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Timing Drive Components: Installation

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the special tool.
    Fig 1: Removing Special Tool (303-465)
    G01611389Courtesy of FORD MOTOR CO.
    2. CAUTION: Do not rotate the camshafts. Damage to the valves and pistons can occur.
    Fig 2: Loosening Camshaft Sprockets Bolts
    G01611390Courtesy of FORD MOTOR CO.
  2. If the camshaft sprockets were not removed, use the flats on the camshafts to prevent camshaft rotation and loosen the sprocket bolts.
  3. If removed, install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.
    Fig 3: Installing Camshaft Sprockets And Bolts
    G01611391Courtesy of FORD MOTOR CO.
  4. Install the LH timing chain guide and the bolts.
    Fig 4: Installing LH Timing Chain Guide Bolts
    G01611392Courtesy of FORD MOTOR CO.
  5. Install the timing chain.
    Fig 5: Installing Timing Chain
    G01611393Courtesy of FORD MOTOR CO.
  6. Install the RH timing chain guide.
    Fig 6: Installing RH Timing Chain Guide
    G01611394Courtesy of FORD MOTOR CO.
  7. Install the timing chain tensioner and the bolts. Remove the paper clip to release the piston.
    Fig 7: Installing Timing Chain Tensioner Bolts
    G01611395Courtesy of FORD MOTOR CO.
  8. Install the special tool.
    Fig 8: Installing Special Tool (303-465)
    G01611396Courtesy of FORD MOTOR CO.
    9. CAUTION: Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshafts can result.
    Fig 9: Using Flats On Camshafts
    G01611397Courtesy of FORD MOTOR CO.
  9. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
    10. CAUTION: Do not use metal scrapers, wire brushes, power abrasive disks or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
  10. Clean and inspect the mounting surfaces of the engine and the front cover.
    11. NOTE: The engine front cover must be installed and the bolts tightened within four minutes of applying the silicone gasket and sealant.
    Fig 10: Applying Bead Of Silicone Gasket And Sealant To Front Cover
    G01611398Courtesy of FORD MOTOR CO.
  11. Apply a 2.5 mm bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm bead of silicone gasket and sealant to the front cover.
  12. Install the engine front cover. Tighten the bolts in the sequence shown, to the following specifications:
    • Tighten the 8 mm bolts to 10 Nm (89 lb-in).
    • Tighten the 13 mm bolts to 48 Nm (35 lb-ft).
      Fig 11: Engine Front Cover Bolts Tightening Sequence
      G01611399Courtesy of FORD MOTOR CO.
    13. NOTE: Remove the thru-bolt from the special tool.
    NOTE: Lubricate the oil seal with clean engine oil.
    Fig 12: Installing Crankshaft Front Oil Seal
    G01611400Courtesy of FORD MOTOR CO.
  13. If a new seal is being installed, use the special tool to install the crankshaft front oil seal.
  14. Position the power steering pump and install the four bolts.
    Fig 13: Positioning Power Steering Pump
    G01611401Courtesy of FORD MOTOR CO.
  15. Using the special tool, install a new O-ring on the PSP tube fitting.
    Fig 14: Installing O-Ring On PSP Tube Fitting
    G01611402Courtesy of FORD MOTOR CO.
  16. Connect the power steering PSP tube fitting.
    Fig 15: Connecting Power Steering PSP Tube Fitting
    G01611403Courtesy of FORD MOTOR CO.
  17. Attach the PSP tube bracket and install the nut.
    Fig 16: Installing PSP Tube Bracket Nut
    G01611404Courtesy of FORD MOTOR CO.
  18. Connect the PSP switch electrical connector.
    Fig 17: Connecting PSP Switch Electrical Connector
    G01611405Courtesy of FORD MOTOR CO.
  19. Install the coolant pump pulley.
    Fig 18: Installing Coolant Pump Pulley
    G01611406Courtesy of FORD MOTOR CO.
  20. Install the accessory drive belt idler pulley.
    Fig 19: Installing Accessory Drive Belt Idler Pulley
    G01611407Courtesy of FORD MOTOR CO.
  21. Install the accessory drive belt tensioner.
    1. Position the tensioner.
    2. Install the tensioner bolts.
      Fig 20: Installing Accessory Drive Belt Tensioner
      G01611408Courtesy of FORD MOTOR CO.
    22. NOTE: Do not reuse the crankshaft damper bolt.
    NOTE: Apply clean engine oil on seal area before installing.
    Fig 21: Installing Crankshaft Pulley
    G01611409Courtesy of FORD MOTOR CO.
  22. Install the crankshaft pulley and hand-tighten the bolt.
    23. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
    NOTE: This step will correctly align the crankshaft pulley to the crankshaft.
    Fig 22: Installing Standard Bolt Through Crankshaft Pulley And Thread Into Front Cover
    G01611410Courtesy of FORD MOTOR CO.
  23. Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover. Rotate the pulley as necessary to align the bolt holes.
    24. CAUTION: Failure to hold the crankshaft pulley in place during bolt tightening can result in damage to the engine.
  24. Using the special tools to hold the crankshaft pulley in place, tighten the pulley bolt in two stages:
    • Stage 1: Tighten to 100 Nm (74 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 23: Tightening Crankshaft Pulley Bolts
      G01611411Courtesy of FORD MOTOR CO.
  25. Remove the special tools.
    Fig 24: Removing Special Tools (205-126)
    G01611412Courtesy of FORD MOTOR CO.
  26. Remove the M6 bolt.
  27. Remove the special tool.
    Fig 25: Removing Special Tools (303-507)
    G01611413Courtesy of FORD MOTOR CO.
  28. Remove the special tool from the camshafts.
    Fig 26: Removing Special Tool (303-465) From Camshafts
    G01611414Courtesy of FORD MOTOR CO.
    29. NOTE: Only turn the engine in the normal direction of rotation.
  29. Turn the engine two complete revolutions.
  30. Install the special tool.
    Fig 27: Installing Special Tool (303-507)
    G01611415Courtesy of FORD MOTOR CO.
    31. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
    NOTE: If it is not possible to install the bolt, correct the engine timing.
    Fig 28: Checking Position Of Crankshaft Pulley
    G01611416Courtesy of FORD MOTOR CO.
  31. Using the 6 mm (0.23 in) x 18 mm (0.7 in) bolt, check the position of the crankshaft pulley.
    32. NOTE: If it is not possible to install the special tool, correct the engine timing.
    Fig 29: Checking Position Of Camshafts Using Special Tool (303-465)
    G01611417Courtesy of FORD MOTOR CO.
  32. Using the special tool, check the position of the camshafts.
  33. Remove the special tool.
    Fig 30: Removing Special Tool (303-465)
    G01611418Courtesy of FORD MOTOR CO.
  34. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    Fig 31: Removing Bolt
    G01611419Courtesy of FORD MOTOR CO.
  35. Remove the special tool.
    Fig 32: Removing Special Tool (303-507)
    G01611420Courtesy of FORD MOTOR CO.
  36. Install the engine plug bolt.
    Fig 33: Installing Engine Plug Bolt
    G01611421Courtesy of FORD MOTOR CO.
    37. NOTE: If the crankshaft position (CKP) sensor is damaged during engine front cover removal a new CKP sensor must be installed. Refer to the manufacturer instructions for sensor installation.
    Fig 34: Connecting CKP Sensor Electrical Connector And Wiring Harness Pin-Type Retainers
    G01611422Courtesy of FORD MOTOR CO.
  37. Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.
  38. Raise the engine.
  39. Install the RH motor mount. For additional information, refer to ENGINE MOUNT-RH .
    Fig 35: Installing RH Motor Mount
    G01611423Courtesy of FORD MOTOR CO.
  40. Install the LH motor mount nut.
    Fig 36: Installing LH Motor Mount Nut
    G01611424Courtesy of FORD MOTOR CO.
  41. Tighten the lower engine mount nuts.
    1. Position the lower engine mount.
    2. Tighten the lower engine mount nuts.
      Fig 37: Tightening Lower Engine Mount Nuts
      G01611425Courtesy of FORD MOTOR CO.
  42. Remove the special tool.
    Fig 38: Removing Special Tool (303-F072)
    G01611426Courtesy of FORD MOTOR CO.
  43. Install the battery tray and bolts.
    Fig 39: Installing Battery Tray Bolts
    G01611427Courtesy of FORD MOTOR CO.
  44. Install the battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  45. Install the valve cover. For additional information, refer to VALVE COVER .
  46. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  47. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
  48. Install the fan and shroud. For additional information, refer to ENGINE COOLING .
  49. Fill and purge the power steering fluid. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
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