Withdrawal
1. To carry out these works, the engine must be removed (section 4).
2. Remove the oil pan (see chapter 2A).
3. Remove the crankshaft pulley (see section 13).
4. Unscrew the bolts securing the front cover (see picture). Pry the cover away from the unit with a large screwdriver or a lever bar (see picture).
Caution: Engage the lever only at the points indicated in the diagram, otherwise the cover gasket surface may be damaged, resulting in oil leaks.
5. Remove the camshaft drive chain shock absorber assembly from the cover (see picture) and determine the degree of wear. Replace with significant wear.
6. Remove the bolts and disconnect the camshaft drive chain tensioner (see picture). Check tensioner support (the surface on which the chain runs). If there are grooves deeper than 1.524 mm (0.06 inch) replace tensioner.
7. To select the slack on the left side of the chain, turn the crankshaft counterclockwise (shown from the front of the engine).
8. Make a mark on the engine block about half way along the left side of the chain, then from that point measure the distance to the chain itself.
9. Rotate the crankshaft in the opposite direction to take up the slack on the right side of the chain. Pull the left side of the chain outward with your finger and take a second measurement of the distance from the mark on the block.
10. To determine chain slack, subtract the first measurement from the second measurement. Compare with the allowable value from the specification. If there is too much slack, replace the chain and sprockets.
11. Turn the crankshaft until the alignment marks on the sprockets are aligned (see picture). The marks are small indentations drilled at the outer edges.
12. Turn off a bolt of fastening of an asterisk to a cam-shaft and remove a washer. If the crankshaft rotates, screw a couple of flywheel bolts into its rear end and put a screwdriver between them. Pull both sprockets and camshaft drive chain forward (see picture) and remove them as a whole.
Installation
Camshaft and sprocket drive chain
13. Use a scraper to scrape off the remaining gasket and sealant from the cover and engine block, then clean the adjacent surfaces with a cloth moistened with solvent or acetone. Clean the target and sprockets with solvent.
14. Make sure that the guide pin in the camshaft and the Woodroffe key in the crankshaft are in place; then put both sprockets and the camshaft drive chain on the shafts, aligning the corresponding marks (see picture).
Each sprocket has a slot that must be aligned with the camshaft pin or crankshaft key. Install the camshaft bolt by installing the washer and tighten the bolt to the correct torque.
Note: The camshaft sprocket bolt washer must be installed with the groove outward towards the bolt head (this means the flat side of the washer should be facing towards the sprocket). Install the tensioner and tighten the bolts to the required torque value. Lubricate the camshaft drive chain and tensioner with engine oil. Position the chain damper assembly in the front cover.
Installing the front cover at the factory
Note: This factory recommended front cover installation method involves installing a new oil seal in the cover after the cover itself is installed on the engine, and this is because the oil seal flange is usually closer to the pulley hub than to the crankshaft. In turn, this makes it difficult to accurately install the cover without a pulley on the crankshaft. However, the factory method is not feasible without a special tool for leveling the cover, which is put on the end of the crankshaft. If such a tool is not available, then we offer you an equally effective - subject to precise and accurate execution - an alternative.
15. Apply light coats of RTV Sealant to both sides of the new front cover gasket and slide the gasket onto the cover. To maintain it, screw a couple of bolts into the holes in the cover.
16. Place the front cover on the engine (remember that the gland is installed after the cover is screwed on).
17. Place a special alignment tool on the end of the crankshaft (Ford NT84P - 6019 C). Make sure the crankshaft key is aligned with the tool key.
18. Screw in the cover bolts and tighten them in a criss-cross pattern. Up to the required tightening torque "reach" in 3 steps Remove the alignment tool.
19. Install a new oil seal and crankshaft pulley (see section 11).
Installing the front cover by an alternative method
20. Replace the old seal in the cap with a new one (see picture).
21. Apply light coats of RTV Sealant to both sides of the front cover gasket and place the gasket in the cover. With a pair of bolts screwed into the holes in the cover, press the gasket against it.
22. Connect the front cover with gasket to the engine Screw in but do not tighten the cover support bolts.
23. Lubricate the mating surface of the pulley hub with grease type "moth" and slide the pulley onto the crankshaft with one hand while supporting the front cover with the other hand. Make sure the key on the crankshaft is aligned with the corresponding slot in the pulley hub. With a slight mismatch, centering is ensured when the hub passes through the stuffing box flange.
24. Tighten the front cover mounting bolts in a criss-cross sequence in three steps.
25. Install the pulley bolt with washer and tighten to the correct torque.
26. Install the oil pan.
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