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    Ford Aerostar 1986-1997 Repair Guide

    Timing Chain Cover and Seal

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    REMOVAL & INSTALLATION



    3.0L Engine

    See Figure 1

    1. Disconnect the negative battery cable.
    2.  
    3. Turn the crankshaft until the No. 1 cylinder is at TDC on the compression stroke with the timing marks aligned. Remove the idler pulley and bracket assembly.
    4.  
    5. Remove the drive and accessory belts.
    6.  
    7. Remove the radiator and water pump, as described earlier in this section.
    8.  
    9. Remove the crankshaft pulley and damper, as described in this section.
    10.  
    11. Remove the lower radiator hose.
    12.  
    13. Remove the oil pan-to-timing cover bolts.
    14.  
    15. Remove the front cover bolts and the front cover. Tap the cover lightly with a plastic mallet, if necessary, to break it loose.
    16.  



    Click image to see an enlarged view

    Fig. Fig. 1: Exploded view of the timing chain front cover mounting-3.0L engines

    To install:
    1. Carefully clean all gasket mating surfaces on the cover and replace the crankshaft damper oil seal as follows:
      1. Coat the lip of the new seal with clean engine oil and drive it into place in the cover using Vibration Damper and Seal Replacer T82L-6316-A and Front Cover Seal Replacer T7OP-6B070-A.
      2.  

    2.  
    3. Carefully cut and remove exposed portion of the oil pan gasket. To install, coat the gasket surface of the oil pan with sealing compound (B5A-19554-A or equivalent), then cut and position the required sections of a new gasket on the oil pan and apply more sealing compound at the corners. Coat the gasket surfaces of the block and cover with sealing compound and position the cover on the block.
    4.  
    5. Install the front cover mounting bolts. Use sealant for the front cover bolt which goes into the water jacket of the block. Tighten all mounting bolts to 15-22 ft. lbs. (20-30 Nm).
    6.  
    7. Install the oil pan-to-timing cover bolts.
    8.  
    9. Install the lower radiator hose.
    10.  
    11. Lubricate the neck of the crankshaft damper with clean engine oil. Install the crankshaft damper and pulley. Tighten the damper bolt to 141-169 ft. lbs. (190-230 Nm) and the pulley bolts to 19-26 ft. lbs. (26-38 Nm).
    12.  
    13. Install the water pump and radiator, as described earlier in this section.
    14.  
    15. Install the idler pulley and drive belt(s). Refill the cooling system. For more information, refer to Routine Maintenance .
    16.  

    When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven about 10 miles (16 km) or more to relearn the strategy.

    1. Connect the negative battery cable.
    2.  
    3. Start the engine and check for leaks.
    4.  

    4.0L Engine

    See Figure 2

    It will be necessary to remove the oil pan to properly reseal the front cover to oil pan. It will also be necessary to remove the transmission to reseal the oil pan.

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the oil pan, as described earlier in this section.
    4.  
    5. Remove the air cleaner outlet tube.
    6.  
    7. Drain the cooling system.
    8.  


    CAUTION
    When draining coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

    1. Remove the accessory drive belt.
    2.  
    3. Remove the air conditioning compressor and position it out of the way. DO NOT disconnect the refrigerant lines.
    4.  
    5. Remove the power steering pump and position it out of the way. DO NOT disconnect the hoses.
    6.  
    7. Remove the alternator. For more information, refer to Engine Performance & Tune-up .
    8.  
    9. Remove the cooling fan, as described earlier in this section.
    10.  

    The engine front cover may be removed with the water pump attached.

    1. Remove the water pump, as described earlier in this section, if desired.
    2.  
    3. Remove the drive pulley/damper from the crankshaft, as described earlier in this section.
    4.  
    5. Remove the crankshaft position sensor. For more information, refer to Emission Controls .
    6.  
    7. Remove the radiator, as described earlier in this section.
    8.  

    While removing the front cover retaining bolts, make sure to note which bolt goes where. The bolts have different lengths and must be reinstalled in the original locations.

    1. Remove the front cover attaching bolts. It may be necessary to tap the cover loose with a plastic mallet.
    2.  
    3. At this time the timing chain cover oil seal can be tapped out of the cover. Make sure not to distort the cover.
    4.  



    Click image to see an enlarged view

    Fig. Fig. 2: Exploded view of the front timing chain cover and fasteners-4.0L engine

    To install:
    1. Remove the gasket material and sealer from the gasket surfaces. Inspect the engine front cover and damper seal surface for nicks, burns, or other roughness which could cause a gasket or seal to fail.
    2.  
    3. Apply sealing compound to the cylinder block sealing surfaces.
    4.  
    5. Apply sealing compound to the front cover gasket surface and position the front cover gasket onto the front cover.
    6.  
    7. If necessary, install a new oil seal using the Crankshaft Front Seal Replacer T90T-6701-A. Carefully tap the new seal in place. Lubricate the lip of the seal with new engine oil.
    8.  
    9. Install the front cover and attaching bolts. Tighten the bolts 2 or 3 turns. Make sure to install the correct bolts in their respective positions.
    10.  
    11. Tighten the retaining bolts to 13-15 ft. lbs. (17-21 Nm).
    12.  
    13. Install the radiator, as described earlier in this section.
    14.  
    15. Install the crankshaft position sensor. For more information, refer to Emission Controls .
    16.  
    17. Install the drive pulley/damper, as described earlier in this section.
    18.  
    19. Install the water pump, as described earlier in this section.
    20.  
    21. Install the cooling fan.
    22.  
    23. Install the alternator.
    24.  
    25. Install the power steering pump.
    26.  
    27. Install the air conditioning compressor.
    28.  
    29. Fill the cooling system.
    30.  
    31. Install the oil pan, as described earlier in this section.
    32.  
    33. Fill the crankcase to the proper level with clean engine oil.
    34.  
    35. Connect the negative battery cable.
    36.  

    When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the Powertrain Control Module (PCM) relearns its adaptive strategy. The vehicle may need to be driven about 10 miles (16 km) or more to relearn the strategy.

    1. Start the vehicle and check for leaks.
    2.  

     
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