Engine Front Cover

Special Tool(s)

	Lifting Bracket, Engine (2 required) 303-D087 (D93P-6001-A1) or equivalent
	Support Bar, Engine 303-F070
	Support Bar, Engine 303-F072
	Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool

Engine Front Cover (View 1 of 4)

Engine Front Cover (View 2 of 4)

Engine Front Cover (View 3 of 4)

NOTE: Oil cooler shown, oil cooler thermostat similar.

Engine Front Cover (View 4 of 4)

Removal

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to Section 100-02 .

2. Release the fuel system pressure. Refer to Section 310-00 .

3. Remove the engine coolant degas bottle. Refer to Section 303-03A .

4. Remove the Supercharger (SC) coolant degas bottle. Refer to Section 303-03B .

5. Drain the SC cooling system. Refer to Section 303-03B

6. Remove the thermostat housing. Refer to Section 303-03A .

7. Loosen the 4 coolant pump pulley bolts.

8. Remove the accessory drive belt, the 2 accessory drive belt idler pulleys and the accessory drive belt tensioner. Refer to Section 303-05 .

9. Remove the 4 bolts and the coolant pump pulley.

10. Disconnect the upper coolant hose from the SC coolant pump.

11. Disconnect the lower coolant hose from the SC coolant pump.

12. Disconnect the SC coolant pump electrical connector and wire retainer.

13. Remove the 2 nuts, bolt and the SC coolant pump.

Vehicle equipped with the cooling package

14. Remove the 2 retaining clips and disconnect the 2 oil hoses from the oil filter adapter.

All vehicles

15. Remove the RH and LH valve covers. Refer to Valve Cover — RH and Valve Cover — LH .

16. Remove the SC drive belt, SC drive belt tensioner and the 3 SC drive belt idler pulleys. Refer to Section 303-05 .

17. Remove the crankshaft front seal. Refer to Crankshaft Front Seal .

18. Disconnect the 2 coolant vent hoses from the intake manifold.

19. Disconnect the 2 upper radiator hoses from the intake manifold.

20. Disconnect the coolant hoses from the Charge Air Cooler (CAC).

21. Disconnect the lower radiator hose assembly from the coolant pump, radiator, oil filter adapter (if equipped) and the coolant tube assembly (located above the generator).
    • Remove the lower radiator hose assembly from the vehicle.

22. Disconnect the Crankshaft Position (CKP) sensor electrical connector.

23. Remove the 8 pin-type retainers and the upper radiator sight shield.

24. Install the Engine Lifting Bracket.

25. Install the Engine Lifting Bracket.

26. NOTE: The heavy duty Engine Support Bar (303-F070) must be used with the draw screws from the light duty Engine Support Bar (303-F072). This will provide enough clearance between the SC and the Engine Support Bar, and enough clearance between the draw screw and the vehicle hood.

    Install the Engine Support Bars.
    • Remove the LH and RH engine support insulator nuts.
    • Using the Engine Support Bars, raise the engine.

27. Remove the 3 bolts and lower the underbody shield.

28. Remove the nut and disconnect the B+ wire terminal from the generator.

29. Disconnect the generator electrical connector.

30. Detach the wiring harness retainer from the oil pan stud bolt.

31. Remove the nut and the wire harness retainer bracket from the oil pan stud bolt.

32. Remove the 3 bolts and the generator.

33. If equipped, disconnect the coolant hose from the oil filter adapter.

34. NOTICE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to correct these concerns may cause engine failure. To diagnose mechanical concerns, refer to Section 303-00 .

    Remove the 6 bolts and the oil cooler or oil cooler thermostat.
    • Discard the gaskets.
    • Inspect the oil cooler.

35. Drain the engine oil.
    • Tighten the drain plug to 26 Nm (19 lb-ft).

36. Remove and discard the engine oil filter.

37. Remove the 3 coolant tube assembly bolts.

38. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness pin-type retainers.

39. Remove the 4 bolts and the LH engine mount bracket.

40. Remove the 8 bolts and the oil filter adapter.
    • Discard the gasket.

41. Remove the oil pan-to-engine front cover bolt and the 3 oil pan-to-engine front cover stud bolts.

42. Remove the 4 bolts and the coolant pump.
    • Discard the gasket.

43. Remove the 16 bolts and the engine front cover.
    • Remove and discard the engine front cover gaskets.

    • NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

      Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.

Installation

All vehicles

1. NOTE: The engine front cover must be installed and all fasteners final tightened within 4 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 4 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

   Apply a bead of Motorcraft® High Performance Engine RTV Silicone to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.

2. NOTE: Make sure that the engine front cover gaskets are in place on the engine front cover before installation.

   Using new gaskets, position the engine front cover onto the dowels and install the 16 bolts. Tighten the bolts in the sequence shown in 2 stages.
   • Stage 1: Tighten bolts 1 through 14 to 25 Nm (18 lb-ft).
   • Stage 2: Tighten bolts 15 and 16 to 48 Nm (35 lb-ft).
   
   
   

   Item	Part Number	Description
   1	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   2	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   3	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   4	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   5	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   6	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   7	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   8	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   9	N808586	Stud bolt, hex head pilot, M8 x 1.25 x 50
   10	N808586	Stud bolt, hex head pilot, M8 x 1.25 x 50
   11	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   12	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   13	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   14	N806177	Bolt, hex head pilot, M8 x 1.25 x 53
   15	N606063	Bolt, hex flange head pilot, M10 x 1.50 x 55
   16	N606063	Bolt, hex flange head pilot, M10 x 1.50 x 55

3. Install the oil pan-to-engine front cover bolt and the 3 oil pan-to-engine front cover stud bolts.
   • Tighten to 25 Nm (18 lb-ft).

4. Using a new gasket, install the coolant pump and the 4 bolts.
   • Tighten to 25 Nm (18 lb-ft).

5. NOTE: Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

   Using a new gasket, install the oil filter adapter and the 8 bolts. Tighten in the sequence shown in 2 stages.
   • Stage 1: Tighten bolts 1 through 6 to 25 Nm (18 lb-ft).
   • Stage 2: Tighten bolts 7 and 8 to 48 Nm (35 lb-ft).

6. Install the LH engine mount bracket and the 4 bolts
   • Tighten to 55 Nm (41 lb-in).

7. Connect the EOP switch electrical connector and the 2 wiring harness pin-type retainers.

8. Install the 3 coolant tube assembly bolts.
   • Tighten to 10 Nm (89 lb-in).

9. Install a new engine oil filter in the following sequence.
   1. Lubricate the oil filter gasket with clean engine oil and tighten until the seal makes contact.
   2. Using an oil filter strap wrench, tighten the filter an additional 270 degrees.

10. NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.

    NOTE: Oil cooler shown, oil cooler thermostat similar.

    Using new gaskets, install the oil cooler or oil cooler thermostat and the 6 bolts. Tighten in the sequence shown in 2 stages.
    • Stage 1: Tighten to 9 Nm (80 lb-in).
    • Stage 2: Tighten an additional 90 degrees.

11. If equipped, connect the coolant hose to the oil filter adapter.

12. Install the generator and the 3 bolts.
    • Tighten to 48 Nm (35 lb-ft).

13. Install the 2 wire harness retainer brackets on the 2 oil pan stud bolts and install the 2 nuts.
    • Tighten to 10 Nm (89 lb-in).

14. Attach the wiring harness retainer to the oil pan stud bolt.

15. Connect the generator electrical connector.

16. Connect the B+ wire terminal to the generator and install the nut.
    • Tighten to 8 Nm (71 lb-in).

17. Position the underbody shield and install the 3 bolts.
    • Tighten to 9 Nm (80 lb-in).

18. Using the Engine Support Bars, lower the engine onto the engine support insulators.

19. Install the upper radiator sight shield and the 8 pin-type retainers.

20. NOTICE: Do not tighten the engine support insulator nuts until the full weight of the engine is on the engine insulator or damage to the engine insulator may occur.

    Install the LH and RH engine support insulator nuts.
    • Tighten to 63 Nm (46 lb-ft).

21. Connect the CKP sensor electrical connector.

22. Install the lower radiator hose assembly to the coolant pump, radiator, oil filter adapter (if equipped) and the coolant tube assembly (located above the generator).

23. Connect the coolant hoses to the CAC .

24. Connect the 2 upper radiator hoses to the intake manifold.

25. Connect the 2 coolant vent hoses to the intake manifold.

26. Install the crankshaft front seal. Refer to Crankshaft Front Seal .

27. Install the 3 SC drive belt idler pulleys, SC drive belt and the SC drive belt tensioner. Refer to Section 303-05 .

28. Install the RH and LH valve covers. Refer to Valve Cover — RH and Valve Cover — LH .

Vehicle equipped with the cooling package

29. Connect the 2 oil hoses to the oil filter adapter and install the 2 retaining clips.

All vehicles

30. Install the SC coolant pump, bolt and the 2 nuts.
    • Tighten the bolt to 10 Nm (89 lb-in).
    • Tighten the nuts to 11 Nm (97 lb-in).

31. Connect the SC coolant pump electrical connector and wire retainer.

32. Connect the lower coolant hose to the SC coolant pump.

33. Connect the upper coolant hose to the SC coolant pump.

34. Install the coolant pump pulley and the 4 bolts.

35. Install the 2 accessory drive belt idler pulleys, the accessory drive belt tensioner and the accessory drive belt. Refer to Section 303-05 .

36. Tighten the 4 coolant pump pulley bolts to 25 Nm (18 lb-ft).

37. Install the thermostat housing. Refer to Section 303-03A .

38. Install the SC coolant degas bottle. Refer to Section 303-03B .

39. Install the engine coolant degas bottle. Refer to Section 303-03A .

40. Fill the engine with clean engine oil.

41. Fill and bleed the SC cooling system. Refer to Section 303-03B .

42. Fill and bleed the engine cooling system. Refer to Section 303-03A .

43. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.