Engine front cover — removal and installation Ford F150
Warning: The engine must be completely cool before beginning this procedure.
Removal
1. Relieve the fuel system pressure (see Fuel and exhaust systems), then disconnect the cable from the negative terminal of the battery (see Engine electrical systems).
2. Drain the cooling system and engine oil, and remove the oil filter (see Tune-up and routine maintenance).
3. Remove the transmission housing cover, if equipped.
4. Remove the expansion tank (see Cooling, heating and air conditioning systems).
5. Remove the air cleaner housing and inlet and outlet ducts (see Fuel and exhaust systems).
6. Disconnect the upper and lower radiator hoses from the engine, then secure the hoses out of the way.
7. On turbocharged models, remove the charge air cooler inlet and outlet pipes (see Fuel and exhaust systems).
8. On 2.7L engines, rotate the turbocharger bypass hose retaining ring counterclockwise 180-degrees and disconnect the lower end of the hose.
9. On 3.5L turbocharged engines, remove the turbocharger inlet and outlet tube (see Fuel and exhaust systems).
10. Remove the engine oil cooler (see Cooling, heating and air conditioning systems).
11. If you’re working on a 3.5L turbocharged engine, remove the intake manifold (see Intake manifold(s) – removal and installation).
12. If you’re working on 3.3L or 3.5L non-turbocharged engine, remove the upper intake manifold support bracket.
13. Remove the valve covers (see Valve covers – removal and installation).
14. Remove the crankshaft pulley and crankshaft front oil seal (see Crankshaft pulley and crankshaft front seal – replacement).
Remove the drivebelt, the idler pulley (indicated), alternator and crankshaft pulley
15. Remove the drivebelt tensioner (see Tune-up and routine maintenance) and remove all accessory brackets attached to the timing chain cover.
16. Remove drivebelt idler pulley bolt and pulley.
17. Remove the alternator bolt and swing the alternator out of the way.
18. On 2.7L models, remove the cabin heater coolant pump (see Cooling, heating and air conditioning systems).
19. Remove the water pump (see Cooling, heating and air conditioning systems).
20. Remove the air conditioning compressor mounting bolts without disconnecting the refrigerant lines (see Cooling, heating and air conditioning systems).
21. Disconnect the oil control solenoid electrical connector then detach the wiring harness retainers and move the harness out of the way.
22. On 2.7L models, remove the oil pan.
23. Remove the front cover bolts and separate the cover from the engine block.
Caution: DO NOT use excessive force or you may crack the cover. If the cover is difficult to remove, double check to make sure all of the bolts have been removed.
Note: There are seven pry spots around the front cover. Work gently at each one until the cover comes off.
Installation
24. Clean the gasket mating surfaces with brake system cleaner.
25. While the cover is off the engine, it’s a good idea to install a new crankshaft front seal (see Crankshaft pulley and crankshaft front seal – replacement). There is also a radial seal in the center of the front cover, a radial seal at the bottom of the front cover (3.3L Duratec and 3.5L EcoBoost engine), an oil gallery seal on the front of the engine block (2.7L engine) and an 0-ring type seal at the lower corner of the front cover (2.7L engine). Install new seals before mounting the front cover.
26. Apply a 1/8-inch bead of High Performance RTV sealant to the mating surface of the cover. Be sure to also apply the sealant to the bosses on the interior of the cover where the bolts go through.
27. Apply a 3/16-inch bead of High Performance RTV sealant to the areas where the oil pan and cylinder heads meet the engine block.
28. Slide the front cover onto the engine. The dowel pins will position it correctly.
2.7L engine front cover bolt tightening sequence
29. On 2.7L models, follow the correct sequence, tighten the bolts to the torque listed in this Chapter’s Specifications. All the bolts must be tightened within 35 minutes.
Caution: The front cover must be installed within 10 minutes of applying the RTV sealant or oil leaks may occur.
30. On 3.3L and 3.5L models, install all the bolts finger-tight within four minutes of applying the High performance RTV.
3.3L/3.5L engine front cover bolt tightening sequence
31. On 3.3L and 3.5L models, follow the correct sequence, tighten the bolts to the torque listed in this Chapter’s Specifications. All the bolts must be tight. ened within 35 minutes.
32. Install the remaining parts in the reverse order of removal.
33. Install a new oil filter, then add engine oil and coolant (see Tune-up and routine maintenance).
34. Run the engine and check for leaks.