPECIFICATIONS
| Item | Specification |
|---|---|
| Motorcraft® High Performance Engine RTV Silicone TA-357 |
WSE-M4G323-A6 |
| Motorcraft® Metal Surface Prep ZC-31-A |
- |
| Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada) XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada) |
WSS-M2C945-A |
| Motorcraft® Silicone Gasket Remover ZC-30 |
- |
| Threadlock and Sealer TA-25 |
WSK-M2G351-A5 |
WARNING:
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.
NOTE:
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
All vehicles
- Install the Alignment Pins.
- Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket 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.
- Install the engine front cover and bolts 17, 18, 19 and 20.
- Tighten in sequence to 3 Nm (27 lb-in).
- Remove the Alignment Pins.
- Install the engine mount bracket and the 3 bolts.
- 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 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).
- Install the engine mount studs in the following sequence.
- Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.
- Clean all the thread sealer from the engine mount studs (old and new studs).
- Apply new Threadlock and Sealer to the engine mount stud threads.
- Install the 2 engine mount studs.
- Tighten to 20 Nm (177 lb-in).
- Install the engine mount bracket and the 2 bolts.
- Tighten to 24 Nm (18 lb-ft).
- Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
- Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Installer, install the crankshaft pulley.
- 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.
- Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).
- Install the power steering pump and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Using the VCT Spark Plug Tube Seal Installer and Handle, install new VCT solenoid and/or spark plug tube seals.
- Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
- Using a new gasket, install the RH valve cover and tighten the bolt and 8 stud bolts.
- Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
- Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
- Using a new gasket, install the RH valve cover and tighten the 9 stud bolts.
- Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
- Install the wiring harness retaining bracket and the 2 nuts.
- Tighten to 4 Nm (35 lb-in).
- Install the Power Steering Pressure (PSP) hose bracket and nut.
- Tighten to 9 Nm (80 lb-in).
- Attach the PSP hose retainer to the engine lifting eye.
- Install the 6 coil-on-plug assemblies and the 6 bolts.
- Tighten to 7 Nm (62 lb-in).
- Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
- Connect the 3 LH coil-on-plug electrical connectors.
- Connect the LH camshaft VCT solenoid electrical connector.
- Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
- Connect the 3 RH coil-on-plug electrical connectors.
- Connect the RH VCT solenoid electrical connector.
- Connect the PSP switch electrical connector.
- Connect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector.
- Using new gaskets, install the upper intake manifold and the 6 bolts.
- Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
- Install the upper intake manifold support bracket bolt.
- Tighten to 10 Nm (89 lb-in).
- Attach the wiring harness retainers to the upper intake manifold.
- Connect the Throttle Body (TB) electrical connector.
- Connect the PCV hose to the PCV valve.
- If equipped, attach the block heater wiring harness retainer to the PSP tube and the power steering reservoir hose.
- If equipped, attach the block heater wiring harness retainer to the upper intake manifold.
- Raise the engine and transaxle assembly into the vehicle.
- Install the engine mount, the nut and the 2 bolts.
- Tighten the bolts to 55 Nm (41 lb-ft).
- Tighten the nut to 63 Nm (46 lb-ft).
- Install the 2 engine mount spacers and the 4 engine mount nuts.
- Tighten in the sequence shown in illustration to 70 Nm (52 lb-ft).
- Install the transaxle support insulator bracket, bolt and the 2 nuts.
- Tighten to 80 Nm (59 lb-ft).
- Install the transaxle support insulator through bolt and nut.
- Tighten to 90 Nm (66 lb-ft).
Front Wheel Drive (FWD) vehicles
- Install the RH catalytic converter support bracket and the 2 bolts.
- Install the 2 catalytic converter support bracket nuts.
- Tighten to 40 Nm (30 lb-ft).
- Tighten the 2 catalytic converter support bracket bolts to 20 Nm (177 lb-in).
All-Wheel Drive (AWD) vehicles
- Install a new PTU seal. For additional information, refer to
ENGINE IGNITION - 3.0L (4V)
.
All vehicles
- Using the Powertrain Lift, raise the subframe into the installed position.
- Install the 2 front subframe nuts.
- Tighten to 150 Nm (111 lb-ft).
- Position the subframe brackets and install the 4 bolts finger-tight.
- Install the 2 rear subframe nuts.
- Tighten to 150 Nm (111 lb-ft).
- Tighten the 2 subframe bracket-to-body bolts to 103 Nm (76 lb-ft).
- Install the stabilizer bar links and nuts to the struts.
- Install the tie-rod ends and nuts.
- Tighten to 48 Nm (35 lb-ft).
- Install new cotter pins.
- Install the engine roll restrictor-to-subframe through bolt.
- Tighten to 90 Nm (66 lb-ft).
AWD vehicles
- Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts (3 shown in illustration).
- Tighten to 70 Nm (52 lb-ft).
All vehicles
- Using new gaskets, install the Y-pipe assembly and the 6 new nuts.
- Tighten to 40 Nm (30 lb-ft).
- Install a new engine oil filter.
- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
- Connect the 2 transmission fluid cooler hoses.
- Connect the power steering cooler tube.
- Slide the steering gear-to-dash seal onto the steering gear and engage the 4 retaining clips into the body.
- From under the vehicle, verify that the seal is correctly installed on the steering gear and the retaining clips are fully engaged into the body.
- If equipped, install the underbody shield and the 6 screws.
- Install the LH splash shield and the 6 pin-type retainers (4 shown in illustration).
- Position the LH fender splash shield and install the 4 screws.
- Install the steering intermediate shaft onto the steering gear and install a new bolt.
- Tighten to 25 Nm (18 lb-ft).
- Install the steering joint cover and the 2 nuts.
- Using a new banjo bolt and 2 new seals, install the PSP tube onto the steering gear.
- Tighten to 37 Nm (27 lb-ft).
- Install the PSP tube bracket and bolt.
- Tighten to 10 Nm (89 lb-in).
- Connect the PCM connectors and pin-type retainers.
- Install the engine mount brace and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
- Install the ground wire and the bolt.
- Tighten to 10 Nm (89 lb-in).
- Connect the fuel supply tube to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
- Attach the power steering reservoir onto the cowl.
- Connect the hose to the power steering reservoir.
- Attach the pin-type retainer to the engine mount brace.
- Install the oil level indicator.
- Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
- Connect the 2 engine wiring harness electrical connectors.
- Attach the 2 wiring harness retainers.
- Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
- Tighten to 8 Nm (71 lb-in).
- Install the A/C tube bracket bolt.
- Tighten to 8 Nm (71 lb-in).
- Install the 2 A/C tube retaining clamp bolts.
- Tighten to 10 Nm (89 lb-in).
- Using a new O-ring seal, connect the A/C tube to the condenser and install the nut.
- Tighten to 8 Nm (71 lb-in).
- Attach the coolant tube retainer clips to the A/C tube.
- If equipped, attach the engine block heater harness to the radiator support, power steering hose, A/C tube and the engine wiring harness.
- Install the ground wire and bolt.
- Tighten to 12 Nm (106 lb-in).
- Position the transaxle control cable bracket in place and install the 3 nuts.
- Tighten to 12 Nm (106 lb-in).
- Connect the transaxle control cable to the control lever.
- Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
- Connect the vacuum hose and the Evaporative Emission (EVAP) tube to the upper intake manifold.
- Install the ground wire and the bolt.
- Tighten to 12 Nm (106 lb-in).
- Install the 2 battery cables to the positive battery cable and the 2 nuts.
- Tighten to 9 Nm (80 lb-in).
- Attach the 2 wiring harness retainers to the transmission mount and the battery tray bracket.
- Connect the 2 engine wiring harness electrical connectors.
- Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
- Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.5L .
- Install the degas bottle. For additional information, refer to ENGINE COOLING .
- Install the LH halfshaft and the intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
- Install the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE - 3.5L .
- Fill the engine with clean engine oil.
- Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
- Fill the power steering system. For additional information, refer to STEERING SYSTEM - HYDRAULIC POWER ASSIST STEERING (HPAS) .
- Check the transaxle fluid and add fluid if necessary. For additional information, refer to the Transmission Fluid Drain and Refill procedure in AUTOMATIC TRANSAXLE/TRANSMISSION - AISIN AW21 .
- Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
- After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.
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:
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. Failure to follow this procedure can cause future oil leakage.
NOTE:
Make sure the 2 Location of dowel pins are seated correctly in the cylinder block.
NOTE:
Do not tighten the bolts at this time.
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.
NOTE:
Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Fig 9: Installing Crankshaft Front Seal Using Crankshaft Vibration Damper Installer And Front Crankshaft Seal Installer
NOTE:
Lubricate the outside diameter sealing surfaces with clean engine oil.
Fig 10: Installing Crankshaft Pulley Using Crankshaft Vibration Damper Installer And Front Cover Oil Seal Installer
NOTE:
Installation of new seals is only required if damaged seals were removed during disassembly of the engine.
NOTE:
Spark plug tube seal installation shown in illustration, Variable Camshaft Timing (VCT) solenoid seal installation similar.
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:
If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
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:
If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
NOTE:
LH shown in illustration, RH similar.
NOTE:
If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
NOTE:
Do not tighten the 2 catalytic converter support bracket bolts at this time.
NOTE:
A new Power Transfer Unit (PTU) seal must be installed whenever the intermediate shaft is removed.
NOTE:
Align the index marks on the subframe to the index marks on the underbody that were made during removal.
NOTE:
LH shown in illustration, RH similar.
NOTE:
LH shown in illustration, RH similar.
NOTE:
LH shown in illustration, RH similar.
NOTE:
LH shown in illustration, RH similar.
NOTE:
LH shown in illustration, RH similar.
NOTE:
LH shown in illustration, RH similar.
NOTE:
Align the index marks made during removal.
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 instruction may cause oil leakage.