Engine Front Cover

Removal

1. Drain the cooling system. Refer to Section 03-03.

2. Remove the fan shroud (8146) and radiator (8005). Refer to Section 03-03.

3. Using a 3/8-inch drive flex handle, lift the drive belt tensioner pulley away from the drive belt (8620). Remove drive belt. Release drive belt tensioner (6B209) slowly.

4. If equipped, discharge air conditioning system and recover refrigerant. Refer to Section 12-00.

5. Remove A/C compressor (19703) if equipped.

6. Remove A/C compressor mounting bracket (2882) with attached power steering pump (3A674) and hoses and set out of the way.

7. Remove the screw and washer from the end of the crankshaft (6303) and remove the crankshaft pulley (6312) using a suitable pulley remover tool.

   

8. Remove electrical connector and misfire sensor. Remove wiring harness bracket.

   

   Item	Part Number	Description
   1	—	Water Pump
   2	9D930	Wiring Harness
   3	14536	Wiring Harness Bracket
   4	45356	Nut
   5	6C351	Misfire Sensor
   6	—	Misfire Sensor Connector (Part of 9D930)
   A	—	Tighten to 8-13 Nm (6-10 Lb-Ft)

   

9. Remove the front oil pan and engine front cover (6019) attaching screws. Loosen the first six bolts on each side of the oil pan (6675). Lightly push oil pan down so it does not exert any upward force on the engine front cover that might affect front seal alignment.

10. Remove the engine front cover.

11. Using a sharp knife, cut the engine front cover gasket (6020) at the edge of the water pump (8501). Remove the part of the engine front cover gasket nut retained by the water pump.

12. Replace crankshaft front seal (6700) whenever the engine front cover is removed.

Installation

1. Clean engine front cover and cylinder block (6010) gasket surfaces with Ford Metal Surface Cleaner F4AZ-19536-RA or equivalent meeting Ford specification WSE-M5B392-A. Also, clean any oil on oil pan gasket (6710) as it will be reinstalled.

2. If the water pump was not removed, trim off the part of the engine front cover gasket that would go under the water pump.

3. Coat engine front cover gasket surfaces of the cylinder block and engine front cover with Perfect Seal Sealing Compound F2AZ-19554-AA or equivalent meeting Ford specifications ESE-M4G115-A. Position a new engine front cover gasket on the cylinder block.

4. NOTE: When applying RTV sealant, always use the bead size specified and join the components within 15 minutes of application. After this amount of time the sealant begins to set up and its sealing effectiveness may be reduced.

   Apply RTV Silicone Rubber D6AZ-19562-AA or F4AZ-19562-B or equivalent meeting Ford specifications WSE-M4G323-A1 to the block/pan junction and a small bead on oil pan gasket sealing surface of the engine front cover. This provides an additional seal between engine front cover and the usedoil pan gasket.

   

5. NOTE: Tighten front cover screws before the oil pan-to-front cover screws to obtain proper engine front cover alignment.

   Position the engine front cover over the end of the crankshaft and against the cylinder block. Start the cover and pan attaching screws. Slide Front Cover Aligner T61P-6019-B over the crank stub and into the seal bore of the engine front cover. Tighten attaching oil pan screws to 20-23 Nm (15-17 lb-ft) and front cover screws to 17-24 Nm (13-18 lb-ft).

   

6. Lubricate the crank stub, crankshaft pulley hub inside diameter and the seal rubbing surface with clean engine oil or 50 weight oil only. DO NOT use grease on seal. Apply a 6mm (1/4-inch) bead of silicone rubber to inside of keyway of crankshaft pulley hub. Align the crankshaft pulley keyway with the key on the crankshaft and install the crankshaft pulley using Crankshaft Sprocket and Damper Replacer T52L-6306-AEE.

   

7. Install the washer and capscrew. Tighten to 177-203 Nm (130-150 lb-ft).

8. Install misfire sensor and tighten to 16-24 Nm (12-18 lb-ft).

9. Connect electrical connector.

10. Install wiring harness bracket and tighten to 8-14 Nm (6-10 lb-ft).

    

    Item	Part Number	Description
    1	—	Water Pump
    2	9D930	Wiring Harness
    3	14536	Wiring Harness Bracket
    4	45356	Nut
    5	6C351	Misfire Sensor
    6	—	Misfire Sensor Connector (Part of 9D930)
    A	—	Tighten to 8-13 Nm (6-10 Lb-Ft)

11. Install A/C compressor mounting bracket to engine and tighten nuts to 54-71 Nm (40-52 lb-ft). Tighten two bolts to 30-40 Nm (22-30 lb-ft).

12. Install A/C compressor, if equipped, and power steering pump brace. Tighten bolts to 30-40 Nm (22-30 lb-ft). Refer to Section 12-00, Climate Control System Service.

13. If not equipped with air conditioning, install power steering pump brace and tighten bolts to 24-31 Nm (18-23 lb-ft).

14. Install power steering pump with assembled hoses and tighten bolts to 40-55 Nm (30-40 lb-ft).

15. Fill and bleed the cooling system. Use the specified antifreeze mix. Refer to Section 03-03.

16.  CAUTION: To avoid damage to the engine (6007) due to entrance of foreign material during repairs, engine oil must be changed when repairs are completed.

    Change the engine oil with proper quantity and quality oil as specified in Section 00-03.

17. Operate the engine at fast idle and check for coolant and oil leaks.