Engine Front Cover: Installation

LHD AWD/LHD RWD 

1. Install new engine front cover gaskets.

   Courtesy of FORD MOTOR COMPANY

2. NOTE: Lubricate the new oil gallery seal with clean engine oil.

   Lubricate and install a new oil gallery seal (6G068).

   Courtesy of FORD MOTOR COMPANY

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: The engine front cover must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.

   Apply 9 mm (0. 35 in) beads of Motorcraft® High Performance Engine RTV Silicone 10 mm (0. 40 in) in length to the cylinder block skirt-to-cylinder block joints and the cylinder head-to-cylinder block joints as indicated.

   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

   Courtesy of FORD MOTOR COMPANY

4. 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 must be installed within 10 minutes of applying the sealer and the bolts must be installed and tightened to 2-5 Nm (18-44 lb-in) within 15 of applying the sealer. Final tightening of the bolts must be completed within 60 minutes of applying the sealer. Failure to follow this procedure can cause future oil leakage.
   1. Apply a 4. 5 mm (0. 18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover sealing surfaces of the inner bolt bosses.

      Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

   2. Apply a 4. 5 mm (0. 18 in) bead of Motorcraft® High Performance Engine RTV Silicone to the chamfer of the engine front cover sealing surfaces.

      Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

   Courtesy of FORD MOTOR COMPANY

5. Install the engine front cover and the fasteners.

   Torque: Stage 1: Tighten bolts 1 through 11 to: 18 lb. ft (24 Nm) Stage 2: Tighten bolts 12 through 13 to: 35 lb. ft (48 Nm) Stage 3: Tighten bolts 14 through 22 to: 18 lb. ft (24 Nm)

   Fig 1: Engine Front Cover Tightening Sequence

   Courtesy of FORD MOTOR COMPANY
6. Install the idler pulley and bolt.

   Torque: 18 lb. ft (24 Nm)

   Courtesy of FORD MOTOR COMPANY

7. Attach the wiring harness retainer.

   Courtesy of FORD MOTOR COMPANY

8. NOTE: A new turbocharger oil supply filter must be installed. Failure to follow these instructions can result in turbocharger damage.

   Install the new turbocharger oil supply tube O-ring seals and the new turbocharger oil supply tube oil filter. Lubricate the new turbocharger oil supply tube O-ring seals with clean engine oil. Refer to: Specifications .

   Courtesy of FORD MOTOR COMPANY

9. NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.
   • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to turbocharger O-ring bore and the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Do not use a metal brush, damage to sealing area will result in leaks. Install new components if needed.
   1. Connect the turbocharger oil supply tube to the turbocharger, then install and tighten the turbocharger oil supply tube bolt.

      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

      Torque: 89 lb. in (10 Nm)

   Courtesy of FORD MOTOR COMPANY

10. Install the turbocharger studs.

    Torque: 106 lb. in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

11. 1. NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.

       Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to engine O-ring bores for both the oil and coolant tubes. Inspect the area for deep scratches and gouges. Do not use a metal brush, damage to sealing area will result in leaks. Install new components if needed.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    2. Install the new gasket, the turbocharger and loosely install the turbocharger nuts. Install the turbocharger oil supply tube to the engine while installing the turbocharger.

    Courtesy of FORD MOTOR COMPANY

12. Install the turbocharger bolt.

    Torque: 44 lb. ft (60 Nm)

    Courtesy of FORD MOTOR COMPANY

13. 1. Tighten the turbocharger nut.

       Torque: 27 lb. ft (37 Nm)

    2. Tighten the turbocharger nut.

       Torque: 44 lb. ft (60 Nm)

    Courtesy of FORD MOTOR COMPANY

14. Re-tighten the turbocharger bolt.

    Torque: 44 lb. ft (60 Nm)

    Courtesy of FORD MOTOR COMPANY

15. 1. Re-tighten the turbocharger nut

       Torque: 27 lb. ft (37 Nm)

    2. Re-tighten the turbocharger nuts.

       Torque: 44 lb. ft (60 Nm)

    Courtesy of FORD MOTOR COMPANY

16. Install a new outer turbocharger coolant supply tube O-ring seal. Lubricate the O-ring seal and the rubber gasket with clean engine coolant. Refer to: Specifications .

    Courtesy of FORD MOTOR COMPANY

17. NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Install new components if needed.
    1. Install the outer turbocharger coolant supply tube, then install and tighten the bolt.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

       Torque: 89 lb. in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

18. Connect the turbocharger wastegate control hose and clamp. Use the General Equipment: Hose Clamp Remover/Installer

    Courtesy of FORD MOTOR COMPANY

19. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger tube to turbocharger O-ring bore and the turbocharger tube to engine O-ring bore. Inspect the area for deep scratches and gouges. Install new components if needed.
    1. Install the turbocharger oil supply tube, then install and tighten the oil supply tube bolt.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

       Torque: 89 lb. in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

20. Install a new turbocharger coolant return tube O-ring seal. Lubricate the new O-ring seal with clean engine coolant. Refer to: Specifications .

    Courtesy of FORD MOTOR COMPANY

21. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges. Install new components if needed.

      Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    1. Connect the turbocharger coolant return tube to the turbocharger, then install and tighten the bolt.

       Torque: 89 lb. in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

22. Install the turbocharger heat shield and the bolts.

    Torque: 89 lb. in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

23. Remove the engine front cover bolts.

    Courtesy of FORD MOTOR COMPANY

24. Using two M8 x 1. 25 x 105 mm bolts and two washers, install the special tools to the engine. Install Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.

    Courtesy of FORD MOTOR COMPANY

25. Install Special Service Tool: 303-F070 Support Bar, Engine.

    Courtesy of FORD MOTOR COMPANY

26. Support the front and rear of the subframe with adjustable jack stands.

    Courtesy of FORD MOTOR COMPANY

27. NOTE: The original bolts should be retained to be used during the LH catalytic converter.

    Remove the rear subframe bolts.

    Courtesy of FORD MOTOR COMPANY

28. NOTE: The original bolts should be retained to be used during the LH catalytic converter.

    Remove the middle subframe bolts.

    Courtesy of FORD MOTOR COMPANY

29. • Remove the front subframe bolts.
    • Discard the bolts.

    Courtesy of FORD MOTOR COMPANY

30. With the aid of an assistant, lower the front jack stand 127 mm (5. 0 in) and the rear jack stand 152. 4 mm (6. 0 in) evenly or until engine mount stud clears the subframe.

    Courtesy of FORD MOTOR COMPANY

31. NOTE: Early build shown, late build similar.
    • Remove the bolts and the LH engine mount.
    • Discard the bolts.

    Courtesy of FORD MOTOR COMPANY

32. Install the new turbocharger oil return tube-to-engine block gasket.

    Courtesy of FORD MOTOR COMPANY

33. Install a new turbocharger oil return tube O-ring seal, then lubricate with clean engine oil. Refer to: Specifications .

    Courtesy of FORD MOTOR COMPANY

34. NOTE: Do not use a metal brush, damage to sealing area will result in leaks.
    • Carefully use a nylon brush to remove the old O-ring residue and use brake cleaner to rinse the O-ring residue out of the turbocharger O-ring bore. Inspect the area for deep scratches and gouges.
    1. Install the turbocharger oil return tube, then install and tighten the turbocharger oil return tube bolts.

       Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

       Torque: 89 lb. in (10 Nm)

    Courtesy of FORD MOTOR COMPANY

35. Install the wire harness bracket, then install and tighten the bolt.

    Torque: 106 lb. in (12 Nm)

    Courtesy of FORD MOTOR COMPANY

    LHD AWD 

36. Install a new seal and lubricate.

    Courtesy of FORD MOTOR COMPANY

37. Install the front axle disconnect actuator and the bolts.

    Torque: 26 lb. ft (35 Nm)

    Courtesy of FORD MOTOR COMPANY

38. Connect the front axle disconnect actuator electrical connector and vent hose.

    Courtesy of FORD MOTOR COMPANY

    LHD AWD/LHD RWD 

39. NOTE: The original rear and middle subframe bolts should be initially installed in the LH engine mount procedure. They will be discarded after the LH catalytic converter is tightened.

    Install the LH engine mount. Refer to: Engine Mount LH .

    LHD AWD 

40. NOTE: LH shown, RH similar.

    Install the front suspension height sensors and the bolts.

    Torque: 133 lb. in (15 Nm)

    Courtesy of FORD MOTOR COMPANY

41. Install the LH and RH front halfshafts. Refer to: Halfshaft .

    LHD AWD/LHD RWD 

42. Install the following items:
    1. Refer to: Crankshaft Front Seal .
    2. Refer to: Generator - 3. 0L EcoBoost .
    3. Refer to: Coolant Pump .
    4. Refer to: Accessory Drive Belt Tensioner .

43. Install the upper and lower radiator hoses and clamps.

    Courtesy of FORD MOTOR COMPANY

44. Install the following items:
    1. Refer to: Oil Cooler .
    2. Refer to: Valve Cover LH .
    3. Refer to: Valve Cover RH .
    4. Refer to: Degas Bottle .
    5. Refer to: Oil Pan .

45. Install a new engine oil filter and fill the engine with clean engine oil. Refer to: Engine Oil Draining and Filling .
46. Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
47. Pressurize the fuel system. Refer to: Fuel System Pressure Release .
48. Fill and bleed the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
49. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
50. Start and check the exhaust system for leaks.
51. Calibrate the suspension system. Connect the scan tool and carry out the ride height calibration routine. Follow the scan tool directions.