Timing Cover: Service and Repair
Engine Front CoverSpecial Tool(s):
Material:
Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Remove the LH and RH valve covers.
3. Remove the radiator. For additional information, refer to Cooling System.
4. Remove the drain plug and drain the engine oil.
5. NOTE: LH shown, RH similar.
Remove the 2 nuts and the 2 radio interference capacitors.
6. Loosen the 4 coolant pump pulley bolts.
7. Rotate the tensioner clockwise and remove the accessory drive belt.
8. Remove the 4 coolant pump pulley bolts and the coolant pump pulley.
9. Remove the bolt and the accessory drive belt idler pulley.
10. Remove the bolts and position the power steering pump aside.
11. Disconnect the A/C compressor electrical connector.
12. Disconnect the crankshaft position (CKP) sensor electrical connector.
13. Disconnect the wire harness from the bracket.
14. Remove the nut, disconnect the tubes and remove the bracket.
15. Disconnect the camshaft position (CMP) sensor electrical connector.
16. Remove the bolt and the CMP sensor.
17. CAUTION: This bolt is torque-to-yield and cannot be reused.
Using the special tool, remove the crankshaft pulley bolt and washer.
^ Discard the crankshaft pulley bolt.
18. Using the special tool, remove the crankshaft pulley.
19. Using the special tool, remove and discard the crankshaft front seal.
20. Remove the front 4 oil pan bolts.
21. Remove the bolts.
22. 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 clean sealing surfaces.
Remove the engine front cover from the front cover-to-cylinder block dowel.
^ Discard the engine front cover gasket.
^ Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
^ Inspect the mating surfaces.
23. If servicing the engine front cover, remove the bolt and the CKP sensor.
Installation
All engines
1. If installing a new engine front cover, install the CKP sensor and the bolt onto the engine front cover.
^ Lubricate the CKP O-ring seal with clean engine oil prior to installation.
^ Tighten to 10 Nm (89 inch lbs).
2. 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 clean sealing surfaces.
NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 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 a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
3. Install the engine front cover with the engine front cover gasket on the front cover-to-cylinder block dowel and loosely install the bolts.
4.6L (2V) engine
4. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 ft. lbs).
5.4L (2V) engine
5. Tighten the engine front cover fasteners in sequence in 3 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
6. Loosely install the bolts, then tighten the bolts in 2 stages following the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs).
^ Stage 2: Tighten an additional 60 degrees.
7. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
8. Using the special tools, install a new crankshaft front seal.
9. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
10. Using the special tool, install the crankshaft pulley.
4.6L (2V) engine
11. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages:
^ Stage 1: Tighten to 120 Nm (89 ft. lbs).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs).
^ Stage 4: Tighten an additional 90 degrees without exceeding 200 Nm (148 ft. lbs).
5.4L (2V) engine
12. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 stages:
^ Stage 1: Tighten to 90 Nm (66 ft. lbs).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs).
^ Stage 4: Tighten an additional 90 degrees.
All engines
13. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Install the CMP sensor and bolt.
^ Tighten to 10 Nm (89 inch lbs).
14. Connect the CMP electrical connector.
15. Position the bracket, connect the tubes and install the nut.
^ Tighten to 10 Nm (89 lb-in) for the 4.6L engine.
^ Tighten to 30 Nm (22 ft. lbs.) for the 5.4L engine.
16. Position the power steering pump and install the 5 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
17. Connect the wire harness to the bracket.
18. Connect the A/C compressor electrical connector.
19. Connect the CKP sensor electrical connector.
20. Position the belt idler pulley and install the bolt.
^ Tighten to 25 Nm (18 ft. lbs).
21. Position the coolant pump pulley and install the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
22. Rotate the tensioner clockwise and install the accessory drive belt.
23. NOTE: LH shown, RH similar.
Install the 2 radio interference capacitors and the 2 nuts.
^ Tighten to 25 Nm (18 ft. lbs).
24. Install the drain plug.
^ Tighten to 23 Nm (17 ft. lbs).
25. Install the RH and LH valve covers.
26. Fill the engine with clean engine oil.
27. Install the radiator. For additional information, refer to Cooling System.