Ford Freestar, Monterey 2004-2006

Timing Chain Cover, Chain, Sprockets, & Seal

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Removal & Installation



  1. Rotate the crankshaft until No. 1 cylinder is at TDC on compression stroke.
  2.  
  3. Remove or disconnect the following:
    NOTE
    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.



    Negative battery cable
     
    Coolant
     
    Air cleaner assembly and air intake duct
     
    Alternator
     
    Coolant hoses
     
    Water pump
     
    Camshaft position sensor
     
    Power steering pump and position aside
     
    Camshaft synchronizer

    Click image to see an enlarged view

    Fig. Exploded view of camshaft synchronizer assembly-3.9L and 4.2L engines

     
    Alternator mounting bracket
     
    Accessory drive belt and tensioner
     
    Oil filter
     
    Right side ABS connector
     
    Place safety stand under right side of subframe
     
    Remove 2 subframe bolts and lower right side of subframe about 2 inches
     
    Crankshaft pulley
     
    Raise subframe and reinstall bolts
     
    Crankshaft front seal

    Click image to see an enlarged view

    Fig. Exploded view of front crankshaft pulley-3.9L and 4.2L engines



    Click image to see an enlarged view

    Fig. Exploded view of front cover and timing components-3.9L and 4.2L engines

     
    Front oil pan bolts
     
    Front cover
     



    Camshaft synchronizer drive gear
     
    Camshaft gear
     

  4.  
  5. Ensure the crankshaft timing marks and keyways align as shown.

    Click image to see an enlarged view

    Fig. Aligning gear timing marks and keyway-3.9L and 4.2L engines

  6.  
  7. Compress and install a retaining pin to hold the timing chain tensioner.
  8.  
  9. Remove or disconnect the following:

    Camshaft gear, crankshaft gear and timing chain as an assembly
     
    Timing chain tensioner
     

  10.  

To install:

  1. Clean all the gasket mating surfaces.
  2.  
  3. Install the timing chain tensioner and tighten the bolt to 71 inch lbs. (11 Nm).
  4.  
  5. Retract the tensioner and insert a retaining pin.
  6.  
  7. Install or connect the following:
    NOTE
    Front cover bolt no. 12 is tightened to 89 inch lbs. (10 Nm)



    Camshaft sprocket, crankshaft sprocket and timing chain. Be sure the timing marks align.
     
    Remove tensioner retaining pin
     
    Camshaft synchronizer drive gear and tighten the bolt to 33 ft. lbs. (45 Nm)
     
    Place silicone gasket sealant on front oil pan mating surface
     
    Install water pump to front cover
     
    Install front cover and torque bolts in sequence to 21 ft. lbs. (28 Nm)
     
    Front oil pan bolts
     



    Click image to see an enlarged view

    Fig. Front cover bolt torque sequence-3.9L and 4.2L engine



    New crankshaft seal in the front cover and lubricate the seal lip with engine oil
     
    Remove right subframe bolts and lower subframe again about 2 inches
     
    Crankshaft pulley and tighten the bolt to 118 ft. lbs. (160 Nm)
     
    Raise subframe, install bolts and tighten to 66 ft. lbs. (90 Nm)
     
    Right side ABS connector
     
    Oil filter
     
    Accessory drive belt and tensioner
     
    Alternator mounting bracket
     
    Camshaft synchronizer
     

  8.  
  9. Coat the camshaft synchronizer gear with clean engine oil.
  10.  
  11. Install the special tool 303-630 onto the top of the camshaft synchronizer.
    NOTE
    During installation the arrow on the special tool will rotate clockwise until the oil pump intermediate shaft engages the camshaft gear.

  12.  
  13. Install the camshaft synchronizer until the arrow on the special tool is at 54 degrees from the centerline of the engine as shown.

    Click image to see an enlarged view

    Fig. Installing special tool on camshaft synchronizer-3.9L and 4.2L engines



    Click image to see an enlarged view

    Fig. Installing camshaft synchronizer-3.9L and 4.2L engines

  14.  
  15. Install or connect the following:

    Power steering pump
     
    Camshaft position sensor
     
    Coolant hoses
     
    Alternator
     
    Air cleaner assembly and air intake duct
     

  16.  
  17. Fill the crankcase with the proper type and quantity of engine oil. Fill and bleed the cooling system. Connect the negative battery cable.
  18.  
  19. Start the engine and check for leaks. Check the ignition timing and curb idle speed and adjust, as necessary.
  20.  

 
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