Timing Cover: Service and Repair

Engine Front Cover





Removal

NOTICE: Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.

NOTICE: 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.

2. Remove the CAC (Charge Air Cooler) inlet tube.

3. Loosen the 3 coolant pump pulley bolts.





4. Remove the crankshaft front seal. For additional information, refer to Crankshaft Front Seal Service and Repair.

5. Disconnect the CKP (Crankshaft Position) sensor electrical connector.





6. Remove the 2 bolts and the CKP (Crankshaft Position) sensor.





7. Remove the nut and the power steering pressure hose bracket from the engine front cover stud bolt.





8. Remove the engine mount. For additional information, refer to Engine Mount .

9. Remove the 2 bolts and the accessory drive belt tensioner.
- Remove the accessory drive belt.






10. Remove the 3 bolts and position the power steering pump aside.





11. Remove the 4 bolts and the power steering pump bracket.





12. Remove the 3 bolts and the coolant pump pulley.





13. Remove the nut and the ground strap.
- Detach the 2 wiring harness retainers from the engine front cover.






14. NOTICE: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

Remove the 20 bolts, 2 stud bolts and the engine front cover.
- Clean and inspect the mounting surfaces of the engine and the front cover.






Installation

1. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.
Apply a 3 mm (0.118 in) bead of Silicone Gasket and Sealant to the sealing surface of the front cover.

- Apply a 2 mm (0.078 in) bead of Silicone Gasket and Sealant to the 5 center sealing surfaces of the front cover.






2. NOTE: The engine front cover must be secured within 10 minutes of Silicone Gasket and Sealant application. If the valve cover is not secured within 10 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft(R) Metal Surface Prep.
Apply beads of silicone gasket and sealant that are 2 mm (0.078 in) in diameter and 5 mm (0.19 in) in length across the cylinder head and cylinder block joint areas.






3. Install the engine front cover, the 20 bolts and 2 stud bolts.
- Tighten in the sequence shown as follows:
- Tighten 1 through 19 to 10 Nm (89 lb-in).

- Tighten 20 through 22 to 48 Nm (35 lb-ft).







4. Attach the 2 wiring harness retainers to the engine front cover.
- Install the ground strap and nut.
- Tighten to 9 Nm (80 lb-in).







5. Install the coolant pump pulley and the 3 bolts.





6. Install the power steering pump bracket and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).






7. Position the power steering pump and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






8. Position the accessory drive belt and install the accessory drive belt tensioner and 2 bolts.
- Tighten to 25 Nm (18 lb-ft).






9. Install the engine mount. For additional information, refer to Engine Mount .

10. Install the power steering pressure hose bracket and nut on the engine front cover stud bolt.
- Tighten to 9 Nm (80 lb-in).






11. Install the CKP (Crankshaft Position) sensor and the 2 bolts.
- Align the CKP (Crankshaft Position) sensor so the 2 bolts are located in the middle of the adjustment slots.
- Tighten to 7 Nm (62 lb-in).







12. Connect the CKP (Crankshaft Position) sensor electrical connector.





13. Install the crankshaft front seal. For additional information, refer to Crankshaft Front Seal Service and Repair.

14. Tighten the 3 coolant pump pulley bolts to 20 Nm (177 lb-in).





15. Install the CAC (Charge Air Cooler) inlet tube.