Installation

Engine Front Cover























Installation

All engines
1. If installing a new engine front cover, install the CKP sensor and the bolt onto the engine front cover.
^ Lubricate the CKP O-ring seal with clean engine oil prior to installation.
^ Tighten to 10 Nm (89 lb-in).

2. CAUTION: 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 clean sealing surfaces.

NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.





3. Install the engine front cover with the engine front cover gasket on the front cover-to-cylinder block dowel and loosely install the bolts.





4.6L (2V) engine
4. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).








5.4L (2V) engine
5. Tighten the engine front cover fasteners in sequence in 3 stages.

Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).
Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).








All engines
6. Loosely install the bolts, then tighten the bolts in 2 stages following the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten an additional 60 degrees.





7. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.





8. Using the special tools, install a new crankshaft front seal.





9. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.





10. Using the special tool, install the crankshaft pulley.





4.6L (2V) engine
11. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt 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 without exceeding 200 Nm (148 lb-ft).





5.4L (2V) engine
12. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages:
^ Stage 1: Tighten to 90 Nm (66 lb-ft).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees.





All engines

13. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Install the CMP sensor and bolt.
^ Tighten to 10 Nm (89 lb-in).





14. Connect the CMP electrical connector.





15. Position the bracket, connect the tubes and install the nut.
^ Tighten to 10 Nm (89 lb-in) for the 4.6L engine.
^ Tighten to 30 Nm (22 lb-ft) for the 5.4L engine.





16. Position the power steering pump and install the 5 bolts.
^ Tighten to 25 Nm (18 lb-ft).





17. Connect the wire harness to the bracket.





18. Connect the A/C compressor electrical connector.





19. Connect the CKP sensor electrical connector.





20. Position the belt idler pulley and install the bolt.
^ Tighten to 25 Nm (18 lb-ft).





21. Position the coolant pump pulley and install the 4 bolts.
^ Tighten to 25 Nm (18 lb-ft).





22. Rotate the tensioner clockwise and install the accessory drive belt.

23. NOTE: LH shown, RH similar.

Install the 2 radio interference capacitors and the 2 nuts.
^ Tighten to 25 Nm (18 lb-ft).





24. Install the drain plug.
^ Tighten to 23 Nm (17 lb-ft).





25. Install the RH and LH valve covers.
26. Fill the engine with clean engine oil.
27. Install the radiator.