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Engine Front Cover: Installation

  1. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply a 3 mm (0.118 in) bead of Silicone Gasket and Sealant to the sealing surface of the front cover.

    • Apply a 2 mm (0.078 in) bead of Silicone Gasket and Sealant to the 5 center sealing surfaces of the front cover.

    GFD339276Courtesy of FORD MOTOR COMPANY
  2. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the engine front cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply beads of silicone gasket and sealant that are 2 mm (0.078 in) in diameter and 5 mm (0.19 in) in length across the cylinder head and cylinder block joint areas.

    GFD339277Courtesy of FORD MOTOR COMPANY
  3. Install the engine front cover and the fasteners and tighten in the sequence shown.

    • Tighten bolts 1 through 3 to 48 Nm (35 lb-ft).

    • Tighten bolts 4 through 22 to 10 Nm (89 lb-in).

    Fig 1: Engine Front Cover Tightening Sequence
    GFD339278Courtesy of FORD MOTOR COMPANY
  4. Attach the 2 wiring harness retainers to the engine front cover.

    • Install the ground strap and nut.

      • Tighten to 9 Nm (80 lb-in).

    GFD339274Courtesy of FORD MOTOR COMPANY
  5. Install the coolant pump pulley and the 3 bolts.
    GFD339273Courtesy of FORD MOTOR COMPANY
  6. Install the engine mount. For additional information, refer to Engine Mount .
  7. NOTE: Remove the through-bolt from the Camshaft Front Oil Seal Installer.
    NOTE: Lubricate the oil seal with clean engine oil.

    Using the Camshaft Front Oil Seal Installer, install the crankshaft front oil seal.

    GFD339225Courtesy of FORD MOTOR COMPANY
  8. NOTE: If equipped, the diamond washer should be cleaned and inspected for any damage. If damage is evident, replace the diamond washer. If no damage, the diamond washer is to be reused. If the diamond washer is not installed, engine damage may occur.
    NOTE: Early build engines are equipped with a diamond washer on each side of the crankshaft sprocket. Late build engines have a laser etched crankshaft sprocket and do NOT require diamond washers. If an early build engine requires crankshaft sprocket replacement, discard the diamond washers and the sprocket and install a new laser etched sprocket (service part). Diamond washers should NEVER be installed with the laser etched sprocket.

    If equipped, install the diamond washer.

    GFD339237Courtesy of FORD MOTOR COMPANY
  9. NOTE: Apply clean engine oil on the seal contact area before installing.

    Position the crankshaft pulley onto the crankshaft and align the TDC guide hole at the 6 o'clock position.

    GFD339238Courtesy of FORD MOTOR COMPANY
  10. NOTE: This step will correctly align the crankshaft pulley to the crankshaft.

    Install a standard bolt through the crankshaft pulley TDC guide hole and into the engine front cover guide hole.

    GFD339239Courtesy of FORD MOTOR COMPANY
  11. NOTE: The crankshaft must remain in the TDC position during installation of the pulley bolt or damage to the engine can occur. Therefore, the crankshaft pulley must be held in place with the Strap Wrench and the bolt should be installed using hand tools only.

    Install a new crankshaft pulley bolt. Use the Crank Damper Holding Tool to hold the crankshaft pulley and tighten the crankshaft pulley bolt in 2 stages:

    • Stage 1: Tighten to 100 Nm (74 lb-ft).

    • Stage 2: Tighten an additional 90 degrees.

    GFD339240Courtesy of FORD MOTOR COMPANY
  12. Remove the bolt.
    GFD339241Courtesy of FORD MOTOR COMPANY
  13. NOTE: Do not tighten the CKP sensor bolts at this time.

    Install the CKP sensor and the 2 bolts.

    GFD339242Courtesy of FORD MOTOR COMPANY
  14. Install the Crankshaft Sensor Alignment Tool onto the CKP sensor and the tooth of the crankshaft pulley trigger wheel.

    • Tighten the 2 bolts to 7 Nm (62 lb-in).

    GFD339243Courtesy of FORD MOTOR COMPANY
  15. Connect the CKP sensor electrical connector.
    GFD339244Courtesy of FORD MOTOR COMPANY
  16. Remove the Crankshaft TDC Timing Peg.
    GFD339232Courtesy of FORD MOTOR COMPANY
  17. Install the engine plug bolt and tighten to 20 Nm (177 lb-in).

    • Install the RH halfshaft bracket, the 2 bolts and the 2 nuts.

      • Tighten to 25 Nm (18 lb-ft).

    GFD339245Courtesy of FORD MOTOR COMPANY
  18. Remove the Camshaft Alignment Tool.
    GFD339272Courtesy of FORD MOTOR COMPANY
  19. Using a wrench on the flats of the intake camshaft to prevent cam rotation, install the brake vacuum pump adapter.

    • Tighten to 63 Nm (46 lb-ft).

    GFD339271Courtesy of FORD MOTOR COMPANY
  20. NOTE: The intake camshaft rear bearing cap must be secured within 10 minutes of Gasket Maker application. If the bearing cap is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft® Metal Surface Prep.

    Apply 1 mm (0.039 in) beads of Gasket Maker to the intake rear camshaft bearing cap mating surface as shown.

    GFD339279Courtesy of FORD MOTOR COMPANY
  21. NOTE: Wipe off any excess sealer from the vacuum pump sealing surface of the cylinder head and camshaft cap.

    Install the rear intake camshaft cap and the 2 bolts. Tighten the bolts in 2 stages:

    • Stage 1: Tighten the bolts to 7 Nm (62 lb-in).

    • Stage 2: Tighten the bolts to 16 Nm (142 lb-in).

    GFD339270Courtesy of FORD MOTOR COMPANY
  22. Install the valve cover. For additional information, refer to Valve Cover .
  23. Install the brake vacuum pump. For additional information, refer to Power Brake Actuation - Brake Booster .
  24. Install the accessory drive belt. For additional information, refer to Accessory Drive .
  25. Install the RH fender splash shield. For additional information, refer to Front End Body Panels .
  26. Tighten the 3 coolant pump pulley bolts to 20 Nm (177 lb-in).
    GFD339269Courtesy of FORD MOTOR COMPANY
  27. Install the CAC inlet tube.
    GFD339268Courtesy of FORD MOTOR COMPANY
  28. Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.
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