Timing Cover: Service and Repair

ENGINE FRONT COVER





REMOVAL
1. Disconnect the battery ground cable.
2. Remove both of the valve covers.
3. Remove the radiator.
4. Remove the water pump.
5. Raise and support the vehicle.





6. Remove the top bolts and the lower bolt and position the power steering pump aside.





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





8. Remove the drain plug and drain the engine oil.





9. Remove the front bolts.
10. Remove the crankshaft front seal.
11. Lower the vehicle.





12. Disconnect the Camshaft Position (CMP) sensor electrical connection.





13. Remove the bolt and the belt idler pulley.





14. Remove the bolts.





15. CAUTION: Do not use metal scrapers, wire blushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Remove the engine front cover from the front cover to cylinder block dowel.
^ Remove the engine front cover gasket and clean and inspect the mating surfaces.

INSTALLATION

All engines





1. 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. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: If the engine front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply the silicone gasket and sealant along the cylinder head to cylinder block surface and the oil pan to cylinder block surface.





2. Install the engine front cover with engine front cover gasket on the front cover to cylinder block dowel and loosely install the bolts.

Romeo engine (4.6L)











3. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs.).


Windsor engine (5.4L)











4. Tighten the engine front cover fasteners in sequence in three stages.
^ Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 ft. lbs.).
^ Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 ft. lbs.).
^ Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 ft. lbs.).

All engines





5. Position the belt idler pulley and install the bolt.





6. Connect the CMP electrical connection.
7. Raise and support the vehicle.
8. Install a new crankshaft front oil seal.





9. Loosely install the bolts, then tighten the bolts in the two stages following the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 60°.





10. Connect the crankshaft position sensor electrical connector.





11. NOTE: The front lower hole in the power steering pump is not used.

Position the power steering pump and install the bolts.





12. Install the drain plug.
13. Lower the vehicle
14. Install the valve covers.
15. Fill the engine with clean engine oil.
16. Install the water pump.
17. Install the radiator.
18. Connect the battery ground cable.