Part 1

Engine Front Cover

Installation (Steps 1-36)

Special Tool(s) (Part 1):

Special Tool(s) (Part 2):

Material:

All vehicles

CAUTION: 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.

1. Install the special tools.

2. CAUTION: Failure to use Motorcraft 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 inch) bead of Motorcraft 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 inch) bead of Motorcraft 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.

3. 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-inch).

4. Remove the special tools (alignment pins).

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

Install the engine mount bracket and the 3 bolts.

6. CAUTION: Do not expose the Motorcraft 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-inch) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft).
^ 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).

7. Install the 2 engine mount studs.
^ Tighten to 18 Nm (13 lb-ft).

8. Install the engine mount bracket and the 2 bolts.
^ Tighten to 24 Nm (18 lb-ft).

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

Using the special tools, install a new crankshaft front seal.

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

Using the special tools, install the crankshaft pulley.

11. Using the special tool, 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.

12. Install the accessory drive belt tensioner and the 3 bolts.
^ Tighten to 10 Nm (89 lb-inch).

13. Install the power steering pump and the 3 bolts.
^ Tighten to 25 Nm (18 lb-ft).

14. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.

NOTE: Spark plug tube seal installation shown, variable camshaft timing (VCT) seal installation similar.

Using the special tools, install new VCT solenoid and/or spark plug tube seals.

15. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.31 inch) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.

16. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-inch).

17. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.31 inch) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.

18. Using a new gasket, install the LH valve cover and 11 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-inch).

19. Install the wiring harness retaining bracket and the 2 nuts.
^ Tighten to 9 Nm (80 lb-inch).

20. Install the power steering pressure (PSP) hose bracket and nut.
^ Tighten to 9 Nm (80 lb-inch).

21. Attach the PSP hose retainer to the engine lifting eye.

22. NOTE: LH shown, RH similar.

Install the 6 coil-on-plug assemblies and the 6 bolts.
^ Tighten to 7 Nm (62 lb-inch).

23. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
24. Connect the 3 LH coil-on-plug electrical connectors.

25. Connect the LH camshaft VCT solenoid electrical connector.

26. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
27. If equipped, connect the heated PCV valve electrical connector.