Installation

Engine Front Cover













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, may cause engine failure.

Installation

1. Raise the engine to the installed position.

2. NOTICE: Only use a 3M Roloc(R) 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 the crankshaft rear seal retainer plate. These tools cause scratches and gouges that make leak paths.

Clean the engine front cover using a 3M™ Roloc(R) 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.

3. 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(TM) Roloc(R) Bristle Disk (2-in white part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also 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.

4. Install the Alignment Pins.





5. NOTICE: Failure to use Motorcraft(R) 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 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket 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(R) High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.

- Apply a 5.5 mm (0.21 in) bead of Motorcraft(R) 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.





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

Install the engine front cover and bolts 17, 18, 19 and 20.

- Tighten in sequence to 3 Nm (27 lb-in).





7. Remove the Alignment Pins.





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

Lower the engine to allow installation of the engine mount bracket and lower bolt.

- Install the engine mount bracket and lower bolt as an assembly.





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

Raise the engine to the installed position.

- Install the 2 upper engine mount bracket bolts.





10. NOTICE: Do not expose the Motorcraft(R) 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 and engine mount bracket bolts in the sequence shown in 2 stages:

- Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in).

- Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).





11. NOTICE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.

Install the engine mount studs in the following sequence.

1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.

2. Clean all the thread sealer from the engine mount studs (old and new studs).

3. Apply new Threadlock and Sealer to the engine mount stud threads.

4. Install the 2 engine mount studs.
- Tighten to 20 Nm (177 lb-in).





12. Install the engine mount bracket and the 2 bolts.
- Tighten to 30 Nm (22 lb-ft).





13. Install the engine mount and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).





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





15. Install the engine mount brace, nut and bolt.
- Tighten to 20 Nm (177 lb-in).





16. Tighten the transaxle mount through bolt to 175 Nm (129 lb-ft).





17. NOTE: LH shown, RH similar.

Install the LH and RH VCT solenoids and bolts.

- Tighten to 10 Nm (89 lb-in).





18. Install the power steering pump and the 3 bolts.
- Tighten to 24 Nm (18 lb-ft).





19. Install the power steering reservoir and the 2 nuts.
- Tighten to 8 Nm (71 lb-in).





20. Install the degas bottle and the 3 bolts.
- Tighten to 9 Nm (80 lb-in).





21. Connect the 3 PCM electrical connectors.





22. Connect the purge valve electrical connector.





23. Install the radio interference capacitor, the ground wire and the nut to the cowl stud.
- Tighten to 10 Nm (89 lb-in).





24. Install the radio interference capacitor wire, the ground wire and the nut to the engine front cover stud.
- Tighten to 10 Nm (89 lb-in).





25. Install the ground wire and bolt on the engine front cover.
- Tighten to 10 Nm (89 lb-in).





26. Connect the 2 engine wiring harness connectors.





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





28. Install the A/C pressure tube bracket and bolt.
- Tighten to 8 Nm (71 lb-in).





29. Connect the A/C suction tube fitting.
- Install the safety clip onto the fitting.





30. Install the LH and RH valve covers. For additional information, refer to Valve Cover - LH Valve Cover - LH and Valve Cover - RH Valve Cover - RH.

31. Install the engine Air Cleaner (ACL) and ACL outlet pipe.

32. If equipped, attach the engine block heater harness to the radiator support, the A/C suction tube and the engine wiring harness.





33. Install the RH front halfshaft.

34. Install and the transaxle bracket and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).





35. Install the engine roll restrictor, transaxle bracket and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).





36. Tighten the engine roll restrictor-to-subframe through bolt to 103 Nm (76 lb-ft).





37. Install the roll restrictor heat shield and the 2 nuts.
- Tighten to 11 Nm (97 lb-in).





38. Position the Y-pipe assembly in place and install the 4 nuts.
- Tighten to 40 Nm (30 lb-ft).





39. Install the 2 exhaust hangers and tighten the exhaust clamp.
- Tighten to 40 Nm (30 lb-ft).





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

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





41. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

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





42. 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.





43. Install the accessory drive belt, tensioner and the power steering belt.

44. NOTICE: Do not expose the Motorcraft(R) 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.

45. Connect the battery ground cable.

46. Evacuate and recharge the A/C system.