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. Disconnect the battery ground cable. For additional information, refer to Battery.
3. Remove the LH and RH valve covers.
4. Remove the radiator. For additional information, refer to Cooling System.
5. Remove the drain plug and drain the engine oil.
6. NOTE: LH shown, RH similar.
Remove the 2 nuts and the 2 radio interference capacitors.
7. Loosen the 4 coolant pump pulley bolts.
8. Rotate the tensioner clockwise and remove the accessory drive belt.
9. Remove the 4 coolant pump pulley bolts and the coolant pump pulley.
10. Remove the bolt and the accessory drive belt idler pulley.
11. Remove the bolts and position the power steering pump aside.
12. Disconnect the A/C compressor electrical connector.
13. Disconnect the crankshaft position (CKP) sensor electrical connector.
14. Disconnect the wire harness from the bracket.
15. Remove the 3 bolts and position the A/C compressor aside.
16. Remove the bolt and the CKP sensor.
^ Discard the O-ring seal.
17. Disconnect the camshaft position (CMP) sensor electrical connector.
18. Remove the bolt and the CMP sensor.
^ Discard the O-ring seal.
19. 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.
20. Using the special tool, remove the crankshaft pulley.
21. Using the special tool, remove and discard the crankshaft front seal.
22. Remove the front 4 oil pan bolts.
23. Remove the bolts.
24. 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.
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 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.
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 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
5. 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.
6. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
7. Using the special tools, install a new crankshaft front seal.
8. 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.
9. Using the special tool, install the crankshaft pulley.
10. 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 without exceeding 200 Nm (148 ft. lbs.).
11. Install a new O-ring seal, the CMP sensor and bolt.
^ Tighten to 10 Nm (89 inch lbs.).
12. Connect the CMP electrical connection.
13. Install a new O-ring seal, the CKP sensor and bolt.
^ Tighten to 10 Nm (89 inch lbs.).
14. Position the A/C compressor and install the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs.).
15. Connect the wire harness to the bracket.
16. Connect the A/C compressor electrical connector.
17. Connect the CKP sensor electrical connector.
18. Position the belt idler pulley and install the bolt.
^ Tighten to 25 Nm (18 ft. lbs.).
19. NOTE: LH shown, RH similar.
Install the 2 radio interference capacitors and the 2 nuts.
^ Tighten to 10 Nm (89 inch lbs.).
20. Install the drain plug.
^ Tighten to 14 Nm (10 ft. lbs.).
21. Install the RH and LH valve covers.
22. Fill the engine with clean engine oil.
23. Install the radiator. For additional information, refer to Cooling System.
24. Connect the battery ground cable. For additional information, refer to Battery.