Mercury 2L8Z-6019-AA Cover - Cylinder Front

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To remove the upper Timing Cover, first improve access by removing the coolant expansion tank mounting bolt, unclipping it at the rear, and moving it aside without disconnecting the hoses. Next, unclip the power steering fluid reservoir and set it aside without disturbing the hoses. Unscrew the four bolts and withdraw the upper Timing Cover as far as possible, but support the engine since the right-hand engine mount must be removed for complete removal. Position a jack at the timing belt end of the oil pan with a block of wood between the oil pan and the jack head, then raise the jack to support the engine's weight. Mark the fitted position of the engine mounting on the inner fender before loosening and removing the nuts/bolts to lift off the right-hand mounting. Unscrew the engine right-hand mounting studs, which have Torx end fittings, and unclip the cylinder head temperature sensor wiring plug attached to the rear of the Timing Cover before lifting off the upper Timing Cover. For installation, reverse the removal procedure, ensuring the mounting studs are tightened securely and the engine mounting aligns with the previously marked position, tightening all bolts to the specified torque setting. For the middle Timing Cover, unbolt and position the coolant expansion tank and power steering fluid reservoir aside without disconnecting hoses, support the engine with a floor jack and a block of wood beneath the oil pan, unbolt the engine right-hand mount, loosen the water pump pulley bolts, and remove the auxiliary drivebelt. After removing the timing belt upper Timing Cover, unbolt the water pump pulley and the auxiliary drivebelt idler pulley, then unscrew the four middle Timing Cover bolts and withdraw the cover. Installation follows the reverse of removal, ensuring the cover edges engage correctly and adhering to specified torque settings. For the lower Timing Cover, remove the crankshaft pulley, unscrew the cover's securing bolts, and withdraw it, with installation being the reverse of removal while ensuring proper engagement of cover edges and adherence to torque specifications. For the inner shield/Timing Cover, remove the timing belt, tensioner components, and camshaft sprockets, then unscrew the two bolts securing the shield to the cylinder head and withdraw it, with installation being the reverse of removal and noting the specified torque settings for fasteners.

To remove the timing cover for 2008 and earlier models, disconnect the negative battery cable, remove the drive belt and tensioner, disconnect the crankshaft position sensor electrical connector, and move the wiring harness away from the engine cover. Remove the crankshaft position sensor, crankshaft pulley, water pump pulley, and the electrical connector to the power steering pressure switch. Move the power steering pump aside after removing its bolt, then remove the bolts securing the engine cover. For 2009 and later models, raise the vehicle and support it on jackstands, disconnect the negative battery terminal, remove the drive belt and idler pulley, and then the crankshaft pulley. Support the engine with a floor jack, remove the front engine oil seal, water pump pulley, drive belt idler pulley and bracket, and the crankshaft position sensor. Loosen the front cover bolts evenly and tap the cover sideways if necessary before removal. For installation, clean the mating surfaces, install the engine cover within four minutes of applying a 2.5 mm bead of RTV sealant, tighten all bolts to specified torque settings, and ensure to re-time the engine using a new crankshaft position sensor with the necessary alignment tool. To remove the timing chain and tensioner, apply the parking brake, jack up the front of the vehicle, and support it on jackstands. Remove the timing cover, compress the timing chain tensioner, and place a pin to hold it in the compressed position. If the ratchet mechanism needs resetting, remove the tensioner, relieve the tension on the ratchet, and then reinstall the tensioner. Remove the tensioner mounting bolts, the loose timing chain guide, and the timing chain. If necessary, the left chain guide and camshaft sprockets can be removed. For installation, remove the camshaft alignment tool if installed, loosen the camshaft sprocket bolts without removing them, and install the left chain guide, timing chain, and right chain guide. Install the timing chain tensioner, tighten the fasteners, and remove the pin to engage the chain guide. Reinstall the camshaft alignment tool and tighten the camshaft sprocket bolts while holding the camshafts in place. Finally, install the timing cover.

To remove the timing cover for 2008 and earlier models, disconnect the negative battery cable, remove the drive belt and tensioner, disconnect the crankshaft position sensor electrical connector, and move the wiring harness away from the engine cover. Remove the crankshaft position sensor, crankshaft pulley, water pump pulley, and the electrical connector to the power steering pressure switch. Move the power steering pump aside after removing its bolt, then remove the bolts securing the engine cover. For 2009 and later models, raise the vehicle and support it on jackstands, disconnect the negative battery terminal, remove the drive belt and idler pulley, and then the crankshaft pulley. Support the engine with a floor jack, remove the front engine oil seal, water pump pulley, drive belt idler pulley and bracket, and the crankshaft position sensor. Loosen the front cover bolts evenly and tap the cover sideways if necessary before removal. For installation, clean the mating surfaces, install the engine cover within four minutes of applying a 2.5 mm bead of RTV sealant, tighten all bolts to specified torque settings, and ensure to re-time the engine using a new crankshaft position sensor with the necessary alignment tool. To remove the timing chain and tensioner, apply the parking brake, jack up the front of the vehicle, and support it on jackstands. Remove the timing cover, compress the timing chain tensioner, and place a pin to hold it in the compressed position. If the ratchet mechanism needs resetting, remove the tensioner, relieve the tension on the ratchet, and then reinstall the tensioner. Remove the tensioner mounting bolts, the loose timing chain guide, and the timing chain. If necessary, the left chain guide and camshaft sprockets can be removed. For installation, remove the camshaft alignment tool if installed, loosen the camshaft sprocket bolts without removing them, and install the left chain guide, timing chain, and right chain guide. Install the timing chain tensioner, tighten the fasteners, and remove the pin to engage the chain guide. Reinstall the camshaft alignment tool and tighten the camshaft sprocket bolts while holding the camshafts in place. Finally, install the timing cover.

The cover must be fitted within 10 minutes of applying the sealant.

Install a new front cover gasket on the engine block, ensuring it fits over the alignment dowels. Then, install the cover and cover fasteners in their original locations and tighten them by hand until the cover is in contact with the block and cylinder heads.

Replace the crankshaft seal and apply a 1/4-inch dab of RTV sealant to the indicated joints.