Engine Front Cover

If the engine front cover (6019) is being removed to check timing chain deflection, refer to Timing Chain Deflection procedure as outlined in Section 03-00.

SPECIAL SERVICE TOOL(S) REQUIRED

Description	Tool Number
Crankshaft Damper Remover	T58P-6316-D
Damper/Front Cover Seal Installer	T82L-6316-A
Vibration Damper Remover Adapter	T82L-6316-B

Removal

1. Drain engine cooling system as outlined in Section 03-03.

2. Disconnect battery ground cable (14301).

3. Remove engine air cleaner (ACL) (9600) and air intake duct.

4. Remove electric fan motor (8C607) , fan blade (8600) and fan shroud (8146) as an assembly.

5. Remove drive belt (8620) and water pump pulley (8509) .

6. Remove power steering pump bracket retaining bolts. Refer to Section 11-02.

   Leaving hoses connected, place power steering pump (3A674) and bracket aside in a position to prevent fluid from leaking out.

7. If equipped with air conditioning, remove A/C compressor front support bracket. Leave A/C compressor (19703) in place.

8. Remove heater water outlet tube retaining bolts, heater water outlet tube (18663) and O-ring from water pump (8501) .

9. Disconnect upper radiator hose (8260) at water outlet connection (8592) .

10. Disconnect fuel charging wiring (9D930) from camshaft position sensor (CMP sensor) (6B288) .

11. Remove hold-down clamp (12270) and lift camshaft position sensor out of the engine front cover .

12. Raise vehicle on hoist. Refer to Section 00-02.

    NOTE: If the crankshaft pulley vibration damper and pulley have to be separated, mark the damper and pulley so that they may be reassembled in the same relative position. This is important, as the damper and pulley are initially balanced as a unit.

13. Remove crankshaft pulley (6312) using Crankshaft Damper Remover T58P-6316-D and Vibration Damper Remover Adapter T82L-6316-B.

    NOTE: If the vibration damper is being replaced, check if the original vibration damper has balance pins installed. If so, new balance pins (E0SZ-6A328-A or equivalent) must be installed on the new vibration damper in the same position as the original vibration damper. The pulley (new or original) must also be installed in the same relative position as originally installed.

14. Remove oil bypass filter (6714).
    
    
    
    

15. Disconnect lower radiator hose (8286) at water pump .

16. Remove oil pan (6675) as outlined.

     CAUTION: The engine front cover cannot be removed without lowering the oil pan.

17. Lower vehicle.

     CAUTION: Do not overlook the engine front cover retaining bolt located behind the oil pump and filter body. The engine front cover will break if pried upon and all retaining bolts are not removed.

18. Remove engine front cover retaining bolts. It is not necessary to remove water pump .

19. Remove engine front cover and water pump as an assembly.

20. Remove engine timing cover gasket (6020) and discard.

Installation

NOTE: Lightly oil all bolt and stud threads before installation except those specifying special sealant.

1. Clean gasket surfaces on the engine front cover and cylinder block (6010) .

   If reusing engine front cover, replace crankshaft front seal (6700) .

2. If a new engine front cover is to be installed:
   1. Install oil pump and filter body (6603).
   2. Clean water pump gasket surface. Position a new water pump housing gasket (8507) on the engine front cover and install water pump . Install water pump retaining bolts, stud bolts and nuts. Tighten bolts and stud bolts to 20-30 Nm (15-22 lb-ft). Tighten retaining nuts to 6-8 Nm (53-71 lb-in).

3. Lubricate crankshaft front seal with clean engine oil.

   NOTE: Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specifications ESR-M11P17-A and ESE-M2G52-A is recommended to hold the engine timing cover gasket in position while the engine front cover is installed.

4. Position a new engine timing cover gasket on the cylinder block and install the engine front cover/water pump assembly using dowels for proper alignment.

5. Install the engine front cover retaining bolts. Tighten to 20-30 Nm (15-22 lb-ft).
   
   
   
   
   
   

   Fastener and Hole No.	Hole No.		Fasteners
   	Water Pump	Front Cover	Part No.	Part Name
   1		4	N805112	Stud
   2		2	N805112	Stud
   3	2	9	N804853	Stud
   4	1	8	N804853	Stud
   5		10	N605787	Bolt
   6	9	15	N804756	Stud Bolt
   7	8	16	N605908	Bolt
   8		11	N605787	Bolt
   9	7	17	N804756	Stud Bolt
   10	6	1	N804852	Stud Bolt
   11	5	7	N804853	Stud
   12	4	13	N605908	Bolt
   13	3	14	N605908	Bolt
   14		6	N804839	Bolt
   15		5	N804841	Cap Screw
   3, 4, 10, 11	2, 1, 5	9, 8, 7	N804578	Nut

   
   

6. Raise vehicle.

7. Install oil pan as outlined.

8. Connect lower radiator hose. Tighten clamp securely.

9. Install oil bypass filter. Refer to illustration following Removal, Step 14.

10. Coat crankshaft pulley sealing surface with clean engine oil.

    NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set-up, and its sealing effectiveness may be reduced.

11. Apply a small amount of Silicone Gasket and Sealant F1AZ-19562-A or equivalent meeting Ford specification WSE-M4G320-A2 to crankshaft keyway.

12. Position crankshaft key in the crankshaft keyway.

13. Install the crankshaft pulley using Damper Front Cover Seal Installer T82L-6316-A.

14. Install crankshaft pulley retaining washer and bolt. Tighten bolt to 140-180 Nm (103-132 lb-ft).

15. Install crankshaft pulley to vibration damper, if removed. Tighten retaining bolts to 26-38 Nm (20-28 lb-ft).

16. Lower vehicle.

17. Inspect heater water outlet tube O-ring (replace as necessary). Install heater water outlet tube and O-ring into water pump . Install and tighten retaining bolts to 8-12 Nm (71-106 lb-in).

18. Install camshaft position sensor. Refer to Section 03-14.

19. Connect upper radiator hose at water outlet connection . Tighten clamp securely.

20. If vehicle is equipped with air conditioning, install A/C compressor and mounting brackets. Tighten retaining bolts to 41-61 Nm (30-45 lb-ft).

21. Install power steering pump and mounting bracket. Tighten retaining bolts to 40-62 Nm (30-45 lb-ft). Refer to Section 11-02.

22. Position drive belt over the pulleys.

23. Install water pump pulley to water pump . Cross-tighten the retaining bolts to 16-24 Nm (12-18 lb-ft).

24. Install fan motor, fan blade and fan shroud as an assembly. Tighten retaining screws. Connect wiring to fan motor.

25. Install drive belt. Refer to Section 03-05.

26. Connect battery ground cable.

27. Fill crankcase to proper level with specified oil.

     CAUTION: The engine has aluminum cylinder heads and requires a special corrosion-inhibited coolant formulation to avoid cooling system damage. Refer to Section 03-03 for coolant specifications.

28. Fill engine cooling system with specified coolant.

29. Install engine air cleaner and air cleaner outlet tube (9B659) as outlined in Section 03-12.

30. Start engine and check for coolant, oil or fuel leaks.