Timing Cover: Service and Repair
Engine Front CoverSpecial Tool(s)
Material
Removal
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, may cause engine failure.
1. With the vehicle in NEUTRAL, position it on a hoist.
2. Recover the A/C system.
3. Remove the air cleaner outlet pipe.
4. Remove the front wheels and tires.
5. Remove the accessory drive belt, tensioner and the power steering belt.
6. Remove the degas bottle.
7. Remove the 2 nuts and disconnect the A/C tubes.
^ Discard the O-ring seals.
8. Remove the nut and the A/C tube-to-receiver/drier.
^ Discard the O-ring seal.
9. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable container.
10. Remove the RH inner fender splash shield.
11. Using the special tool, remove the crankshaft bolt and washer.
^ Discard the bolt.
12. Using the special tool, remove the crankshaft pulley.
13. Using the special tool, remove and discard the crankshaft front seal.
14. Remove the 4 nuts and the Y-pipe-to-catalytic converter nuts.
^ Discard the nuts.
15. Remove the 2 Y-pipe flange nuts.
^ Detach the exhaust hanger and remove the Y-pipe.
^ Discard the gaskets and nuts.
16. Remove the drain plug and drain the engine oil.
^ Install the drain plug and tighten to 27 Nm (20 lb-ft).
17. Disconnect the hose from the power steering reservoir.
18. Remove the RH and LH valve covers.
19. Remove the bolt and the ground cable.
20. Disconnect the fuel efficient power steering system solenoid electrical connector.
21. Disconnect the power steering pressure (PSP) switch electrical connector.
22. Remove the PSP tube bracket-to-power steering pump bolt.
23. Remove the 3 bolts and position aside the power steering pump.
24. CAUTION: The special tool must be carefully aligned to the mounting bosses on the oil pan. Failure to follow these instructions may result in damage to the oil pan.
Position a floor jack and the special tool under the oil pan.
25. Remove the nut, bolt and engine mount brace.
26. Remove the 4 engine mount nuts.
27. Remove the 3 bolts and the engine mount.
28. Remove the 2 bolts and the engine mount bracket.
29. Remove the 2 engine mount studs.
30. Remove the 2 upper engine mount bracket bolts.
31. Loosen the lower engine mount bracket bolt and remove the engine mount bracket and bolt as an assembly.
32. Remove the A/C tube bracket bolt.
33. Remove the A/C tube retaining clamp bolt.
34. Remove the A/C tube-to-evaporator bolt and the 2 A/C tubes.
^ Discard the O-ring seals.
35. Using the floor jack, raise the engine slightly.
36. Remove the 22 engine front cover bolts.
37. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover.
^ Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released.
- Remove the engine front cover.
Installation
1. CAUTION: Only use a 3M Roloc Bristle Disk (2-in white, part number 07528), to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover. These tools cause scratches and gouges that make leak paths.
Clean the engine front cover using a 3M Roloc Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
^ Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
2. CAUTION: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan may cause engine failure.
CAUTION: Do not use wire brushes, power abrasive discs or 3M Roloc Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of sealant, including any sealant from the inner surface of the cylinder block and cylinder head.
Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.
1. Remove any large deposits of silicone or gasket material.
2. Apply silicone gasket remover and allow to set for several minutes.
3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
3. Install the special tools.
4. CAUTION: Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
NOTE: The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tighten within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
^ Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.
5. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and bolts 17, 18, 19 and 20.
^ Tighten in sequence to 3 Nm (27 lb-in).
6. Remove the special tools (alignment pins).
7. Install the engine mount bracket and lower bolt.
^ Do not tighten at this time.
8. Install the 2 upper engine mount bracket bolts.
^ Do not tighten at this time.
9. CAUTION: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
Install the remaining engine front cover bolts.
Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:
^ Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft).
^ Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
10. Using the floor jack, lower the engine to the installed position.
11. Install the new O-ring seals and the A/C tubes-to-evaporator and the bolt.
^ Tighten to 15 Nm (11 lb-ft).
12. Install the A/C tube retaining clamp bolt.
^ Tighten to 10 Nm (89 lb-in).
13. Install the A/C tube bracket bolt.
^ Tighten to 10 Nm (89 lb-in).
14. Install the 2 engine mount studs.
^ Tighten to 18 Nm (13 lb-ft).
15. Install the engine mount bracket and the 2 bolts.
^ Tighten to 24 Nm (18 lb-ft).
16. Install the engine mount and the 3 bolts.
^ Tighten to 90 Nm (66 lb-ft).
17. Install the 4 engine mount nuts.
^ Tighten to 63 Nm (46 lb-ft).
18. Install the engine mount brace, nut and bolt.
^ Tighten to 20 Nm (15 lb-ft).
19. Position the power steering pump and install the 3 bolts.
^ Tighten to 25 Nm (18 lb-ft).
20. Install the power steering pressure (PSP) tube bracket-to-power steering pump bolt.
^ Tighten to 10 Nm (89 lb-in).
21. Connect the PSP switch electrical connector.
22. Connect the fuel efficient power steering system solenoid electrical connector.
23. Install the ground cable bolt.
^ Tighten to 12 Nm (9 lb-ft).
24. Install the RH and LH valve covers.
25. Connect the hose to the power steering reservoir.
26. Using a new gasket, install the exhaust Y-pipe and install the 2 new nuts.
^ Tighten to 40 Nm (30 lb-ft).
^ Attach the exhaust hanger.
27. Install the exhaust Y-pipe assembly and 4 new nuts.
^ Tighten to 40 Nm (30 lb-ft).
28. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Using the special tools, install a new crankshaft front seal.
29. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the special tools, install the crankshaft pulley.
30. Using the special tool, install the crankshaft pulley washer and new bolt and tighten 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.
31. Install the RH inner fender splash shield.
32. Connect the power steering cooler tube.
33. Install a new O-ring seal and the A/C tube-to-receiver/drier and the nut.
^ Tighten to 15 Nm (11 lb-ft).
34. Using new O-ring seals, connect the A/C tubes and install the 2 nuts.
^ Tighten to 15 Nm (11 lb-ft).
35. Install the degas bottle.
36. Install the accessory drive belt, tensioner and the power steering belt.
37. Install the front wheels and tires.
38. Install the engine air cleaner outlet pipe.
39. CAUTION: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
Fill the engine with clean engine oil.
40. Fill the power steering system.
41. Recharge the A/C system.