Timing Cover: Service and Repair
CAUTION:
Aluminum Components
Do not work on aluminum engine components until the engine is cold.
Cleaning Aluminum Surfaces
Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminum sealing surfaces.
Removing Aluminum Components
When removing engine components, always remove retaining bolts in reverse of tightening sequence or damage to engine components may occur.
REMOVAL
CAUTION: The valve covers (6582), oil pan (6675) and oil pan gasket (6710) must be removed prior to the engine front cover (6019) or possible engine damage and leakage may occur upon reassembly.
1. Remove cooling fan motor/fan blade (8600) and fan shroud (8146) assembly. Refer to Cooling System.
2. Loosen water pump pulley bolts.
3. Remove accessory drive belt (8620).
4. Remove water pump pulley (8509).
5. Raise and support vehicle.
NOTE: The front lower bolt on the power steering pump (3A674) will not come all the way out.
6. Remove bolts retaining power steering pump to cylinder block (6010) and engine front cover.
7. Wire power steering pump out of way.
8. Remove oil pan and oil pan gasket.
9. Remove crankshaft pulley from crankshaft.
10. Lower vehicle.
11. Remove bolts retaining power steering oil reservoir (3A697) to the LH coil bracket and position power steering oil reservoir out of the way.
12. Remove both RH and LH valve covers
13. Disconnect the fuel charging wiring (9D930) from both ignition coils (12029) and camshaft position sensor (CMP)(6B288).
14. Remove three bolts retaining RH ignition coil bracket to engine front cover.
15. Remove LH ignition coil from bracket and lay on top of engine.
16. Remove three nuts retaining LH ignition coil bracket to engine front cover.
17. Slide RH ignition coil bracket and ignition wires off mounting studs and lay assembly on top of engine.
18. Remove bolts retaining belt idler pulley, then remove pulley.
19. Disconnect fuel charging wiring from crankshaft position sensor (CKP)(6C315).
20. Remove nine stud bolts and six bolts retaining engine front cover to engine.
21. Remove engine front cover.
INSTALLATION
1. Remove all traces of dirt, oil or previously applied sealant from the engine front cover, cylinder heads and cylinder block sealing surfaces. Sealing surfaces must be clean and dry before applying sealant.
2. Replace crankshaft front seal (6700) and engine front cover gasket (three each).
3. Clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.
NOTE: Install engine front cover and tighten retainers in no more than four minutes after applying sealer.
4. Apply an 8-12 mm (0.32-0.47 inch) bead of Silicone Gasket Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 in locations shown.
5. Install engine front cover on engine no more than four minutes after applying sealant.
6. Install studs and bolts retaining engine front cover to engine in location as shown in illustration. Tighten to 20-30 Nm (15-22 ft. lbs.) in no more than four minutes after applying sealant.
7. Connect fuel charging wiring to the crankshaft position sensor.
8. Install RH and LH ignition coil bracket and ignition wires as an assembly. Tighten nuts to 20-30 Nm (15-22 ft. lbs.).
9. Position and install power steering oil reservoir.
10. Connect engine control sensor extension wire (12A522) to both ignition coils and camshaft position sensors.
11. Install valve covers
12. Raise and support vehicle.
Crankshaft Pulley Keyway Silicone Gasket Sealant Application Locations:
13. Clean sealing surfaces of crankshaft, crankshaft pulley and keyway with Metal Surface Cleaner, to remove all residues that may interfere with the sealer's ability to adhere.
14. Apply Silicone Gasket and Sealant to end of the keyway and crankshaft pulley.
15. Position crankshaft pulley on crankshaft. Make sure crankshaft key and keyway are aligned.
16. Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley.
17. Install crankshaft pulley bolt and crankshaft pulley retaining washer. Tighten in four steps:
Step 1 ... Tighten to 90 Nm (66 ft. lbs.).
Step 2 ... Loosen one complete turn 360°.
Step 3 ... Tighten to 50 Nm (36 ft. lbs.).
Step 4 ... Tighten an additional 90°.
18. Install oil pan and oil pan gasket
19. Position power steering pump on engine and install four retaining bolts. Tighten to 20-30 Nm (15-22 ft. lbs.).
20. Lower vehicle.
21. Install water pump pulley with four bolts. Tighten to 20-30 Nm (15-22 ft. lbs.).
22. Install accessory drive belt.
23. Install cooling fan motor/fan blade and fan shroud assembly.
24. Start engine and check for leaks.