Installation

Timing Cover Aligner:

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

2. Install a new crankshaft front seal in the engine front cover.

3. Lubricate the timing chain with clean engine oil or equivalent meeting Ford specification.

4. Coat surface of the oil pan gasket with sealer. Apply Silicone Rubber or equivalent, meeting Ford specification, at the corners.

5. Coat the gasket surfaces of the cylinder block and engine front cover with Perfect Seal Sealing Compound or equivalent meeting Ford specification and position a new engine timing cover gasket on the cylinder block.

6. Position the engine front cover on the cylinder block. Use care when installing the engine front cover to avoid seal damage or possible gasket mis-location.

7. Install the cylinder front cover to seal alignment tool into proper position.

8. It may be necessary to force the engine front cover downward to slightly compress the oil pan gasket. This operation can be facilitated by using Front Cover Aligner.

9. Coat the threads of the retaining bolts with oil-resistant Pipe Sealant with Teflon or equivalent meeting Ford specification and install the bolts. While pushing in on the alignment tool, tighten the oil pan-to-engine front retaining bolts to 12-16 Nm (110-144 lb-in).

10. Tighten the engine front cover-to-cylinder block retaining bolts to 16-24 Nm (12-18 lb-ft). Remove the pilot.

Crankshaft Sprocket And Damper Replacer:

11. Apply Multi-Purpose Grease or equivalent meeting Ford specification to the crankshaft front seal rubbing surface of the vibration damper inner hub to prevent damage to the crankshaft front seal. Apply Silicone Gasket and Sealant or equivalent meeting Ford specification to the keyway before installing on the crankshaft.

12. Line up the crankshaft vibration damper keyway with the crankshaft key on the crankshaft. Install the vibration darn per on the crankshaft using Crankshaft Sprocket and Damper Replacer. Install the capscrew and washer. Tighten the bolt to 149-176 Nm (110-130 lb-ft). Install the crankshaft pulley.

13. Install the retaining bolts and stud bolts. Tighten to 20-28 Nm (15-21 lb-ft).

Water Pump:

14. Connect the lower radiator hose, heater water hose and water bypass hose at the water pump.

15. Install all the accessory brackets which attach to the water pump. Install the water pump pulley.

16. Install the drive belt.

17. Install the cooling fan motor, fan blade and fan shroud as an assembly.

18. Connect cooling fan motor to headlamp dash panel junction wire.

19. Fill and bleed the engine cooling system.

20. Operate the engine until normal operating temperatures have been reached and check for leaks.

21. Fill the crankcase with the proper grade and quantity of engine oil.

22. Fill and bleed the engine cooling system.

23. Operate the engine at fast idle. Check for engine coolant and oil leaks.