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Home >> Ford >> 1994 >> Taurus V6-195 3.2L DOHC SHO >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Timing Components >> Timing Cover >> Service and Repair

Timing Cover: Service and Repair



Tools Required:
- Puller T67L-3600-A
- Strap Wrench D85L-6000-A
- Vibration Damper and Seal Installer T82L-6316-A
- Crankshaft Seal Installer/Cover Aligner T88T-6701-A
- Screw and Washer Set T89P-6701-A
- Step Plate Adapter D80L-630-3
- Inch Pound Torque Wrench D81L-600-A
- Rotunda Offset Belt Tension Gauge 021-0028A
Images of some of these tools are found under Tools and Equipment. Tools and Equipment

Removal

Note: This engine is a dual overhead cam motor with a single timing belt sprocket on each bank, the second camshaft is driven by a chain under the valve cover of each cylinder head. For Service and Repair of the chain and tensioner, refer to Camshaft Service and Repair. Service and Repair

1. Disconnect battery cables.
2. Remove battery.

Engine Support Damper:






3. Remove RH front engine support damper.
4. Disconnect wiring to ignition control module.

Intake Manifold Assembly:






5. Remove engine air inlet connector bolts.
6. Loosen engine air inlet connector hose clamps.
7. Remove engine air inlet connector.

Relieving Belt Tension:






8. Rotate drive belt tensioner clockwise to relieve drive belt tension and remove single drive belt.
9. Disconnect air inlet connector.

Drive Belt Pulleys:






10. Remove bolts retaining upper and lower drive belt idler pulleys to engine and remove pulleys.
11. Using strap wrench D85L-6000-A or equivalent, to hold power steering pump pulley, remove nut, washer and remove power steering pulley.
12. Remove retaining bolt from drive belt tensioner and remove drive belt tensioner.
13. Remove upper and center outer timing belt covers.
14. Disconnect crankshaft position (CKP) sensor connectors.
15. Place transaxle in NEUTRAL.

Camshaft Sprocket Marks:






16. Set engine to TDC on No. 1 cylinder.
Ensure that "white" index mark on crankshaft vibration damper and pulley aligns with 0 degree index mark on lower outer timing belt cover and that index marks on intake camshaft sprockets align with index marks on upper inner timing belt cover.
17. Raise vehicle on a hoist.
18. Remove RH front wheel and tire assembly.
19. Loosen fender splash shield and place out of the way.
20. Remove crankshaft vibration damper and pulley using Steering Wheel Puller T67L-3600-A, Step Plate Adapter D80L-630-3 and Screw and Washer Set T89P-6701-A.
21. Remove lower outer timing belt cover and timing belt guide.
22. Remove upper timing belt tensioner bolt.
23. Slowly loosen lower timing belt tensioner bolt and remove timing belt tensioner.
24. Lower vehicle.
25. Remove belt.

Installation

Timing Belt Exploded View:






CAUTION:
- Before installing timing belt, inspect it for cracks, wear or other damage. Replace if damaged.
- Do not allow timing belt to come in contact with gasoline, oil, water, coolant or steam.
- Do not turn belt inside out or twist belt.
- Always store belt in a cool dark place.
- Always keep belt in protective packaging until ready for use.
- Never hit or squeeze belt with hammer or screwdriver.

WARNING: USE CAUTION WHEN COMPRESSING TIMING BELT TENSIONER IN VISE TO ENSURE THAT TENSIONER DOES NOT SLIP FROM VISE.

1. Slowly compress timing belt tensioner in a soft jawed vise until hole in tensioner housing aligns with hole in tensioner rod.
2. Insert a 1.5 mm (1/20 inch) hex wrench through holes.

Timing Belt Tensioner:






3. Release timing belt tensioner from vice.
4. If a new timing belt is being installed, loosen timing belt tensioner idler pulley bolt.






5. Ensure engine is at TDC on No. 1 cylinder.
Check that camshaft sprocket marks line up with index marks on upper inner timing belt cover and that crankshaft sprocket aligns with index mark on oil pump.

6. Install timing belt on crankshaft sprocket and route to camshaft sprockets.
Lettering on belt "KOB" should be readable from rear of engine (top of lettering to front of engine). Also ensure that the yellow lines are aligned with the index marks on all the sprockets.

Note: The timing belt has three yellow lines. Each line aligns with the index marks shown.

7. Install timing belt tensioner on cylinder block while pushing timing belt idler pulley toward belt.
Tighten timing belt tensioner bolts to 16-23 Nm (12-17 ft-lbs).

CAUTION: Do not install timing belt tensioner with rod extended.

Grommets:






8. Install grommets between timing belt tensioner and oil pump.
9. Remove 1.5 mm (1/20 inch) hex wrench from timing belt tensioner.

Note:
- If a new timing belt is being installed, perform steps 10 through 13.
- If the original timing belt is being used, go to step 14.

Special Tool - Timing Belt Tensioner:






10. Position Timing Belt Tensioner Tool T93P-6254-B using holes in power steering pump support.
Lightly tighten timing belt tensioner adjustment bolt to bottom the timing belt tensioner idle pulley to prevent it from pivoting during adjustment.

Idler Pulley Torquing:






11. Hand-tighten timing belt tensioner idler pulley bolt.
12. Using Inch Pound Torque Wrench D81L-600-A or equivalent, rotate Torque Wrench Attachment T93P-6254-A clockwise to 0.5 Nm (4.3 In lbs).
13. Tighten timing belt tensioner idler pulley bolts to 36-50 Nm (27-37 ft lbs).
Then remove Belt Tensioning Tool T93P-6254-B and Torque Wrench Attachment T93P-6254-A.
14. Raise vehicle on hoist.
15. Install timing belt guide and lower outer timing belt cover.
Tighten retaining bolts to 16-23 Nm (12-17 ft lbs).
16. Install crankshaft vibration damper and pulley using Crankshaft Seal Installer/Cover Aligner T88T-6701-A with forcing screw from Vibration Damper and Seal Installer T82L-6316-A.

White Index Mark:






17. Rotate crankshaft two revolutions in the clockwise direction until the white index mark on crankshaft vibration damper and pulley aligns with 0 degree mark on lower outer timing belt cover.
18. Lower vehicle.

Camshaft Sprocket Marks:





19. Ensure index marks on camshaft sprockets align with marks on rear outer timing belt cover.
20. Route crankshaft position sensor wiring and connect with engine control sensor wiring.
21. Install center outer timing belt cover.
Tighten retaining bolts to 16-23 Nm (12-17 ft lbs).
22. Install upper outer timing belt cover.
Tighten retaining bolts to 16-23 Nm (12-17 ft lbs).
23. Install water pump pulley.
Tighten retaining nut to 16-23 Nm (12-17 ft lbs).
24. Install single drive belt while rotating drive belt tensioner clockwise.
25. Install engine air inlet connector.
Tighten bolts to 15-23 Nm (11-17 ft lbs).
26. Install engine support damper.
27. Connect wiring to ignition control module (ICM).
28. Install battery.
29. Connect battery cables.
30. Raise vehicle.
31. Install front fender splash shield.
32. Install RH front tire and wheel assembly.
Tighten wheel lug nuts to 115-142 Nm (85-105 ft lbs).
33. Lower vehicle.
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