Engine Front Cover: Installation

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to clean sealing surfaces.

NOTE: If the engine front cover is not secured 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. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.

Fig 1: Identifying Area For Silicone Gasket Application

Courtesy of FORD MOTOR CO.

Install the engine front cover with the engine front cover gasket on the engine front cover-to-cylinder block dowel and loosely install the bolts.

Fig 2: Installing Engine Front Cover With Engine Front Cover Gasket On Front Cover-To-Cylinder Block Dowel

Courtesy of FORD MOTOR CO.

Tighten the engine front cover fasteners in sequence in 2 stages.

* Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).

* Stage 2: Tighten fasteners 6 through 15 to 48 Nm (35 lb-ft).

Item	Part Number	Description
1	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
2	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
3	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
4	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
5	N806177	Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
6	N808529	Stud, Hex-Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30
7	N808529	Stud, Hex-Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30
8	N808142	Screw and Washer, Hex Pilot, M10 x 1.5 x 54
9	N808142	Screw and Washer, Hex Pilot, M10 x 1.5 x 54
10	N808142	Screw and Washer, Hex Pilot, M10 x 1.5 x 54
11	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
12	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
13	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
14	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
15	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27

Fig 3: Engine Front Cover Fasteners Torque Sequence

Courtesy of FORD MOTOR CO.

Loosely install the bolts, then tighten the bolts in 2 stages following the sequence shown.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 60 degrees.

Fig 4: Identifying Tightening Sequence Of Front Oil Pan Bolts

Courtesy of FORD MOTOR CO.

Using a new O-ring seal, position the CKP sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 5: Locating Crankshaft Position (CKP) Sensor Bolt

Courtesy of FORD MOTOR CO.

Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.

Fig 6: Locating Crankshaft Front Seal

Courtesy of FORD MOTOR CO.

Using the special tools, install a new crankshaft front seal.

Fig 7: Installing Crankshaft Front Seal Using Special Tools

Courtesy of FORD MOTOR CO.

NOTE: If not secured 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. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

Fig 8: Identifying Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the crankshaft front seal inner lip with clean engine oil prior to installation.

Using the special tool, install the crankshaft pulley.

Fig 9: Installing Crankshaft Pulley Using Special Tool

Courtesy of FORD MOTOR CO.

Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages:
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees without exceeding 200 Nm (148 lb-ft).

Fig 10: Holding Crankshaft Pulley Using Special Tool (303-D055)

Courtesy of FORD MOTOR CO.

Using a new O-ring seal, position the CMP sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 11: Locating LH CMP Sensor Bolt

Courtesy of FORD MOTOR CO.

Connect the CMP electrical connector.

Fig 12: Locating Camshaft Position (CMP) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Position the belt idler pulley and install the bolt.
- Tighten to 25 Nm (18 lb-ft).

Fig 13: Accessory Drive Belt Idler Pulley And Retaining Bolt

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors and the 2 nuts.
- Tighten to 25 Nm (18 lb-ft).

Fig 14: Radio Interference Capacitor And Retaining Nut

Courtesy of FORD MOTOR CO.

Position the A/C compressor and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 15: A/C Compressor Bolts

Courtesy of FORD MOTOR CO.

Connect the CKP sensor electrical connector.

Fig 16: Identifying Crankshaft Position Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the A/C compressor electrical connector.

Fig 17: A/C Compressor Electrical Connector

Courtesy of FORD MOTOR CO.

Position the bracket, connect the tubes and install the nut.
- Tighten to 30 Nm (22 lb-ft).

Fig 18: Bracket & Nut

Courtesy of FORD MOTOR CO.

Connect the wiring harness to the bracket.

Fig 19: Wiring Harness

Courtesy of FORD MOTOR CO.

Position the power steering pump and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 20: Power Steering Pump Bolts

Courtesy of FORD MOTOR CO.

Position the coolant pump pulley on the coolant pump and install the 4 bolts finger tight.

Fig 21: Identifying Coolant Pump Pulley Bolts

Courtesy of FORD MOTOR CO.

Rotate the tensioner clockwise and install the accessory drive belt.

Fig 22: Rotating Tensioner Clockwise

Courtesy of FORD MOTOR CO.

Tighten the 4 coolant pump bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 23: Identifying Coolant Pump Pulley Bolts

Courtesy of FORD MOTOR CO.

Install the oil drain plug.
Install the valve covers. For additional information, refer to Valve Cover - LH and Valve Cover - RH .
Install the radiator. For additional information, refer to ENGINE COOLING article.
Fill the engine with clean engine oil.