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Home >> Ford >> 2015 >> Explorer Limited, 3.5L Eng VIN 8, AWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 3 (Engine - 3.5L GTDI) >> In-Vehicle Repair >> Engine Front Cover >> Installation

Engine Front Cover: Installation

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    NOTE: 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 the engine front cover.

  1. 1.
    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.
    NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc ® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces of the engine block, cylinder heads, and oil pan. These tools cause contamination that can cause premature engine failure. Remove all traces of sealant, including any sealant from the inner surface of the cylinder block and cylinder head.
    NOTE: 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.

  1. 2.
    Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.

    1. 1.

      Remove any large deposits of silicone or gasket material with a plastic scraper.

    1. 2.

      Apply silicone gasket remover, following package directions and allow to set for several minutes.

    1. 3.

      Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.

    1. 4.

      Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.

    1. 5.

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

  1. 3.

    Install the Special Tool(s): Alignment Pins 307-399.
GFD34870Courtesy of FORD MOTOR COMPANY
    NOTE: The engine front cover and bolts 17, 18, 19 and 20 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 these instructions can cause future oil leakage.
    NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

  1. 4.
    Apply a 3.0 mm (0.11 in) bead of silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
    • Apply a 5.5 mm (0.21 in) bead of 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.
GFD34871Courtesy of FORD MOTOR COMPANY
    NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

  1. 5.
    Install the engine front cover and bolts 17, 18, 19 and 20.
    • Tighten in sequence to 3 Nm (27 lb-in).
Fig 1: Engine Front Cover Bolts Tightening Sequence
GFD34872Courtesy of FORD MOTOR CO.

  1. 6.

    Remove the Special Tool(s): Alignment Pins 307-399.
GFD34873Courtesy of FORD MOTOR COMPANY

  1. 7.

    Install the engine mount bracket and lower bolt.
    • Do not tighten at this time.
GFD34867Courtesy of FORD MOTOR COMPANY

  1. 8.

    Using the floor jack, raise the engine slightly.

  1. 9.

    Install the 2 upper engine mount bracket bolts.
    • Do not tighten at this time.
GFD34866Courtesy of FORD MOTOR COMPANY
    NOTE: Do not expose the Motorcraft ® High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

  1. 10.
    Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:
    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in).
    • Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
Fig 2: Engine Front Cover Bolts Tightening Sequence
GFD34874Courtesy of FORD MOTOR CO.

  1. 11.

    Install the HO2S connector bracket and stud bolt.
    • Tighten to 10 Nm (89 lb-in).
    • Attach the HO2S electrical connector.
GFD34865Courtesy of FORD MOTOR COMPANY

  1. 12.

    Install the engine mount. Refer to Engine Mount .
    NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

  1. 13.
    Special Tool(s): Installer, Front Crankshaft Seal 303-1251 and Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B). Install a new crankshaft front seal.
GFD34569Courtesy of FORD MOTOR COMPANY

  1. 14.

    Lubricate with clean engine oil.
GFD34573Courtesy of FORD MOTOR COMPANY

  1. 15.

    Special Tool(s): Installer, Front Cover Oil Seal 303-335 and Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B). Install the crankshaft pulley.
GFD34574Courtesy of FORD MOTOR COMPANY

  1. 16.

    General Equipment: Strap Wrench. Install the crankshaft pulley washer and new bolt and tighten in 4 stages.
    • Stage 1: Tighten to 120 Nm (89 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
GFD34875Courtesy of FORD MOTOR COMPANY
    NOTE: The bracket has 3 keyed tabs to orient the roll restrictor.

  1. 17.
    Position the rear roll restrictor bracket with the keyed tabs aligned to the rear roll restrictor and install the 2 bolts.

    1. 1.

      Tighten the 2 bolts to 103 Nm (76 lb-ft).

    1. 2.

      Tighten the bolt to 103 Nm (76 lb-ft).
GFD34876Courtesy of FORD MOTOR COMPANY

  1. 18.

    Install the front roll restrictor bolt.
    • Tighten to 103 Nm (76 lb-ft).
GFD34863Courtesy of FORD MOTOR COMPANY

  1. 19.

    Install the accessory drive belt tensioner and belt. REFER to Accessory Drive .

  1. 20.

    Install the RH inner fender splash shield. REFER to Front End Body Panels .

  1. 21.

    Install the underbody air duct and the 3 twist lock retainers.
GFD34445Courtesy of FORD MOTOR COMPANY

  1. 22.

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

  1. 23.

    Connect the LH HO2S electrical connector.
    • Attach the HO2S connector retainer to the bracket.
GFD34861Courtesy of FORD MOTOR COMPANY
    NOTE: Do not expose the RTV Silicone Sealant to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.

  1. 24.
    Fill the engine with clean engine oil.

  1. 25.

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