Timing Cover: Service and Repair

REMOVAL
1. Disconnect battery ground cable (14301).
2. Remove LH and RH valve cover (6582).
3. Install Three Bar Engine Support D88L-6000-A or equivalent onto engine lifting eyes (17A084) and support engine.
4. Remove power steering pressure hose bracket retainer bolt from upper front engine support bracket (6028).
5. Disconnect power steering pressure hose (3A719) from power steering pump (3A674) and position power steering pressure hose out of the way.

NOTE: Mark location of upper front engine support bracket prior to removal of front engine support bracket.

6. Remove retaining nuts and front engine support bracket from engine and upper front engine support insulator (6038).
7. Disconnect low coolant level sensor connector from wire harness.
8. Remove radiator coolant recovery reservoir retainers and position radiator coolant recovery reservoir (8A080) aside.
9. Remove upper front engine support insulator.
10. Set radiator coolant recovery reservoir into position.
11. Disconnect fuel charging wiring (9D930) at the three connectors located on in-line connector bracket at front of RH cylinder head (6049). Position fuel charging wiring aside.
12. Loosen power steering pump pulley retaining bolts. DO NOT REMOVE bolts completely.
13. Remove drive belt (8620).
14. Remove power steering pump pulley (3A733) from power steering pump.
15. Remove power steering pump and power steering pump support retaining nuts and bolts and remove power steering pump and power steering pump support (3C511).
16. Raise and support vehicle.
17. Remove oil pan drain plug (6730) and drain engine oil. Replace oil pan drain plug with a new oil pan drain plug gasket (6734). Tighten to 22-30 Nm (16-22 ft. lbs.).
18. Remove through bolt for LH and RH front engine support insulators.
19. Lower vehicle on hoist.
20. Raise engine to gain access for removal of oil pan (6675). Support engine with Three Bar Engine Support D88L-6000-A or equivalent.
21. Raise and support vehicle.
22. Remove RH front wheel and tire assembly.
23. Position generator (GEN) (10300) aside and remove generator mounting bracket (10153) from engine.
24. Remove crankshaft pulley (6312).
25. Disconnect fuel charging wiring from crankshaft position sensor and camshaft position sensor electrical connectors.





26. Remove oil pan.
27. Loosen A/C compressor retaining bolts and position A/C compressor (19703) to gain access to front cover retaining bolt.
28. Partially lower vehicle on hoist.
29. Remove lower fuel charging wiring bracket retainers and A/C hose retaining bracket from the engine front cover retaining stud bolts. Position fuel charging wiring aside.

NOTE: It may be necessary to raise and lower the vehicle on the hoist several times in order to follow the engine front cover bolt removal sequence.





30. Remove engine front cover bolts in sequence as shown.
31. Remove engine front cover (6019) and engine front cover gaskets from vehicle. Discard engine front cover gaskets.

INSTALLATION
1. Clean engine front cover-to-cylinder block and cylinder head sealing surfaces.

NOTE: Install engine front cover and retaining bolts and stud bolts in the location and sequence shown in no more than six minutes after applying sealer.

2. Apply a 3 mm (0.118 inch) diameter bead, approximately 12 mm (0.472 inch) long, of Black Silicone Rubber F4AZ-19562-B or equivalent sealant meeting Ford specification WSE-M4G323-A6 in six locations on cylinder block (6010) as shown.
3. Install engine front cover with new engine front cover gaskets over alignment dowels to cylinder block and cylinder heads.





4. Install engine front cover retaining bolts and stud bolts in locations and sequence as shown in no more than six minutes after applying sealer. Tighten retaining bolts 1/4 turn after engine front cover contacts cylinder block and cylinder heads.





5. Install remaining engine front cover retaining bolts and stud bolts.
6. Tighten all engine front cover retaining bolts and stud bolts in sequence shown to 20-30 Nm (15-22 ft. lbs.).
7. If removed, install drive belt idler pulley onto RH side of engine front cover. Tighten drive belt idler pulley retaining bolt to 20-30 Nm (15-22 ft. lbs.).
8. Position fuel charging wiring and install lower fuel charging wiring bracket retainers and A/C hose retaining bracket to the engine front cover retaining stud bolts. Tighten retaining nut to 8-12 Nm (71-106 ft. lbs.).
9. Raise and support vehicle.





10. Position A/C compressor and tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.).
11. If required, replace crankshaft front seal (6700).

WARNING: EYE PROTECTION IS REQUIRED TO BE WORN DURING USE OF COMPRESSED AIR. FAILURE TO WEAR EYE PROTECTION COULD RESULT IN POSSIBLE PERSONAL INJURY.

12. Clean oil pan with suitable soap and water solution. Dry completely with compressed air. Inspect oil pan for damage. Replace oil pan as necessary.
13. Clean oil pan to lower cylinder block sealing surfaces on oil pan and lower cylinder block with shop towel and Metal Surface Cleaner F4AZ-19A536-RA meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.
14. Install a new oil pan gasket (6710) and apply an 8 mm (0.31 inch) diameter bead of Black Silicone Rubber F4AZ-19562-B or equivalent sealant meeting Ford specification WSE-M4G323-A6 on oil pan gasket as shown in the illustration.





15. Install oil pan and oil pan retaining bolts and studs to lower cylinder block in locations shown. Push the oil pan against the transaxle case and tighten oil pan to transaxle bolts to 34-46 Nm (25-34 ft. lbs.). Tighten oil pan retaining bolts and studs in sequence shown to 20-30 Nm (15-22 ft. lbs.).
16. Connect fuel charging wiring, crankshaft position sensor and camshaft position sensor electrical connectors.
17. Install crankshaft pulley.





18. Install generator mounting bracket and generator to engine.
19. Install RH front wheel and tire assembly.
20. Lower vehicle on hoist.
21. Lower engine to installed position. Support engine with Three Bar Engine Support D88L-6000-A or equivalent.
22. Raise and support vehicle.
23. Install through bolt for LH and RH front engine support insulators.
24. Lower vehicle on hoist.





25. Install power steering pump support and power steering pump to front of engine. Tighten pump support retaining nuts to 8-12 Nm (71-106 inch lbs.). Tighten pump retaining bolts to 20-30-Nm (15-22 ft. lbs.).
26. Install power steering pump pulley onto power steering pump. Loosely install retaining bolts.
27. Install accessory drive belt.
28. Tighten power steering pump pulley retaining bolts to 20-30 Nm (15-22 ft. lbs.).
29. Position and connect fuel charging wiring to the three connectors located on the in-line connector bracket at front of RH cylinder head.
30. Install upper front engine support insulator and upper front engine support bracket.
31. Remove Three Bar Engine Support D88L-6000-A or equivalent.
32. Connect battery ground cable.
33. Fill crankcase to proper level with specified engine oil.
34. Fill power steering system with specified fluid.
35. Run engine and check for leaks. Recheck fluid levels.