Sunday, October 30, 2011

How to replace Timing Chain Cover on 2003 Ford Focus?


Removal & Installation



2.3L (VIN Z) Engine

WARNING
The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.

  1. Before servicing the vehicle, refer to the Precautions section.
  2. Disconnect battery negative cable from battery and properly isolate to prevent accidental reconnection.
  3. Remove or disconnect the following:
    NOTE
    If the crankshaft position (CKP) sensor is damaged during engine front cover removal a new CKP sensor must be installed.



    Crankshaft pulley/damper
    Wire harness from the front cover studs



    CKP sensor electrical connector
    Accessory belt tensioner
    Power steering pressure (PSP) switch electrical connector and bracket
    Power steering pump pulley using special tool 211-016 or a suitable pulley remover
    PSP tube and discard the O-ring
    Four bolts and position the power steering pump aside
    Coolant pump pulley
    RH motor mount
    Accessory drive belt idler pulley
    Retainers and the engine front cover

    Click image to see an enlarged view
    Fig. Tightening sequence of front cover bolts.
To install:

WARNING
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.

  1. Clean and inspect the mounting surfaces of the engine and the front cover.
    NOTE
    The engine front cover must be installed and the bolts tightened within four minutes of applying the silicone gasket and sealant.
  2. Apply a 2.5-mm bead of silicone gasket and sealant to the cylinder head and oil pan joint areas.
  3. Apply a 2.5-mm bead of silicone gasket and sealant to the front cover.
  4. Install the front cover. Tighten the bolts in the sequence shown to the following specifications:

    Tighten the 8 mm bolts to 89 inch lbs. (10 Nm)
    Tighten the 13 mm bolts to 35 ft. lbs. (48 Nm)
  5. Position the power steering pump and tighten the bolts to 18 ft. lbs. (25 Nm)
  6. Install a new O-ring on the PSP tube fitting.
  7. Connect the power steering PSP tube fitting and tighten the nut to 15 ft. lbs. (20 Nm)
  8. Install the power steering pump pulley using special tool 211-185 or a suitable pulley installer.
  9. Attach the PSP tube bracket and tighten the nut to 10 inch lbs. (13 Nm)
  10. Connect the PSP switch electrical connector.
  11. Install the coolant pump pulley and tighten the bolts to 18 ft. lbs. (25 Nm)
  12. Install the accessory drive belt idler pulley and tighten the bolts to 18 ft. lbs. (25 Nm)
  13. Install the accessory drive belt tensioner and tighten the bolts to 18 ft. lbs. (25 Nm)
  14. Install the RH motor mount
  15. Connect the CKP sensor electrical connector and the wiring harness pin-type retainers.
  16. Install the crankshaft pulley.
  17. Connect the battery ground cable.
  18. Fill and purge the power steering fluid.



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