Installation

NOTE: Lightly oil all bolt and stud threads before installation except those specifying special sealant.

1. Clean gasket surfaces on the engine front cover and cylinder block.

If reusing engine front cover replace crankshaft front seal.

2. If a new engine front cover is to be installed:

a. Install oil pump and filter body.





b. Clean water pump gasket surface. Position a new water pump housing gasket on the engine front cover and install water pump. Install water pump retaining bolts, stud bolts and nuts. Tighten bolts and stud bolts to 20-30 Nm (15-22 lb-ft). Tighten retaining nuts to 6-8 Nm (53-71 lb-in).

3. Lubricate crankshaft front seal with clean engine oil.

NOTE: Gasket and Trim Adhesive or equivalent meeting Ford specifications is recommended to hold the engine timing cover gasket in position while the engine front cover is installed.

4. Position a new engine timing cover gasket on the cylinder block and install the engine front cover/water pump assembly using dowels for proper alignment.

5. Install the engine front cover retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft).





6. Raise vehicle.

7. Install oil pan as outlined.

8. Connect lower radiator hose. Tighten clamp securely.

9. In stall oil bypass filter. Refer to illustration following Removal, Step 14.

10. Coat crankshaft pulley sealing surface with clean engine oil.

NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set-up, and its sealing effectiveness may be reduced.

11. Apply a small amount of Silicone Gasket and Sealant or equivalent meeting Ford specification to crankshaft keyway.

12. Position crankshaft key in the crankshaft keyway.

13. Install the crankshaft pulley using Damper Front Cover Seal Installer.

14. Install crankshaft pulley retaining washer and bolt. Tighten bolt to 140-180 Nm (103-132 lb-ft).

15. Install crankshaft pulley to vibration damper, if removed. Tighten retaining bolts to 26-38 Nm (20-28 lb-ft).

16. Lower vehicle.

17. Inspect heater water outlet tube 0-ring (replace as necessary). Install heater water outlet tube and 0-ring into water pump. Install and tighten retaining bolts to 8-12 Nm (71-106 lb-in).

18. Install camshaft position sensor.

19. Connect upper radiator hose at water outlet connection. Tighten clamp securely.

20. If vehicle is equipped with air conditioning, install A/C compressor and mounting brackets. Tighten retaining bolts to 41-61 Nm (30-45 lb-ft).

21. Install power steering pump and mounting bracket. Tighten retaining bolts to 40-62 Nm (30-45 lb-ft).

22. Position drive belt over the pulleys.

23. Install water pump pulley to water pump. Cross-tighten the retaining bolts to 16-24 Nm (12-18 lb-ft).

24. Install fan motor, fan blade and fan shroud as an assembly. Tighten retaining screws. Connect wiring to fan motor.

25. Install drive belt.

26. Connect battery ground cable.

27. Fill crankcase to proper level with specified oil.

CAUTION: The engine has aluminum cylinder heads and requires a special corrosion-inhibited coolant formulation to avoid cooling system damage.

28. Fill engine cooling system with specified coolant.

29. Install engine air cleaner and air cleaner outlet tube.

30. Start engine and check for coolant, oil or fuel leaks.