Engine Front Cover: Installation

WARNING: This page is about a different variant/trim than selected.

Using the special tools, install the engine front cover to coolant pipe seal. Use Special Service Tool: 205-149 (T80T-4000-R) Installer, Spindle Bearing, 205-153 (T80T-4000-W) Handle.

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Install Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

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- 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 the 6 bolts must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 10 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. Failure to follow this procedure can cause future oil leakage.
  
  Apply a 3 mm (0.12 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover inner bolt bosses.
  
  Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Apply a 5 mm (0.19 in) bead of Motorcraft® High Performance Engine RTV Silicone on the chamfer, as shown.
  Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Apply a 9 mm (0.35 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 places as indicated.
  Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and the bolts.

Torque: 27 lb.in (3 Nm)

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Remove Special Service Tool: 307-399 Alignment Pins, Transmission Fluid Pump.

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NOTE: The engine front cover bolts must be installed and tightened within 10 minutes of the initial sealant application.

Install the remaining engine front cover bolts.

Torque: Stage 1: Tighten bolts 1 through 20 to: 89 lb.in (10 Nm)

Stage 2: Tighten bolts 1 through 19 and 22 to: 177 lb.in (20 Nm)

Stage 3: Tighten bolts 1 through 19 and 22 an additional: 45°

Stage 4: Tighten bolt 20 to: 177 lb.in (20 Nm)

Stage 5: Tighten bolt 20 an additional: 90°

Stage 6: Tighten bolt 21 to: 89 lb.in (10 Nm)

Stage 7: Tighten bolt 21 an additional: 45°

Fig 1: Engine Front Cover Tightening Sequence
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Using the special tool and a hammer, install the oil pump electrical connector seal. Use Special Service Tool: 303-1663 Installer, VDOP Seal.

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Make sure the oil pump electrical connector seal is below the top of the oil pump electrical connector or the oil pump electrical connector seal may leak oil.

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1. Position the generator.
2. Install the stud bolt.
  Torque: 71 lb.in (8 Nm)
3. Install the bolt.
  Torque: 35 lb.ft (47 Nm)
4. Install the nut.
  Torque: 35 lb.ft (47 Nm)
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Install the accessory drive belt tensioner and the bolts.
Torque: 18 lb.ft (25 Nm)

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- Connect the oil pressure control solenoid wiring harness electrical connector.
- Attach the wiring harness retainers to the engine front cover.
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Position the transmission cooling tubes and bracket and install the nut.
Torque: 97 lb.in (11 Nm)

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Install the transmission cooling tubes to the cooler bypass valve.
Torque: 22 lb.ft (30 Nm)

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Connect the transmission cooling tubes.

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Position the coolant tubes and install the bolt in the oil pan.
Torque: 80 lb.in (9 Nm)

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- Lubricate the oil filter seal with clean engine oil and install and tighten in 2 stages.
- Stage 1: Install to initial gasket contact.
- Stage 2: Tighten 3/4 to 1 turn.
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Install the rear underbody shield, bolts and retainers.
Torque: 22 lb.in (2.5 Nm)

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Install the following items:
1. Install the crankshaft front seal. Refer to: Crankshaft Front Seal .
2. Install the coolant pump. Refer to: Coolant Pump .
3. Install the RH valve cover. Refer to: Valve Cover RH .
4. Install the LH valve cover. Refer to: Valve Cover LH .
Fill the engine with clean engine oil. Refer to: Specifications .

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Connect the battery ground. Refer to: Battery Disconnect and Connect . .
Fill the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
Check the transmission fluid level.
- If equipped with 10R60. Refer to: Transmission Fluid Level Check .
- If equipped with 10R80. Refer to: Transmission Fluid Level Check .
Pressurize the fuel system pressure. Refer to: Fuel System Pressure Release .
Use the Powertrain Control Module (PCM) Misfire Monitor Profile Correction routine in the diagnostic scan tool.