Monday, March 12, 2012

How to Replace Timing Chain & Sprockets on Ford Windstar?

Timing Chain & Sprockets Replacing procedure is as follows :----

Timing Chain & Sprockets
REMOVAL & INSTALLATION instructions are given below:----

3.0L Engines
  1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
  2. Remove or disconnect the following:

    Negative battery cable
    Accessory drive belts
    Idler pulley or automatic tensioner, as necessary
    Lower radiator hose and the heater hose from the water pump and front cover
    Crankshaft pulley and damper
    On flexible fuel vehicles, the CKP sensor
    Engine oil
    Oil pan
    If necessary, the water pump pulley bolts, then remove the pulley
    Bolts from the timing cover to the cylinder block
    Timing cover
  3. Tap the seal out of the cover with a seal driver.
  4. Remove the crankshaft damper and timing chain front cover.
  5. Rotate the crankshaft until the No. 1 piston is at TDC of its compression stroke and the timing marks are aligned. 

    Fig. Be sure the timing marks are facing each other after the chain has been installed-3.0L (OHV) engine
  6. Remove the camshaft sprocket attaching bolt and washer. Slide both sprockets and timing chain forward and remove as an assembly.
  7. Check the timing chain and sprockets for excessive wear. Replace if necessary.
To install:
  1. Before installation, clean and inspect all parts. Clean the gasket material and dirt from the oil pan, cylinder block and front cover.
  2. Slide both sprockets and timing chain onto the camshaft and crankshaft with the timing marks aligned. Install the camshaft bolt and washer and tighten to 46 ft. lbs. (63 Nm). Apply clean engine oil to the timing chain and sprockets after installation.
    The camshaft bolt has a drilled oil passage in it for timing chain lubrication. Prior to installation, clean the passage and be sure it is clear. Never replace the camshaft bolt with a standard bolt.
  3. Lightly oil all bolt and stud threads except bolts 1, 2 and 3 that require a suitable pipe sealant.
  4. Install or connect the following:

    New seal in the timing cover
    New timing cover gasket over the cylinder block dowels
    Timing cover/water pump assembly onto the cylinder block with the water pump pulley loosely attached to the water pump hub
  5. Apply a non-hardening sealant to bolt numbers 1, 2 and 3 and hand start them along with the rest of the cover bolts. Tighten bolts 1-10 to 19 ft. lbs. (25 Nm) and bolts 11-15 to 84 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Timing chain front cover bolt location and identification-3.0L (OHV) engine
  6. Install or connect the following:

    Engine oil pan. Tighten the bolts to 108 inch lbs. (12 Nm).
    Water pump pulley bolts, hand-tight
    Crankshaft damper and pulley. Tighten the damper bolt to 107 ft. lbs. (145 Nm).
    On flexible fuel vehicles, the CKP sensor. Tighten the bolt to 44-61 inch lbs. (5-7 Nm).
    Automatic belt tensioner or idler pulley, as necessary
    Water pump and accessory drive belts. Tighten the water pump pulley bolts to 16 ft. lbs. (21 Nm).
    Lower radiator hose and the heater hose and tighten the clamps
    Engine oil
    Negative battery cable
3.8L Engine
  1. Before servicing the vehicle, refer to the Precautions section.
  2. Remove or disconnect the following:
    If the crankshaft pulley and vibration damper have to be separated, mark the damper and pulley so they may be reassembled in the same relative position. This is important as the damper and pulley are initially balanced as a unit. If the crankshaft damper is being replaced, check if the original damper has balance pins installed. If so, new balance pins must be installed on the new damper in the same position as the original damper. The crankshaft pulley, new or original, must also be installed in the same relative position as originally installed.

    The front cover cannot be removed without lowering the oil pan.

    Do not overlook the cover retaining bolt located behind the oil filter adapter. The front cover will break if pried on, and all retaining bolts are not removed.

    The front cover contains the oil pump, water pump and crankshaft seal. If a new front cover is to be installed, remove the water pump and oil pump from the old front cover and install them on the new cover along with a new crankshaft seal.

    If the crankshaft sprocket is difficult to remove, pry the sprocket off the shaft using a pair of large prybars positioned on both sides of the sprocket.

    Negative battery cable
    Air cleaner assembly and air intake duct
    Fan/clutch assembly and shroud
    Accessory drive belt idlers, drive belts and the water pump pulley
    Power steering pump bracket retaining bolts. Leaving the hoses connected, place the pump/bracket assembly aside in a position to prevent fluid from leaking out.
    Compressor front support bracket but leave the compressor in place
    Coolant bypass hose and heater hose at the water pump
    Upper radiator hose at the thermostat housing
    Coil wire from the distributor cap
    Cap with the secondary wires attached
    Distributor hold-down clamp and lift the distributor out of the front cover
    Crankshaft damper and pulley

    Oil filter
    Lower radiator hose at the water pump
    Oil pan

    Front cover retaining bolts. It is not necessary to separate the water pump from the front cover.

    Front cover and water pump as an assembly. Drive the crankshaft seal out of the front cover with a suitable seal driver. Remove and discard the cover gasket.

    Camshaft bolt and washer from the end of the camshaft
    Distributor drive gear, camshaft sprocket, crankshaft sprocket and timing chain
To install:
  1. Clean all gasket mating surfaces. If reusing the front cover, replace the front cover oil seal.
  2. If removed, install the timing chain vibration damper. Tighten the mounting bolts to 71-123 inch lbs. (8-14 Nm).
  3. Rotate the crankshaft to position the No. 1 piston at TDC and the crankshaft keyway at the 12 o' clock position.
  4. Lubricate the timing chain with engine oil.
  5. Install or connect the following:

    Camshaft sprocket, crankshaft sprocket and timing chain. Be sure the timing marks align.
    Distributor drive gear. Install the bolt and washer assembly on the end of the camshaft and tighten to 30-37 ft. lbs. (40-50 Nm).
    New crankshaft seal in the front cover and lubricate the seal lip with engine oil
    New gasket on the cylinder block and install the front cover using dowels for proper alignment. Install the front cover retaining bolts and tighten to 15-22 ft. lbs. (20-30 Nm).
    Oil pan
    Lower radiator hose
    Oil filter
  6. Coat the crankshaft damper sealing surface with clean engine oil. Apply a small amount of silicone sealer to the crankshaft keyway.
  7. Position the crankshaft pulley key in the crankshaft keyway and install the damper, using a suitable installation tool.
  8. Install or connect the following:

    Damper washer and retaining bolt and tighten to 103-132 ft. lbs. (140-180 Nm).
    Crankshaft pulley and tighten the retaining bolts to 20-28 ft. lbs. (26-38 Nm).
    Coolant bypass hose
    Distributor with the rotor pointing at the No. 1 distributor cap tower
    Distributor cap and coil wire
    Upper radiator hose at the thermostat housing
    Heater hose
    Compressor and mounting brackets. Tighten the retaining bolts to 30-45 ft. lbs. (41-61 Nm).
    Power steering pump and mounting bracket. Tighten the retaining bolts to 30-45 ft. lbs. (41-61 Nm).
    Water pump pulley. Position the accessory drive belts over the pulleys.
    Fan/clutch assembly and fan shroud. Cross-tighten the fan/clutch assembly retaining bolts to 12-18 ft. lbs. (16-24 Nm).
  9. Fill the crankcase with the proper type and quantity of engine oil. Fill and bleed the cooling system. Connect the negative battery cable.
  10. Start the engine and check for leaks. Check the ignition timing and curb idle speed and adjust, as necessary.

    Click image to see an enlarged view
    Fig. The timing marks should be facing each other, when the timing chain is installed correctly-3.8L engines

This will help.


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