ford Workshop Repair Guides

Ford Maverick Workshop Service and Repair Manuals

ABOUT US
Cylinder Head RH - Vehicles Built From: 12-2003 > < Cylinder Head LH - Vehicles Built From: 12-2004

Engine Front Cover Replacement - Maverick 2005 (12-2003+)

Engine - 3.0L Duratec-VE (VE6) - Engine Front Cover—Vehicles Built From: 12/2003 Maverick 2005 (08/2004-)
In-vehicle Repair

Materials
Name
Specification
Motorcraft Metal Surface Cleaner
ZC-21
WSE-M5B392-A
Silicone Gasket and Sealant
TA-30
WSE-M4G323-A6
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent
WSS-M2C930-A

 
Item
Part Number
Description
1
W505415
Generator upper air duct bolt
2
10C392
Generator upper air duct
3
W505415
Generator shield bolt
4
W705848
Pin-type retainer
5
10A389
Generator shield
6
W709986
Generator bolt (2 required)
7
W520414
Generator stud nut
8
W710416
Generator stud
9
10300
Generator
10
W701542
Heated oxygen sensor (HO2S) electrical connector bracket nut
11
15A024
HO2S electrical connector bracket

 
Item
Part Number
Description
12
W701625-S
Accessory drive belt tensioner bolt
13
6B209
Accessory drive belt tensioner
14
—
Accessory drive belt idler pulley bolt (part of 6C348)
15
6C348
Accessory drive belt idler pulley
16
14A464
Crankshaft position (CKP) sensor electrical connector (part of 9H589)
17
14A464
Camshaft position (CMP) sensor electrical connector (part of 9H589)
18
W701656-S
Power steering pump bolt (3 required)
19
3A696
Power steering pump
20
W708221-S
Engine front cover bolt (3 required)
21
W708222-S
Engine front cover bolt (3 required)

 
Item
Part Number
Description
22
W709678
Oil pan-to-front cover bolts (2 required)
23
W701525-S
Engine front cover bolt (7 required)
24
W710030-S
Engine front cover stud bolt (3 required)
25
6019
Engine front cover
26
—
Engine front cover gasket (3 required)

Removal

CAUTION:
CAUTION:During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
  1. Release the fuel system pressure. For additional information, refer to Section 310-00.
  1. Disconnect the battery ground cable. For additional information, refer to Section 414-01.
  1. Remove the crankshaft front seal. For additional information, refer to Lower End Components - Exploded View and Crankshaft Front Seal in this section.

  1. Remove the 5 bolts and the pin-type retainer and the RH lower splash shield.
  1. Remove the generator upper air duct bolt and the air duct.
  1. Remove the generator shield pin-type retainer, bolt and the generator shield.
  1. Remove the 2 generator bolts.
  1. Remove the generator stud nut and stud and position the generator aside.
  1. Remove the LH and RH valve covers. For additional information, refer to Valve Cover - LH and Valve Cover - RH in this section.
  1. Remove the engine support insulator. For additional information, refer to Engine Support in this section.
  1. Remove the bolt and the accessory drive belt tensioner.
  1. Remove the bolt and the idler pulley.
  1. Remove the nut and position the heated oxygen sensor (HO2S) electrical connector bracket aside.
  1. Disconnect the crankshaft position (CKP) sensor electrical connector.
  1. Disconnect the camshaft position (CMP) sensor electrical connector.
  1. NOTE:
    NOTE:The bolt positioned behind the power steering pressure tube will remain in the pump housing.
    Remove the 3 power steering pump bolts and position the power steering pump aside.
  1. If equipped, remove the 3 nuts and position the speed control actuator aside.
  1. Remove the 2 oil pan-to-front cover bolts.
  1. Remove the 13 bolts, 3 stud bolts and the engine front cover.
    • Remove and discard the gaskets.

Installation

  1. CAUTION:
    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.
    CAUTION:
    CAUTION:Do not damage the oil pan gasket while cleaning the sealant from the lower cylinder block-to-oil pan joint.
    Use a plastic scraping tool to remove all traces of sealant.
    • Clean all sealing surfaces with metal surface cleaner and install new gaskets.

  1. NOTE:
    NOTE:The engine front cover must be installed and the bolts tightened within 4 minutes of applying sealant.
    Apply a 6 mm (0.23 in) diameter dot of silicone gasket and sealer to the cylinder block, lower cylinder block, cylinder head and oil pan mating surfaces.

  1. NOTE:
    NOTE:Fasteners 1, 8 and 16 are stud bolts.
    Position the engine front cover and install the bolts.
    • Tighten in the sequence shown to 25 Nm (18 lb-ft).
  1. Install the 2 oil pan-to-front cover bolts.
    • Tighten to 25 Nm (18 lb-ft).
  1. Remove the oil pan plug and drain the engine oil.
    • Install the plug and tighten to 26 Nm (19 lb-ft).
  1. Position the power steering pump and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  1. Connect the CMP electrical connector.
  1. Connect the CKP electrical connector.
  1. Position the HO2S bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
  1. Install the idler pulley and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
  1. Install the accessory drive belt tensioner and the bolt.
    • To install, tighten to 45 Nm (33 lb-ft).
  1. If equipped, install the speed control actuator and 3 nuts.
  1. Install the engine support insulator. For additional information, refer to Engine Support Insulators in this section.
  1. Install the LH and RH valve covers. For additional information, refer to Valve Cover - LH and Valve Cover - RH in this section.
  1. Position the generator and install the stud.
    • Tighten to 7 Nm (62 lb-in).
  1. Install the generator stud nut.
    • Tighten to 47 Nm (35 lb-ft).
  1. Install the 2 generator bolts.
    • Tighten to 47 Nm (35 lb-ft).
  1. Install the generator shield, bolt and pin-type retainer.
    • Tighten to 4 Nm (35 lb-in).
  1. Install the generator upper air duct and the bolt.
    • Tighten to 4 Nm (35 lb-in).

  1. Install the RH lower splash shield, 5 bolts and the pin-type retainer.
    • Tighten to 8 Nm (71 lb-in).
  1. Install the crankshaft front seal. For additional information, refer to Lwer End Components - Exploded View and Crankshaft Front Seal in this section.
  1. Fill the engine with clean engine oil.
  1. Connect the battery ground cable. For additional information, refer to Section 414-01.

Cylinder Head RH - Vehicles Built From: 12-2003 > < Cylinder Head LH - Vehicles Built From: 12-2004