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    1998 Ford Escort 2.0L MFI SOHC SPI 4cyl

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    1720 S RIDGEWOOD A
    (386) 427-1210

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    Ford Windstar 1999-2003

    Timing Chain & Sprockets

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    Removal & Installation



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

      Negative battery cable
       
      Coolant
       
      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
       

    4.  
    5. Tap the seal out of the cover with a seal driver.
    6.  
    7. Remove the crankshaft damper and timing chain front cover.
    8.  
    9. Rotate the crankshaft until the No. 1 piston is at TDC of its compression stroke and the timing marks are aligned.

      Click image to see an enlarged view

      Fig. Be sure the timing marks are facing each other after the chain has been installed-3.0L (OHV) engine

    10.  
    11. Remove the camshaft sprocket attaching bolt and washer. Slide both sprockets and timing chain forward and remove as an assembly.
    12.  
    13. Check the timing chain and sprockets for excessive wear. Replace if necessary.
    14.  

    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.  
    3. 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.
      NOTE
      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.

    4.  
    5. Lightly oil all bolt and stud threads except bolts 1, 2 and 3 that require a suitable pipe sealant.
    6.  
    7. 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
       

    8.  
    9. 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

    10.  
    11. 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
       
      Coolant
       
      Negative battery cable
       

    12.  

    3.8L Engine
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:
      NOTE
      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.


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


      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.


      NOTE
      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.


      NOTE
      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
       
      Coolant
       
      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
       

    4.  

    To install:

    1. Clean all gasket mating surfaces. If reusing the front cover, replace the front cover oil seal.
    2.  
    3. If removed, install the timing chain vibration damper. Tighten the mounting bolts to 71-123 inch lbs. (8-14 Nm).
    4.  
    5. Rotate the crankshaft to position the No. 1 piston at TDC and the crankshaft keyway at the 12 o' clock position.
    6.  
    7. Lubricate the timing chain with engine oil.
    8.  
    9. 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
       

    10.  
    11. Coat the crankshaft damper sealing surface with clean engine oil. Apply a small amount of silicone sealer to the crankshaft keyway.
    12.  
    13. Position the crankshaft pulley key in the crankshaft keyway and install the damper, using a suitable installation tool.
    14.  
    15. 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).
       

    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.

      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

    20.  

     
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