Engine Front Cover

Special Tool(s)

	Handle 205-153 (T80T-4000-W)
	Installer, Spindle Bearing 205-149 (T80T-4000-R)
	Installer, Spindle Bearing 205-150 (T80T-4000-S)

NOTE: Engine Front Cover (View 1 of 2)

NOTE: Engine Front Cover (View 2 of 2)

Removal

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.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

2. Disconnect the battery ground cable. For additional information, refer to Section 414-01 .

3. Remove the LH and RH valve covers. For additional information, refer to Valve Cover — LH and Valve Cover — RH in this section.

4. Remove the degas bottle. For additional information, refer to Section 303-03A .

5. Remove the drain plug and drain the engine oil.
   • Install the drain plug and tighten to 27 Nm (20 lb-ft).

6. Remove the coolant pump. For additional information, refer to Section 303-03A .

7. Remove the nut, bolt and position the generator aside.

8. Remove the generator stud.

9. Remove the 2 bolts and the accessory drive belt tensioner.

10. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal in this section.

11. Remove the 22 engine front cover bolts.

12. Using a suitable pry tool, locate the 7 pry pads shown and pry the engine front cover loose and remove.

13. NOTE: The front cover radial seal must be replaced.

    Using the Spindle Bearing Installer and Handle, remove the front cover radial seal from the rear side of the front cover.

Installation

1. NOTICE: Only use a 3M™ Roloc® 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. These tools cause scratches and gouges that make leak paths.

   Clean the engine front cover using a 3M™ Roloc® 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.

2. 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™ Roloc® 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 causes 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 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.

3. Using the Spindle Bearing Installer, install the front cover radial seal from the rear side of the front cover.

4. NOTICE: 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 1, 2, 7, 8, 16, 17, 18, 19, 20 and 21 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® High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 2 engine front cover bolt bosses.
   • Apply a 5.5 mm (0.21 in) 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.

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

   Install the engine front cover and bolts 1, 2, 7, 8, 16, 17, 18, 19, 20 and 21.
   • Tighten in sequence to 3 Nm (27 lb-in).

6. Install the remaining 12 engine front cover bolts. Tighten all of the engine front cover bolts in the sequence shown in 4 stages:
   • Stage 1: Tighten bolts 1 through 21 to 10 Nm (89 lb-in).
   • Stage 2: Tighten bolts 1 through 20 to 24 Nm (18 lb-ft).
   • Stage 3: Tighten bolt 21 to 20 Nm (177 lb-in) then an additional 90 degrees.
   • Stage 4: Tighten bolt 22 to 10 Nm (89 lb-in) then an additional 45 degrees.

7. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal in this section.

8. Install the accessory drive belt tensioner and the 2 bolts.
   • Tighten to 25 Nm (18 lb-ft).

9. Install the generator stud.
   • Tighten to 8 Nm (71 lb-in).

10. Position the generator and install the nut and bolt.
    • Tighten to 48 Nm (35 lb-ft).

11. Install the coolant pump. For additional information, refer to Section 303-03A .

12. Install the degas bottle. For additional information, refer to Section 303-03A .

13. Install the LH and RH valve covers. For additional information, refer to Valve Cover — LH and Valve Cover — RH in this section.

14. Connect the battery ground cable. For additional information, refer to Section 414-01 .

15. Fill the engine with clean engine oil.