Friday, March 9, 2012

Replacing Timing Chain Cover For 2009 Ford?

The details are for 2008 and 2009 Ford Taurus.


Timing Chain Cover
REMOVAL & INSTALLATION instructions are as follows : ----


NOTE
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, may cause engine failure.

  1. With the vehicle in NEUTRAL, position it on a hoist.
  2. Recover the A/C system.
  3. Remove the air cleaner outlet pipe.
  4. Remove the front wheels and tires.
  5. Remove the accessory drive belt, tensioner and the power steering belt.
  6. Remove the degas bottle.
  7. Remove the 2 nuts and disconnect the A/C tubes.
  8. Discard the O-ring seals.
  9. Remove the nut and the A/C tube-to-receiver/drier. Discard the O-ring seal.
  10. Disconnect the power steering cooler tube and drain the power steering fluid into a suitable container.
  11. Remove the RH inner fender splash shield.
  12. Using the special tool, remove the crankshaft bolt and washer. Discard the bolt.
  13. Using the special tool, remove the crankshaft pulley.
  14. Using the special tool, remove and discard the crankshaft front seal.
  15. Remove the 4 nuts and the Y-pipe-to-catalytic converter nuts. Discard the nuts.
  16. Remove the 2 Y-pipe flange nuts.
  17. Detach the exhaust hanger and remove the Y-pipe. Discard the gaskets and nuts.
  18. Remove the drain plug and drain the engine oil.
  19. Install the drain plug and tighten to 20 ft. lbs. (27 Nm).
  20. Disconnect the hose from the power steering reservoir.
  21. Remove the RH and LH valve covers. Refer to Valve Cover.
  22. Remove the bolt and the ground cable.
  23. Disconnect the fuel efficient power steering system solenoid electrical connector.
  24. Disconnect the power steering pressure (PSP) switch electrical connector.
  25. Remove the PSP tube bracket-to-power steering pump bolt.
  26. Remove the 3 bolts and position aside the power steering pump.
    NOTE
    The special tool must be carefully aligned to the mounting bosses on the oil pan. Failure to follow these instructions may result in damage to the oil pan.
  27. Position a floor jack and the special tool under the oil pan.
  28. Remove the nut, bolt and engine mount brace.
  29. Remove the 4 engine mount nuts.
  30. Remove the 3 bolts and the engine mount.
  31. Remove the 2 bolts and the engine mount bracket.
  32. Remove the 2 engine mount studs.
  33. Remove the 2 upper engine mount bracket bolts.
  34. Loosen the lower engine mount bracket bolt and remove the engine mount bracket and bolt as an assembly.
  35. Remove the A/C tube bracket bolt.
  36. Remove the A/C tube retaining clamp bolt.
  37. Remove the A/C tube-to-evaporator bolt and the 2 A/C tubes. Discard the O-ring seals.
  38. Using the floor jack, raise the engine slightly.
  39. Remove the 22 engine front cover bolts.
  40. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover.
  41. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released.
  42. Remove the engine front cover.
To install:

NOTE
Only use a 3M Roloc® Bristle Disk (2-in white, part number 07528), to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover. These tools cause scratches and gouges that make leak paths.

  1. Clean the engine front cover using a 3M Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
  2. Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
    NOTE
    Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan may cause engine failure.


    NOTE
    Do not use wire brushes, power abrasive discs or 3M Roloc® Bristle Disk (2-in white, part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of sealant, including any sealant from the inner surface of the cylinder block and cylinder head.
  3. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.
    1. Remove any large deposits of silicone or gasket material.
    2. Apply silicone gasket remover and allow to set for several minutes.
    3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  4. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  5. Install the special tools.
    NOTE
    Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.


    NOTE
    The engine front cover and bolts 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket bolts must be installed and tighten within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.



    Click image to see an enlarged view
    Fig. Front cover special tools
  6. Apply a 3.0 mm (0.11 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
  7. Apply a 5.5 mm (0.21 in) bead of Motorcraft High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover.
    NOTE
    Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  8. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 27 inch lbs. (3 Nm).
  9. Remove the special tools (alignment pins).
  10. Install the engine mount bracket and lower bolt. Do not tighten at this time.
  11. Install the 2 upper engine mount bracket bolts. Do not tighten at this time.
    NOTE
    Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
  12. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:
    1. Stage 1: Tighten bolts 1 thru 22 to 89 inch lbs. (10 Nm) and bolts 23, 24 and 25 to 11 ft. lbs. (15 Nm).
    2. Stage 2: Tighten bolts 1 thru 22 to 18 ft. lbs. (24 Nm) and bolts 23, 24 and 25 to 55 ft. lbs. (75 Nm).

      Click image to see an enlarged view
      Fig. Front cover tightening sequence
  13. Using the floor jack, lower the engine to the installed position.
  14. Install the new O-ring seals and the A/C tubes-to-evaporator and the bolt. Tighten to 11 ft. lbs. (15 Nm).
  15. Install the A/C tube retaining clamp bolt. Tighten to 89 inch lbs. (10 Nm).
  16. Install the A/C tube bracket bolt. Tighten to 89 inch lbs. (10 Nm).
    NOTE
    The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new thread sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.
  17. Install the engine mount studs in the following sequence.
    1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.
    2. Clean all the thread sealer from the engine mount studs (old and new studs).
    3. Apply new thread sealer to the engine mount stud threads.
    4. Install the 2 engine mount studs. Tighten to 15 ft. lbs. (20 Nm).
  18. Install the engine mount bracket and the 2 bolts. Tighten to 18 ft. lbs. (24 Nm).
  19. Install the engine mount and the 3 bolts. Tighten to 66 ft. lbs. (90 Nm).
  20. Install the 4 engine mount nuts. Tighten to 46 ft. lbs. (63 Nm).
  21. Install the engine mount brace, nut and bolt. Tighten to 15 ft. lbs. (20 Nm).
  22. Position the power steering pump and install the 3 bolts. Tighten to 18 ft. lbs. (25 Nm).
  23. Install the power steering pressure (PSP) tube bracket-to-power steering pump bolt. Tighten to 89 inch lbs. (10 Nm).
  24. Connect the PSP switch electrical connector.
  25. Connect the fuel efficient power steering system solenoid electrical connector.
  26. Install the ground cable bolt. Tighten to 106 inch lbs. (12 Nm).
  27. Install the RH and LH valve covers. Refer to Valve Cover.
  28. Connect the hose to the power steering reservoir.
  29. Using a new gasket, install the exhaust Y-pipe and install the 2 new nuts. Tighten to 30 ft. lbs. (40 Nm).
  30. Attach the exhaust hanger.
  31. Install the exhaust Y-pipe assembly and 4 new nuts. Tighten to 30 ft. lbs. (40 Nm).
    NOTE
    Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
  32. Using the special tools, install a new crankshaft front seal.
    NOTE
    Lubricate the outside diameter sealing surfaces with clean engine oil.
  33. Using the special tools, install the crankshaft pulley. Refer to Crankshaft Damper.
  34. Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
    1. Stage 1: Tighten to 89 ft. lbs. (120 Nm).
    2. Stage 2: Loosen one full turn.
    3. Stage 3: Tighten to 37 ft. lbs. (50 Nm).
    4. Stage 4: Tighten an additional 90 degrees.
  35. Install the RH inner fender splash shield.
  36. Connect the power steering cooler tube.
  37. Install a new O-ring seal and the A/C tube-to-receiver/drier and the nut. Tighten to 11 ft. lbs. (15 Nm).
  38. Using new O-ring seals, connect the A/C tubes and install the 2 nuts. Tighten to 11 ft. lbs. (15 Nm).
  39. Install the degas bottle.
  40. Install the accessory drive belt, tensioner and the power steering belt.
  41. Install the front wheels and tires.
  42. Install the engine air cleaner outlet pipe.
    NOTE
    Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
  43. Fill the engine with clean engine oil.
  44. Fill the power steering system.
  45. Recharge the A/C system.

This will help.
Thanks.





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