Timing Chain: Service and Repair

REMOVAL
1. Drain the cooling system.
2. Remove the bolts securing the fan shroud to the radiator. Position the shroud over the fan.
3. Disconnect the radiator lower hose, heater hose and bypass hose at the water pump. Remove accessory drive belt.
4. Remove the drive belts, fan, fan spacer and pulley. Remove the fan shroud.
5. If so equipped, remove AC compressor upper bracket. Remove power steering pump mount from AC compressor and water pump.

Crankshaft, Vibration Damper Removal:

6. Remove the crankshaft pulley from the crankshaft vibration damper. Remove the damper attaching bolt and washer. Install Damper Remover D80L-522-A, Crankshaft Damper Remover T58P-6316-D, Damper Remover/Replacer Tool T79T-6316-A or equivalents on the crankshaft vibration damper and remove the vibration damper.
7. Remove the oil pan-to-cylinder block front cover attaching bolts. Use a thin-bladed knife to cut the oil pan gasket flush with the cylinder block face prior to separating the cover from the cylinder block. Remove the cylinder front cover and water pump as an assembly.
8. Discard the cylinder front cover gasket.
9. Check the timing chain deflection. If deflection exceeds 12.7 mm (0.500 inches) replace the chain and sprockets.

Fig. 8 Timing Mark Alignment.:

10. Crank the engine until the timing marks on the sprockets are aligned.

Remove Replace Timing Chain:

11. Remove the camshaft sprocket capscrew, washers and fuel pump eccentric. Slide both sprockets and the timing chain forward, and remove them as an assembly.

INSTALLATION
1. Position the sprockets and timing chain on the camshaft. Be sure the timing marks on the sprockets are positioned as shown.
2. Install the fuel pump eccentric, washers and camshaft sprocket capscrew. Tighten the sprocket capscrew to 55-61 Nm (40-45 ft lb).
3. Clean the cylinder front cover, oil pan and the cylinder block gasket surfaces. Clean the oil pan gasket surface where the oil pan and front cover fasten.

NOTE: When removing front cover, install a new oil seal.

4. Lubricate the timing chain and sprockets with heavy engine oil. Apply engine oil of the quality recommended in the Owner's Manual to the fuel pump eccentric.
5. Coat the gasket surface of the oil pan with sealer, then cut and position the required sections of a new gasket on the oil pan and apply sealer at the corners. Install the pan seal as required. Coat the gasket surfaces of the block and cover with Ford Perfect Seal B5A-19554-A or equivalent, and position a new gasket on the block.
6. Position the cylinder front cover on the cylinder block. Use care when installing the cover to avoid seal damage or possible gasket mislocation.

Aligning Front Cylinder Cover:

7. Install the cylinder front cover-to-seal alignment using Front Cover Aligner Tool T61P-6019-B or equivalent.
8. It may be necessary to force the cover downward to slightly compress the pan gasket. This operation can be facilitated by using a suitable tool at the front cover attaching hole locations.
9. Coat the threads of the attaching screws with Ford Perfect Seal B5A-19554-A or equivalent and install the screws. While pushing in on the alignment tool, tighten the oil pan-to-cover attaching screws to 17-24 Nm (12-18 ft lb). Tighten the cover-to-cylinder block attaching screws to 17-24 Nm (12-18 ft lb). Remove the alignment tool.
10. Apply Ford Polyethylene Grease D0AZ-19584-A or equivalent to the oil seal rubbing surface of the vibration damper inner hub to prevent damage to the seal and to the front of the crankshaft for damper installation.

Install Front Crankshaft Seal:

11. Line up the crankshaft vibration damper keyway with the key on the crankshaft. Install the vibration damper on the crankshaft using Damper Remover/ Replacer Tool T7ST-6316-A or equivalent. Install the capscrew and washer. Tighten the screw to 95-122 Nm (70-90 ft lb). Install the crankshaft pulley 48-67 Nm (35-50 ft lb).
12. Install water pump, tighten bolts to 17-24 Nm (12-18 ft lb).
13. Install the air conditioning compressor, power steering bracket over the stud bolt on the water pump and attach to cylinder head. Check hoses for correct routing.

Belt Routing Pattern:

14. Position the fan shroud over the water pump install the pulley. Tighten clutch and fan bolts 17-24 Nm (12-18 ft lb). Install the drive belt on the automatic belt tensioner and other remaining pulleys. Connect the radiator hose, heater hose, and bypass hose. Install the fan shroud bolts, 5.4-8 Nm (4-6 ft lb).
15. Fill and bleed the cooling system.
16. Operate the engine at fast idle and check the coolant level and check for oil leaks. Check and adjust the ignition timing to specifications on engine decal.
17. Install the air cleaner and intake duct assembly, including the crankcase ventilation hose.