Engine Front Cover

Engine Front Cover

WARNING: Before beginning any service procedure, REFER to Safety Warnings . Failure to follow this instruction may result in serious personal injury.

Special Tool(s)






Material(s)






Exploded View

Engine Front Cover and Retainers









Removal

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

1. Recover the A/C (Air Conditioning) system. Vehicles with EMTC (Electronic Manual Temperature Control), REFER to Air Conditioning (AC) System Recovery, Evacuation and Charging . Vehicles with DATC (Dual Automatic Temperature Control), REFER to Air Conditioning (AC) System Recovery, Evacuation, and Charging

2. Release the 2 tabs and position the degas bottle aside.





3. Loosen the 3 coolant pump pulley bolts.





4. Remove the cowl panel. REFER to Cowl Panel .

5. Using 303-F072 , support the engine.





6. Remove the crankshaft front seal. REFER to Crankshaft Front Seal .

7. Remove the 2 bolts and the accessory drive belt tensioner.





8. Remove the 3 bolts and the coolant pump pulley.





9. Remove the nut and disconnect the A/C (Air Conditioning) line.

- Discard the O-ring seal.






10. Detach the A/C (Air Conditioning) line from the retainer on the engine mount and remove the retainer from the engine mount.





11. Remove the 2 nuts, 2 bolts and the engine mount.





12. Remove the 22 bolts and the engine front cover.





Installation

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Clean and inspect the mounting surfaces of the engine and the front cover.

2. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.
Apply a 15 mm (0.59 in) bead of Silicone Gasket and Sealant to the cylinder head and oil pan joint areas.





3. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.

Apply a 3 mm (0.1181 in) bead of Silicone Gasket and Sealant to the sealing surface of the front cover. Apply a 2 mm (0.0787 in) bead of Silicone Gasket and Sealant to the 4 center sealing surface of the front cover.





4. Position the engine front cover and tighten the 22 engine front cover bolts in the sequence shown.
- Tighten bolts 1 through 17 to 10 Nm (89 lb-in).
- Tighten bolts 19 through 21 to 48 Nm (35 lb-ft).
- Tighten bolt 22 to 25 Nm (18 lb-ft).
- Tighten bolt 18 to 48 Nm (35 lb-ft).





5. Install the engine mount and install the 2 nuts and bolts finger tight and tighten in 2 stages.
- Stage 1: Tighten the 2 bolts to 90 Nm (66 lb-ft).
- Stage 2: Tighten the 2 nuts to 80 Nm (59 lb-ft).





6. Install the A/C (Air Conditioning) line retainer onto the engine mount and position the A/C (Air Conditioning) line in the retainer.





7. Using a new O-ring seal, connect the A/C (Air Conditioning) line and install the nut.
- Tighten to 15 Nm (133 lb-in).





8. Install the coolant pump pulley and the 3 bolts.
- Do not torque at this time.





9. Install the accessory drive belt tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).





10. Install the crankshaft front seal. REFER to Crankshaft Front Seal .

11. Install the cowl panel. REFER to Cowl Panel .

12. Tighten the 3 coolant pump pulley bolts.
- Using a torque adaptor, tighten to 20 Nm (177 lb-in).





13. Position the degas bottle onto the 2 retaining tabs.





14. Evacuate and charge the A/C (Air Conditioning) system. Vehicles with EMTC (Electronic Manual Temperature Control), REFER to Air Conditioning (AC) System Recovery, Evacuation and Charging . Vehicles with DATC (Dual Automatic Temperature Control), REFER to Air Conditioning (AC) System Recovery, Evacuation, and Charging .