Monday, March 12, 2012

Timing Belt Cover & Seal Removal on Ford Windstar?

Timing Belt Cover & Seal Replacing procedure is as follows :---


Timing Belt Cover & Seal
REMOVAL & INSTALLATION Details are as follows :----


3.0L Engine
  1. Disconnect the negative battery cable.
  2. Drain and recycle the engine coolant.
  3. Loosen the four water pump pulley retaining bolts while the accessory drive belts are still tight.
  4. Rotate the automatic tensioner down and to the left.
  5. Remove the accessory drive belt.
  6. Remove the two nuts and bolt retaining the drive belt automatic tensioner to the engine, then remove the tensioner.
  7. Disconnect and remove the lower radiator and heater hose from the water pump.
  8. Remove the crankshaft pulley and damper.
    NOTE
    Do not cut and seal the oil pan gasket. Always replace it with a new oil pan gasket.
  9. Drain and recycle the engine oil.
  10. Remove the oil pan.
  11. Remove the screw securing the power steering line bracket to the front subframe at the right front of the engine.
  12. Remove the water pump pulley.
  13. Disconnect the crankshaft position sensor electrical harness. 
    NOTE
    The engine front cover and water pump may be removed as an assembly by not removing bolt numbers 11-15 as illustrated.

    image
    Fig. By first removing the water pump, front cover removal will be easier


    Click image to see an enlarged view
    Fig. The crankshaft position sensor is bolted to the engine front cover
  14. Remove front cover bolts and lift the front cover from the engine.

    Click image to see an enlarged view
    Fig. Remove the engine front cover bolts
  15. Using a seal puller, remove the front cover seal.
To install:

NOTE
Be careful not to gouge the aluminum surfaces when scraping the old gasket material from the mating surfaces of the water pump and front cover.

  1. Clean all gasket mating surfaces thoroughly.
  2. Lightly oil all bolt and stud threads except those requiring thread sealant.
  3. Using a seal driver, install a new front cover seal.
  4. Align and install a new front cover gasket.
  5. Install the engine front cover and water pump as an assembly with the water pump pulley loosely attached.
  6. Hand start the engine front cover bolts after applying Teflon® pipe sealant to bolts No. 1, 2 and 3 as illustrated. Tighten bolts 1-10 to 15-22 ft. lbs. (20-30 Nm).
  7. If the water pump was removed separately, tighten bolts 11 through 15 to 71-106 inch lbs. (8-12 Nm).
  8. Install oil pan using a new gasket.
  9. Install crankshaft damper and pulley.
  10. Hand tighten the water pump pulley retaining bolts.
  11. Install the automatic belt tensioner assembly. Tighten the two retaining nuts and bolt to 35 ft. lbs. (47 Nm).
  12. Install the accessory drive belt.
  13. Final tighten the water pump pulley retaining bolts to 15-22 ft. lbs. (22-30 Nm).
  14. Connect the lower radiator and heater hoses.
  15. Fill and bleed the cooling system.
  16. Connect the negative battery cable.
  17. Start the engine and check for leaks.
3.8L Engine
  1. Disconnect the negative battery cable.
  2. Drain and recycle the engine coolant.
  3. Loosen the drive belt tensioner, then remove the drive belts.
  4. Remove the lower radiator hose.
  5. Remove the lower nut on both front engine supports.
  6. Remove the alternator.
  7. Position a drain pan under the power steering pump.
  8. Disconnect power steering pressure line from pump using a fuel line disconnect tool (T90T-9550-S), or equivalent.
  9. Remove the power steering reservoir filler cap.
  10. Disconnect the water bypass hose and oil cooler hose from the heater water outlet tube.
  11. Remove the retaining bolt and disconnect the heater water outlet tube from the water pump.
  12. Remove the A/C bracket brace.
  13. Raise the engine approximately 2 inches (51mm) to provide necessary clearance for water pump removal.
  14. Remove the water pump pulley.
  15. Remove the drive belt tensioner form the power steering pump support.
  16. Remove the power steering pump support and place the pump and support aside in the engine compartment.
  17. Remove the crankshaft pulley and vibration damper.
  18. Remove the oil bypass filter and oil cooler assembly.
  19. Remove the oil pan.
    NOTE
    Do not overlook the engine front cover retaining bolt located behind the oil pump and filter body. The engine front cover will break if pried upon and all retaining bolts are not removed.
  20. Remove the engine front cover.
    NOTE
    It is not necessary to remove the water pump. The water pump and front cover may be removed as an assembly.
To install:

NOTE
Be careful not to gouge the aluminum surfaces when scraping the old gasket material from the mating surfaces of the water pump and front cover.

  1. Clean all gasket mating surfaces thoroughly.
    NOTE
    Install the bolt nearest the oil bypass filter flange last and tighten last. Apply Loctite® or equivalent thread locker to bolt prior to installation.
  2. Install the engine front cover and tighten bolts to 15-22 ft. lbs. (20-30 Nm) and nuts to 71-106 inch lbs. (8-12 Nm).
  3. Install the oil pan.
  4. Install the oil bypass filter and oil cooler assembly.
  5. Install the crankshaft pulley and vibration damper.
  6. Install the power steering pump support.
  7. Install the drive belt tensioner.
  8. Install the water pump pulley.
  9. Lower the engine.
  10. Install the A/C bracket brace.
  11. Connect the heater water outlet tube.
  12. Connect the water bypass hose and oil cooler hose.
  13. Install the power steering reservoir filler cap.
  14. Connect power steering pressure line using fuel line connect tool (T90T-9550-S), or equivalent.
  15. Install the alternator.
  16. Install the lower nut on both front engine supports.
  17. Install the lower radiator hose.
  18. Install the drive belts.
  19. Fill and bleed the cooling system.
  20. Connect the negative battery cable.

This details will help.
Thanks.




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