Sunday, March 11, 2012

How to Replace Timing Chain Cover, Chain, Sprockets, & Seal On Ford Taurus?


The instructions are similar for 2006 and 2007 ford Taurus Car models.

Timing Chain Cover, Chain, Sprockets, & Seal
REMOVAL & INSTALLATION Details are as follows :-------

3.0L (VIN S) Engine
  1. Before servicing the vehicle, refer to the precautions section.
  2. Disconnect the negative battery cable.
  3. Remove the valve covers.
  4. Remove the power steering pump.
  5. Remove the oil pan.
  6. Remove the retaining nut and position the power steering pressure line and muffler out of the way.
  7. Remove the upper retaining bolts from the alternator.
  8. Remove the bolts, nuts and the engine-to-transaxle bracket.
  9. Remove the torque converter inspection cover.
  10. Remove the retainers and position the front rocker panel moulding aside.
  11. Remove the rear portion of the front fender splash shield.
  12. Remove the two screws and the alternator splash shield.
  13. Install a Flywheel Holding Tool.
    NOTE
    The pulley bolt has a reverse thread.
  14. Remove the crankshaft damper pulley.
  15. Remove the crankshaft damper bolt and washer.
  16. Using the tool illustrated, remove the crankshaft damper.

    Click image to see an enlarged view
    Fig. Using the tool illustrated, remove the crankshaft damper-3.0L (VIN S) Engine
  17. Remove the Flywheel Holding Tool.
  18. Disconnect the Crankshaft Position (CKP) sensor.
  19. Remove the alternator bolt and position the alternator to gain access to the electrical connector and terminal nut.
  20. Disconnect the alternator electrical connectors.
  21. Remove the bolts and the A/C compressor to front cover bracket.
  22. Disconnect the Camshaft Position (CMP) sensor
  23. Remove the tie strap from the power steering hose.
  24. Remove the retaining nut and position the A/C low-pressure hose out of the way.
  25. Remove the bolts and position the A/C high-pressure hose on top of the belt tensioner.
  26. Remove the bolt and remove the belt tensioner.
  27. Disconnect the engine cooling fan electrical connector and unclip the wiring harness.
  28. Remove the bolt and the engine cooling fan.
  29. Install the lift eye hooks to support the engine.
  30. Remove the two upper A/C compressor bolts.
  31. Remove the two lower A/C compressor bolts and position the A/C compressor aside.
  32. Remove the bolts from the A/C bracket.
  33. Raise the engine away from the A/C bracket using an engine support tool.
  34. Remove the bolts, studs and the engine front cover.
    CAUTION
    This pulse wheel is used with several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30 RFF" only (orange in color).
  35. Remove the ignition pulse wheel.

    Click image to see an enlarged view
    Fig. Remove the ignition pulse wheel-3.0L (VIN S) Engine
  36. Install the damper bolt.
  37. Remove the spark plugs.
  38. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position. This will position the number one cylinder at Top Dead Center (TDC). Verify that the camshafts are correctly located. If not, rotate the crankshaft one additional turn and recheck.

    Click image to see an enlarged view
    Fig. Rotate the crankshaft clockwise to position the crankshaft keyway in the 11 o'clock position and position the camshafts in the correct position-3.0L (VIN S) Engine


    Click image to see an enlarged view
    Fig. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the right hand camshafts in the neutral position -3.0L (VIN S) Engine
  39. Rotate the crankshaft clockwise 120 degrees to the 3 o'clock position to locate the right hand camshafts in the neutral position.
  40. Verify that the right hand camshafts are in the neutral position.

    Click image to see an enlarged view
    Fig. Verify that the right hand camshafts are in the neutral position-3.0L (VIN S) Engine
  41. Remove the right hand timing chain tensioner arm.
  42. Remove the bolts, right hand timing chain guide and the timing chain.

    Click image to see an enlarged view
    Fig. Remove the bolts, right hand timing chain guide and the timing chain-3.0L (VIN S) Engine


    Click image to see an enlarged view
    Fig. Rotate the crankshaft clockwise 600 degrees (12/3 turns) to position the crankshaft keyway in the 11 o'clock position-3.0L (VIN S) Engine
  43. Rotate the crankshaft clockwise 600 degrees (1- 2 / 2 turns) to position the crankshaft keyway in the 11 o'clock position. This will position the left hand camshafts in the neutral position.
  44. Verify that the left hand camshafts are in the neutral position.

    Click image to see an enlarged view
    Fig. Verify that the left hand camshafts are in the neutral position-3.0L (VIN S) Engine
  45. Remove the left hand timing chain and tensioner arm.
  46. Remove the left hand timing chain and timing chain guide.

    Click image to see an enlarged view
    Fig. Remove the left hand timing chain and timing chain guide-3.0L (VIN S) Engine
  47. Remove the damper bolt and the crankshaft sprockets.
To install:

CAUTION
Failure to verify correct timing drive component alignment will result in severe engine damage.


NOTE
Install the sprockets with the timing marks facing outward.

  1. Install the crankshaft sprockets.
  2. Position the chain tensioner in a soft-jawed vise.
  3. Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.
    CAUTION
    During tensioner compression, do not release the ratchet stem until the tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.
  4. Slowly compress the timing chain tensioner.
  5. Retain the tensioner piston with a 0.06 (1.5 mm) wire or paper clip.
  6. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the left and right hand timing chains as follows:
    1. Mark any link to use as the crankshaft timing mark (1).
    2. Starting with the crankshaft timing mark, count 29 links and mark the link (2).
    3. Continue counting to 42 and mark the link (3).

      Click image to see an enlarged view
      Fig. If timing marks in the timing chains are not evident, use a permanent-type marker to mark the crankshaft and camshaft timing marks on the left and right hand timing chains-3.0L (VIN S) Engine
  7. Position the left timing chain and guide and install the bolts.
  8. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.

    Click image to see an enlarged view
    Fig. Align the marks on the left hand timing chain with the marks on the camshaft and crankshaft sprockets-3.0L (VIN S) Engine
  9. Install the left hand timing chain tensioner and tensioner arm. Tighten the bolts to 18 ft. lbs. (25 Nm).
  10. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position.

    Click image to see an enlarged view
    Fig. Install the crankshaft damper bolt and rotate the crankshaft clockwise 120 degrees until the crankshaft keyway is in the 3 o'clock position-3.0L (VIN S) Engine
  11. Verify that the right hand camshafts are correctly positioned.

    Click image to see an enlarged view
    Fig. Verify that the right hand camshafts are correctly positioned-3.0L (VIN S) Engine
  12. Position the right timing chain and chain guide and install the bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  13. Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.

    Click image to see an enlarged view
    Fig. Align the marks on the right hand timing chain with the marks on the camshaft and crankshaft sprockets-3.0L (VIN S) Engine
  14. Install the right hand timing chain tensioner and tensioner arm. Tighten the bolts to 18 ft. lbs. (25 Nm).
  15. Remove the right and left hand timing chain tensioner piston retaining wires.
  16. Rotate the crankshaft counterclockwise 120 degrees to top dead center (TDC)
    CAUTION
    Failure to verify correct timing drive component alignment will result in severe engine damage.
  17. Verify the timing drive component alignment with the following steps.
    1. There should be 12 chain links between the front camshaft timing marks.
    2. There should be 27 chain links between the camshaft and crankshaft timing marks.
    3. There should be 30 chain links between the camshaft and crankshaft timing marks.

      Click image to see an enlarged view
      Fig. Refer to the procedure to verify the timing drive component alignment-3.0L (VIN S) Engine
  18. Remove the crankshaft damper bolt.
  19. Install the spark plugs.
    CAUTION
    This pulse wheel is used with several different engines. Install the pulse wheel with the keyway in the slot stamped "30" or "30 RFF" only (orange in color).
  20. Install the ignition pulse wheel.
    CAUTION
    Do not use metal scrapers, wire brushes, power abrasive discs, or other means to clean the sealing surface. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of sealant.
  21. Clean all sealing surfaces with metal surface cleaner.
  22. Install three new gaskets in the front cover.
    NOTE
    The engine front cover must be installed and the bolts tightened within six minutes of applying the sealant.
  23. Apply a 0.24 inch (6 mm) diameter dot of gasket and sealer to the cylinder block to lower cylinder block and cylinder head mating surfaces.
    NOTE
    Fasteners No. 1 and 6 are studs.



    Click image to see an enlarged view
    Fig. Apply a 0.24 inch (6 mm) diameter dot of gasket and sealer to the cylinder block to lower cylinder block and cylinder head mating surfaces-3.0L (VIN S) Engine
  24. Position the cover and install the bolts in the sequence shown. Tighten the bolts to 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view
    Fig. Engine front cover torque sequence-3.0L (VIN S) Engine
  25. Using the engine support tool, lower the engine back together with the A/C bracket.
  26. Install the bolts and tighten the bolts in two steps:
    1. Step 1: Tighten to 18 ft. lbs. (25 Nm).
    2. Step 2: Tighten an additional 90 degrees.
  27. Position the A/C compressor and install the two lower bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  28. Install the two upper A/C compressor bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  29. Remove the lifting hooks.
  30. Install the engine cooling fan and install the bolt.
  31. Connect the engine cooling fan electrical connector and clip the wiring harness.
  32. Install the belt tensioner and install the bolt. Tighten the bolts to 18 ft. lbs. (25 Nm).
  33. Install the A/C high-pressure hose and install the bolts.
  34. Install the A/C low-pressure hose and install the retaining nut.
  35. Install the tie strap to the power steering hose.
  36. Install the CMP sensor
  37. Position the A/C compressor to front cover bracket and install the bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  38. Install the alternator.
  39. Install the CKP sensor.
  40. Reposition the power steering line and muffler and install the retaining nut.
  41. Install a flywheel holding tool.
    NOTE
    Seal surfaces must be free of dirt and oil.
  42. Apply silicone gasket and sealant to the keyway slot.
    NOTE
    Lubricate the outside diameter sealing surface of the crankshaft pulley with clean motor oil.



    Click image to see an enlarged view
    Fig. Apply silicone gasket and sealant to the keyway slot-3.0L (VIN S) Engine
  43. Using the tool illustrated, install the crankshaft damper.

    Click image to see an enlarged view
    Fig. Using the tool illustrated, install the crankshaft damper-3.0L (VIN S) Engine
  44. Install the damper bolt and washer and tighten in four steps:
    1. Step1: Tighten to 89 ft. lbs. (120 Nm).
    2. Step 2: Loosen 360 degrees.
    3. Step 3: Tighten to 37 ft. lbs. (50 Nm).
    4. Step 4: Tighten 90 degrees.
      NOTE
      The pulley has reverse threads.
  45. Install the crankshaft pulley. Tighten the bolt to 74 ft. lbs. (100 Nm).
  46. Remove the Flywheel Holding Tool.
  47. Install the alternator splash shield.
  48. Install the rear portion of the front fender splash shield.
  49. Install the front rocker panel moulding.
  50. Install the torque converter inspection cover.
  51. install the engine-to-transaxle bracket and install the nuts and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  52. Install the oil pan.
  53. Install the valve covers.
  54. Connect the negative battery cable.
  55. Install the power steering pump.
  56. Start the engine and check for leaks.
3.0L (VIN U, 2) Engines
  1. Before servicing the vehicle, refer to the precautions section.
  2. Disconnect the negative battery cable.
  3. Drain and recycle the engine coolant.
  4. Remove the engine anti-roll strut brace.
  5. Remove the engine anti-roll strut.
  6. Remove the coolant expansion tank.
  7. Loosen the four water pump pulley bolts.
  8. Remove the crankshaft damper.
  9. Disconnect the lower radiator hose.
  10. Remove the Crankshaft Position (CKP) sensor.
  11. Remove the oil pan.
  12. Remove the alternator.
  13. Remove the accessory drive belt idler pulley.
  14. Remove the accessory drive belt tensioner.
  15. Remove the A/C compressor bracket.
  16. Disconnect the heater hose.
  17. Remove the water pump pulley.
  18. Remove the engine front cover bolts, cover and the water pump as an assembly.
  19. Remove and discard the front cover gasket.
  20. Rotate the crankshaft and align the timing marks.

    Click image to see an enlarged view
    Fig. Rotate the crankshaft and align the timing marks-3.0L (VIN U, 2) Engines
  21. Remove the camshaft sprocket bolt.
  22. Remove the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
To install:
  1. Align the timing marks.
  2. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
  3. Install the camshaft sprocket bolt and tighten to 46 ft. lbs. (63 Nm).
  4. Clean all sealing surfaces and position a new front cover gasket.
  5. Install the engine front cover and water pump assembly. Apply Pipe Sealant with Teflon® to the bolts illustrated.

    Click image to see an enlarged view
    Fig. Install the engine front cover and water pump assembly. Apply Pipe Sealant with Teflon® to the bolts illustrated-3.0L (VIN U, 2) Engines
  6. Install the water pump pulley and tighten the bolts to 18 ft. lbs. (25 Nm).
  7. Connect the heater hose.
  8. Install the A/C compressor bracket and tighten the bolts to 18 ft. lbs. (25 Nm).
  9. Install the accessory drive belt tensioner and tighten the bolts to 35 ft. lbs. (48 Nm).
  10. Install the accessory drive belt idler pulley and tighten the bolts to 35 ft. lbs. (48 Nm).
  11. Install the alternator.
  12. Install the CKP sensor.
  13. Connect the lower radiator hose.
  14. Install the oil pan.
  15. Install the crankshaft damper.
  16. Install the coolant expansion tank.
  17. Install the engine anti-roll strut and tighten the bolts to 35 ft. lbs. (48 Nm).
  18. Install the engine anti-roll strut brace and tighten the bolts to 35 ft. lbs. (48 Nm).
  19. Connect the negative battery cable.
  20. Fill and bleed the cooling system.



This will help.
Thanks.


FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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