Engine Front Cover

Special Tool(s)

	3 Jaw Puller 303-D121 or equivalent
	Alignment Pins 307-399
	Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
	Installer, Front Crankshaft Seal 303-1251
	Remover, Oil Seal 303-409 (T92C-6700CH)
	Replacer, Crankshaft Vibration Damper 303-102 (T74P-6312-B)

Removal

NOTICE: During engine repair procedures, cleanliness is extremely important. Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

2. Recover the A/C system. For additional information, refer to Section 412-00 .

3. Release the fuel system pressure. For additional information, refer to Section 310-00 .

4. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

5. Remove the accessory drive belt and the tensioner. For additional information, refer to Section 303-05 .

6. If equipped, release the 4 retainers and remove the underbody shield.

7. Drain the cooling system. For additional information, refer to Section 303-03 .

8. Using hose clamp pliers, pinch the lower degas bottle hose and remove the hose from the coolant inlet pipe.

9. Remove the degas bottle. For additional information, refer to Section 303-03 .

10. Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal and gasket seal.

11. Disconnect the fuel supply tube from the fuel rail supply tube. For additional information, refer to Section 310-00 .
    • Remove the fuel tube-to-engine front cover bolt.

12. Remove the LH and RH valve covers. For additional information, refer to Valve Cover — LH and Valve Cover — RH in this section.

13. Remove the generator nut and stud.
    • Loosen the bolt and position the generator aside.

14. Remove the RH front wheel and tire. For additional information, refer to Section 204-04 .

15. Remove the 3 lower rubber shield scrivets from the subframe.

16. Remove the RH inner fender splash shield. For additional information, refer to Section 501-02 .

17. Remove the crankshaft pulley bolt and washer.
    • Discard the bolt.

18. Using the 3 Jaw Puller, remove the crankshaft pulley.

19. Using the Oil Seal Remover, remove and discard the crankshaft front seal.

20. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).

21. NOTICE: Failure to position the wood block and floor jack as illustrated can result in damage to the oil pan.

    Position a floor jack with a block of wood under the front of the oil pan.

22. Remove the 4 engine mount nuts.

23. Remove the 3 bolts and the engine mount.

24. NOTICE: Do not allow the A/C compressor to contact the subframe. Failure to follow this direction may result in damage to the A/C compressor.

    Using the floor jack, lower the engine to access the lower engine front cover bolt.
    • Remove the lower M10 engine front cover bolt.

25. Using the floor jack, raise the engine.

26. Remove the 2 M10 engine front cover bolts.

27. Remove the 22 M8 engine front cover bolts.

28. Remove the M6 engine front cover bolt.

29. Using a suitable pry tool, locate the 5 pry pads shown and pry the engine front cover loose and remove.

Installation

1. NOTICE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean front cover.

   Clean the engine front cover using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
   • Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.

2. NOTICE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

   NOTICE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces of engine block, cylinder heads, and oil pan. These tools can cause contamination that will cause premature engine failure. Remove all traces of the gasket.

   
   Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.
   1. Remove any large deposits of silicone or gasket material.
   2. Apply silicone gasket remover and allow to set for several minutes.
   3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
   4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
   5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

3. Install the Alignment Pins.

4. NOTICE: 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 7, 8, 15, 17, 18, 21 and 22 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 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.

   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 4 inner bolt 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.

5. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

   Install the engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22.
   • Tighten in sequence to 3 Nm (27 lb-in).

6. Remove the Alignment Pins.

7. NOTE: Do not tighten the bolt at this time.

   Install the M6 engine front cover bolt.

8. NOTE: Do not tighten the bolts at this time.

   Install the 2 upper M10 engine front cover bolts.

9. NOTICE: Do not allow the A/C compressor to contact the subframe. Failure to follow this direction may result in damage to the A/C compressor.

   NOTE: Do not tighten the bolt at this time.

   Using the floor jack, lower the engine to allow installation of the lower M10 engine front cover bolt.
   • Install the lower M10 engine front cover bolt.

10. NOTICE: 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.

    Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts in the sequence shown in 7 stages:
    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in).
    • Stage 2: Tighten bolts 23, 24 and 25 to 15 Nm (133 lb-in).
    • Stage 3: Tighten bolt 26 to 10 Nm (89 lb-in).
    • Stage 4: Loosen bolt 26 one full turn.
    • Stage 5: Tighten bolts 23, 24 and 25 to 30 Nm (22 lb-ft) plus an additional 90 degrees.
    • Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lb-in) plus an additional 45 degrees.
    • Stage 7: Tighten bolt 26 to 10 Nm (89 lb-in) plus an additional 45 degrees.

11. Use the floor jack to raise the engine to the installed position and install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).

12. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).

13. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

    Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.

14. NOTE: Lubricate the outside diameter sealing surfaces and crankshaft front seal inner lip with clean engine oil.

    Using the Front Cover Oil Seal Installer and Crankshaft Vibration Damper Replacer, install the crankshaft pulley.

15. 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.

16. Install the RH inner fender splash shield. For additional information, refer to Section 501-02 .

17. Install the 3 accessory drive shield scrivets to the subframe.

18. Install the RH front wheel and tire. For additional information, refer to Section 204-04 .

19. Position the generator and install the stud and nut.
    • Tighten the stud to 8 Nm (71 lb-in).
    • Tighten the nut to 47 Nm (35 lb-ft).
    • Tighten the bolt to 47 Nm (35 lb-ft).

20. Install the LH and RH valve covers. For additional information, refer to Valve Cover — LH and Valve Cover — RH in this section.

21. Install the fuel tube-to-engine front cover bolt.
    • Tighten the bolt to 10 Nm (89 lb-in).
    • Connect the fuel supply tube to the fuel rail supply tube. For additional information, refer to Section 310-00 .

22. Using a new O-ring seal, connect the A/C pressure tube fitting and install the nut.
    • Tighten to 8 Nm (71 lb-in).

23. Install the degas bottle. For additional information, refer to Section 303-03 .

24. Connect the coolant hose to the coolant inlet pipe.
    • Remove the hose clamp pliers.

25. Install the accessory drive belt and the tensioner. For additional information, refer to Section 303-05 .

26. NOTICE: 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.

    Fill the engine with clean engine oil.

27. Connect the battery ground cable. For additional information, refer to Section 414-01 .

28. Fill the cooling system. For additional information, refer to Section 303-03 .

29. If equipped, install the underbody shield and attach the 4 retainers.

30. Evacuate and recharge the A/C system. For additional information, refer to Section 412-00 .

31. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.