Removal and Installation - Front Engine Cover

Special Service Tools / General Equipment

Materials

Removal

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as specified in this procedure. The crankshaft pulley and crankshaft sprocket are not keyed to the crankshaft. The crankshaft, crankshaft sprocket and pulley are connected to each other by friction. For this reason the crankshaft sprocket can also come loose if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked with the special service tools, otherwise serious engine damage may occur.

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 oil pan may cause engine failure.

1. 1
   Drain the cooling system.
   Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03C Engine Cooling – General Procedures).
2. 2
   Remove the air conditioning (A/C) compressor inlet pipe.
   Refer to: Air Conditioning (A/C) Compressor Inlet Pipe - 2.5 L Duratec - Hybrid (121 kW/164 L PS) (BG) (412-00 Climate Control System - General Information, Removal and Installation).
3. 3
   Remove the front crankshaft seal.
   Refer to Front Crankshaft Seal (Engine 303-01C, Removal and Installation).
4. 4
   Remove the engine mount bracket.
   Refer to: Engine Mounts (Engine 303-01C, Removal and Installation).
5. 5
   Raise the engine 88.9 mm (3.5 in).
   Use common service equipment: Floor jack

   

6. 6
   Disconnect the hose, remove the bolts and the coolant outlet assembly.

   

7. 7
   Remove the engine mount studs.

   

8. 8
   Remove the bolts and the front engine cover.

   

Installation

1. 1
   Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
   Use common service equipment: plastic scraper
   Material: Motorcraft® silicone gasket remover / ZC-30-A, AZC-30-C
   Material: Motorcraft® metal brake parts cleaner / PM-4-A, PM-4-B, APM-4-C
   Material: Motorcraft® metal surface preparation wipes / ZC-31-B

   

2. 2
   Refer to: RTV Sealing Surface Cleaning and Preparation (303-00 Engine System - General Information, General Procedures).
   Use common service equipment: plastic scraper
   Material: Motorcraft® silicone gasket remover / ZC-30-A, AZC-30-C
   Material: Motorcraft® metal brake parts cleaner / PM-4-A, PM-4-B, APM-4-C
   Material: Motorcraft® metal surface preparation wipes / ZC-31-B

   

3. 3
   Apply a 15 mm (0.59 in) bead of silicone sealant at the junctions of the cylinder head and the oil pan.
   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

   

4. 4
   Apply a 3 mm bead of silicone sealant to the outside sealing surfaces of the front engine cover. Apply a 2 mm bead of silicone sealant to the inside sealing surfaces.
   Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSS-M4G323-A6)

   

5. 5
   Install the front engine cover and bolts. Tighten in the sequence shown.
   Torque:
   Stage 1: Bolts 1-3: 35 lb-ft (48 N·m)
   Stage 2: Bolts 4-16: 89 lb-in (10 N·m)
   Stage 3: Bolt 17: 35 lb-ft (48 N·m)
   Stage 4: Bolts 18-22: 89 lb-in (10 N·m)

   

6. 6
   Install the engine mount studs.
   Torque: 106 lb-in (12 N·m)

   

7. 7
   Inspect the O-ring of the engine coolant outlet assembly and replace if necessary.

   

8. 8
   Install the engine coolant outlet pipe, bolts and connect the hose.
   Torque: 89 lb-in (10 N·m)

   

9. 9
   Lower the engine 88.9 mm (3.5 in).
   Use general equipment: Floor jack

   

10. 10
    Install the engine mount.
    Refer to: Engine Mount (Engine 303-01C, Removal and Installation).
11. 11
    Install the front crankshaft seal.
    Refer to Front Crankshaft Seal (Engine 303-01C, Removal and Installation).
12. 12
    Install the A/C compressor inlet tube.
    Refer to: A/C Compressor Inlet Tube — 2.5 L Duratec — Hybrid (121 kW/164 L PS) (BG) (412-00 Climate Control System — General Information, Removal and Installation).
13. 13
    Fill the cooling system.
    Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding (303-03C Engine Cooling, General Procedures).
14. 14