Front Cover Installation

1. Install the timing chain tensioner. Tighten the retaining bolts to 8-14 Nm (6-10 lb-ft).





2. Make sure the balance shaft timing mark is at the 6 o'clock position. See Figure 8.

3. Install the timing chain, crankshaft sprocket and camshaft sprocket as an assembly.





4. Make sure the timing marks and the keyways are aligned. See Figure 9.

5. Apply tension to the timing chain by removing the pick from the tensioner housing.

6. Install the camshaft position sensor drive gear. Tighten the retaining bolt to 40-50 Nm (30-36 lb-ft).

NOTE:
Remember to carefully remove the plugs and rags from the passages and oil pan before installing the new gasket.

7. Position the new front cover gasket on the engine block.

8. Apply Silicone Gasket and Sealant (F7AZ-19554-EA) or equivalent to the exposed portion of the oil pan.

9. Position the front cover assembly onto the engine block.

NOTE:
Some water pump mounting studs are included in the parts kit just in case a stud is damaged during disassembly. All fasteners that are removed from the vehicle may be reused if they are not damaged. If water pump studs 3 and 4 are being reinstalled, apply Pipe Sealant with Teflon(R) (D8AZ-19554-A) or equivalent to the short threaded end of the studs which go into the block. If the kit contains a black-colored stud, part number W701927-S430, DO NOT use this stud. Refer to the Fastener Location Matrix for fastener location and part numbers.





10. Install four (4) water pump studs in the locations shown in Figure 10. The two (2) studs with thread sealer must be installed in the proper positions. Using double nuts, tighten the studs to 7 Nm (62 lb-in). Remove the double nuts after the studs have been tightened.

11. Install the remaining three (3) front cover retaining bolts.

12. Apply Pipe Sealant with Teflon(R) (D8AZ-19554-A) or equivalent meeting Ford specification WSK-M2G350-A2 to the Allen head capscrew, then install the capscrew into the lower part of the front cover.

13. Seat the front cover on the engine block by partially tightening all installed front cover bolts. Do not final tighten the bolts at this time.

14. Position the new water pump gasket on the front cover.

15. Position the water pump on the front cover.

16. Install the water pump retaining bolts.

17. Install the stud nuts on all front cover/water pump studs.

NOTE:
The torque specifications in the following step have been revised and are different from those in the service manual.





18. Tighten the front cover/water pump retainers in the sequence shown in Figure 11 to 28 Nm (20 lb-ft). Tighten the Allen head capscrew 11 to 22 Nm (16 lb-ft).

CAUTION
The proper seal installation tools (T94P-6701-AH, T88T-6701-A1 and T82L-6316-A) must be used on the front crankshaft seal. Oil leaks and contamination will result if the proper tools are not used.

19. Install the crankshaft seal in the front cover as follows:

^ Lubricate the crankshaft front oil seal lip with clean engine oil.

^ Place Front Crankshaft Seal Replacer (T94P-6701-AH) and the crankshaft front seal on Front Crankshaft Seal Installer/Aligner (T88T-6701-A1).

^ Place above assembly over the crankshaft.

^ Insert the forcing screw from Damper/Front Cover Seal Replacer (T82L-6316-A) into Front Crankshaft Seal Installer/Aligner (T88T-6701-A2).

^ Thread the forcing screw into the crankshaft.

^ Hold the forcing screw with a wrench and tighten the draw nut until the flange of the aligner is flush with the front cover surface.

20. Lubricate the crankshaft front oil seal surface on the crankshaft vibration damper with clean engine oil.

21. Apply Silicone Gasket and Sealant (F7AZ-19554-EA) or equivalent to the crankshaft damper keyway.

22. Using Damper/Front Cover Seal Replacer (T82L-6316-A), install the crankshaft vibration damper.

23. Install the crankshaft damper retaining bolt. Tighten the bolt to 140-180 Nm (103-132 lb-ft).

24. Install the crankshaft pulley. Tighten the retainers to 26-38 Nm (19-28 lb-ft).

25. Install the water pump pulley to the water pump. Tighten the retainers to 8-11 Nm (71-101 lb-in).

26. Fill the new engine oil filter with clean 5W-30 engine oil meeting Ford specification WSS-M2C153-G. Lubricate the O-ring then install the filter.

27. Connect the lower radiator hose to the water pump.

28. Install the drive belt tensioner pulley. Tighten the retainer to 47-63 Nm (35-46 lb-ft).

29. Install the top drive belt idler pulley. Tighten the retainer to 47-63 Nm (35-46 lb-ft).

30. Make sure the timing mark on the damper is aligned with the TDC mark on the front cover gauge.

31. Install the camshaft synchronizer assembly as follows:

^ Make sure Synchro Positioning Tool (T96T-12200-A) is properly installed on the synchronizer assembly.





^ Insert the camshaft synchronizer assembly in the front cover. Install the synchronizer assembly so that the arrow on the alignment tool is 54 degrees from the centerline of the engine. See Figure 12. This ensures that the CMP sensor electrical connector has proper clearance.

^ Install and tighten the hold-down bolt to 20-30 Nm (15-22 lb-ft).

^ Remove Synchro Positioning Tool.

^ Install the camshaft position sensor to the synchronizer assembly. Tighten the retaining screws to 5-8 Nm (45-70 lb-in).

32. Install the power steering pump bracket. Tighten the retainers to 40-55 Nm (30-41 lb-ft).

33. Using Steering Pump Pulley Replacer (T91P-3A733-A), install the power steering pump pulley. The pulley face must be flush (within 0.25 mm [0.010 inch]) of the end of the power steering pump shaft.





34. Connect the coolant hose (shown) to the water outlet tube. See Figure 13.

35. Lubricate the water outlet tube O-ring with antifreeze, then install it in the water pump. Tighten the retaining bolt to 8-11 Nm (71-97 lb-in).

36. Connect the remaining three (3) coolant hoses to the water outlet tube.

37. Connect the EGR tube to the EGR valve. Tighten the tube nut to 34-47 Nm (25-34 lb-ft).

38. Connect the heater hose to the fitting on the lower intake manifold.

39. Install the vacuum line to the EGR valve.

40. Connect the throttle position sensor electrical connector.

41. Route the engine wiring harness down the front of the engine. Secure the wiring anchor to the water pump stud.

42. Attach the engine wiring harness pushpin to the water outlet tube flange.

43. Connect the camshaft position sensor electrical connector.

44. Install the drive belt.

45. Install the engine cooling fan and the fan shroud. Tighten the cooling fan retainer to 47-63 Nm (35-46 lb-ft). Tighten the fan shroud retainers to 8-10 Nm (71-89 lb-in).

46. Install the upper radiator hose.

47. Install the front air deflector.

48. Install the jack handle.

49. Raise and support the vehicle.

50. Drain the engine oil. Tighten the drain plug to 14 Nm (123 lb-in).

51. Connect the oil pressure sender electrical connector.

52. Connect the crankshaft position sensor electrical connector.

53. Route the wiring harness to the knock sensor, setting the pushpin and the anchor, then connect the knock sensor electrical connector.

54. Lower the vehicle.

55. Connect the battery negative cable, then remove the memory saver.

56. Fill the cooling system.

57. Fill the engine with 5W-30 engine oil meeting Ford specification WSS-M2C153-G or equivalent.

58. Prime the lubrication system with fresh oil by cranking the engine for 15 seconds with the coil disconnected or until the oil light turns off or the gauge registers pressure.

59. Reconnect the coil, then start the engine and check for leaks. Allow the engine to warm up to operating temperature, then make sure it is operating properly.

NOTE:
If coolant was detected in the oil before the front cover gasket was replaced, make sure there is not an internal coolant leak by pressure testing the cooling system at operating temperature.