Timing Chain Guide: Service and Repair
REMOVALCAUTION: At no time, when the timing chain(s) are removed and the cylinder heads (6049) are installed, may the crankshaft (6303) and/or camshafts (6250) be rotated without following established procedures. Failure to follow these directions will result in valve and/or piston damage.
NOTE: Because this is NOT a free-wheeling engine, if it has jumped time, there will be damage to the valves and/or pistons (6108) and will require the removal of the cylinder heads.
1. Remove engine front cover (6019).
2. Remove roller followers.
3. Remove crankshaft position sensor pulse wheel.
Fig. 17 Setting Engine To TDC Of No. 1 Cylinder:
4. Rotate engine to No.1 top dead center (TDC).
NOTE: To prevent accidental rotation of the camshafts and possible engine damage, install Camshaft Positioning Tool T93P-6256-A and Camshaft Holding Tool T93P-6256-AH.
Fig. 18 Camshaft Positioning Tool Installation:
5. Install Camshaft Positioning Tool T93P-6256-A in rear D-slots of camshafts as shown.
CAUTION: Failure to use Camshaft Holding Tool T93P-6256-AH while assembling or disassembling timing chains will result in damage to D-slots or Camshaft Positioning Tool T93P-6256-A.
Fig. 24 Camshaft Holding Tool:
6. Install Camshaft Holding Tool T93P-6256-AH onto camshafts as shown to keep camshafts from rotating and to prevent deformation of Camshaft Positioning Tool T93P-6256-A.
RH Timing Chain Tensioner:
7. Remove two bolts retaining RH primary timing chain tensioner (6L266) to cylinder head and remove primary timing chain tensioner.
8. Remove bolt retaining RH timing chain tensioner arm (6L253) and remove timing chain tensioner arm.
NOTE: Two bolts retaining the timing chain guide (6K297) to the cylinder head are longer than the one to the cylinder block (6010).
9. Remove three bolts retaining RH timing chain guide and remove timing chain guide.
10. Remove RH primary timing chain from camshaft sprocket (6256) and crankshaft sprocket (6306).
11. Remove RH crankshaft sprocket.
CAUTION: Failure to use Camshaft Holding Tool T93P-6256-AH while removing or tightening camshaft bolts may result in damage to camshaft D-slots or Camshaft Positioning Tool T93P-6256-A.
12. If it is necessary to remove primary or secondary camshaft sprockets or secondary timing chain tensioners, install camshaft torquing tool at center area of camshafts.
NOTE: Camshaft Positioning Tool T93P-6256-A must be installed on camshafts to prevent camshafts from rotating.
13. Remove camshaft sprocket retaining bolts.
CAUTION: Secondary timing chain tensioner plunger is spring-loaded. Care must be taken to prevent plunger from dropping out of timing chain tensioner during disassembly.
14. Unlock and compress secondary timing chain tensioners and lock the timing chain tensioner in the compressed position using clip. Remove secondary timing chain and camshaft sprockets.
15. Remove LH crankshaft sprocket.
CAUTION: Failure to use Camshaft Holding Tool T93P-6256-AH while removing or tightening camshaft bolts may result in damage to camshaft D-slots or Camshaft Positioning Tool T93P-6256-A.
16. Remove two bolts retaining LH primary timing chain tensioner to cylinder head and remove primary timing chain tensioners.
17. Remove bolt retaining LH timing chain tensioner arm and remove LH timing chain tensioner arm.
18. Remove three bolts retaining LH timing chain guide and remove timing chain guide.
19. Remove LH primary timing chain from camshaft sprocket and crankshaft sprocket.
20. If necessary, remove primary or secondary camshaft sprockets or secondary timing chain tensioners with Camshaft Holding Tool T93P-6256-AH at center area of camshafts.
21. Remove camshaft sprocket retaining bolts.
CAUTION: Secondary timing chain tensioner plunger is spring-loaded. Care must be taken to prevent plunger from dropping out of timing chain tensioner during disassembly.
22. Unlock and compress secondary chain tensioner and lock the chain tensioner in the compressed position using clip. Remove secondary timing chain and camshaft sprockets.
CAUTION: Do not rotate crankshaft and/or camshaft or engine damage may occur.
NOTE: Camshaft Holding Tool T93P-6256-AH and Camshaft Positioning Tool T93P-6256-A must be installed on camshafts to prevent camshafts from rotating.
23. Inspect friction material on timing chain tensioner arms and timing chain guides. If worn or damaged, remove and clean oil pan (6675) and replace oil pump screen cover and tube (6622).
INSTALLATION
CAUTION: If engine has jumped time, make sure that all service to engine components and/or valve train has been made.
NOTE:
A Camshaft Key has been added to the camshafts as an assembly aid. Do not remove the keys from the keyways.
Timing Chain Tensioners Make sure primary and secondary timing chain tensioners are in collapsed position and retained with clip.
Fig. 17 Setting Engine To TDC Of No. 1 Cylinder:
1. If cylinder head was removed from cylinder block, position crankshaft keyway to 270° (or at nine o'clock position).
NOTE: The roller followers must not be installed in the cylinder heads at this time.
2. Install cylinder heads on cylinder block.
LH Camshafts Keyways:
3. Install Camshaft Positioning Tool T93P-6256-A into D-slots on rear of camshafts to position both intake and exhaust camshafts with the keyways pointing down toward crankshaft.
NOTE: Do not remove Camshaft Holding Tool T93P-6256-AH from camshafts until all parts are installed and tightened.
4. Install Camshaft Holding Tool T93P-6256-AH on center of camshafts.
5. If removed, install LH secondary timing chain tensioner. Tighten retaining bolts to 8-12 Nm (71-106 inch lbs.).
Part 1 Of 2:
Part 2 Of 2:
6. If removed, install LH secondary camshaft sprockets and secondary timing chain as an assembly with hubs of camshaft sprockets facing as shown in the illustration.
7. Install LH primary camshaft sprocket and camshaft sprocket spacer (6265) on LH camshaft.
NOTE: Secondary camshaft sprockets must be free to turn.
8. Install washers and camshaft sprocket retaining bolts. Finger-tighten only.
Secondary Timing Chain Tensioner:
9. Install Tensioner Tool T93P-6256-BH on LH secondary timing chain tensioner.
CAUTION: Failure to use Camshaft Holding Tool T93P-6256-AH while assembling or disassembling timing chains will result in damage to D-slots or Camshaft Positioning Tool T93P-6256-A.
10. Install Camshaft Positioning Tool T93P-6265-A into D-slots.
11. Install Camshaft Holding Tool T93P-6256-AH at center area of LH intake and exhaust camshafts.
12. Tighten camshaft sprocket bolts to 110-130 Nm (82-95 ft. lbs.).
NOTE: Do not remove Camshaft Positioning Tool or Camshaft Holding Tool.
13. Repeat Steps 1 through 12 for RH cylinder head.
NOTE: Crankshaft sprockets are identical. They may only be installed one way. Make sure tapered part of crankshaft sprocket faces away from cylinder block for LH primary timing chain crankshaft sprocket. Refer to the illustration for proper crankshaft sprockets installation.
Fig. 26 Crankshaft Sprocket Position:
14. Install LH crankshaft sprocket.
Marking The Timing Chain:
^ If copper links of timing chain are not visible, split both chains in half and mark the two opposing links as shown.
Fig. 25 Crankshaft To Camshaft Timing:
15. Install LH primary timing chain on LH primary camshaft sprocket. Make sure copper link of timing chain lines up with timing mark of camshaft sprocket.
16. Install LH primary timing chain on crankshaft sprocket. Make sure copper link of timing chain lines up with timing mark of crankshaft sprocket.
NOTE: Make sure tapered part of crankshaft sprocket faces toward cylinder block for RH primary timing chain crankshaft sprocket.
Fig. 25 Crankshaft To Camshaft Timing:
17. Repeat Steps 14, 15 and 16 for RH primary timing chain.
NOTE: For timing chain guides, two bolts to the cylinder head are longer than the bolt to the cylinder block.
Timing Chain Guides:
18. Install RH and LH timing chain guides and secure with three bolts on each. Tighten bolts to 8-12 Nm (71-106 inch lbs.).
19. Lubricate timing chain tensioner arm contact surfaces with clean engine oil meeting Ford specification WSS-M2C 153-F and install RH and LH timing chain tensioner arms using one bolt each. Tighten to 10-15 Nm (89-132 inch lbs.).
NOTE: Do not remove lock pins until timing chain guides are installed.
20. Install RH and LH primary timing chain tensioners and secure with two bolts on each. Tighten bolts to 20-30 Nm (15-22 ft. lbs.).
21. Remove lock pins from primary timing chain tensioners and make sure all timing marks are aligned.
22. Remove Camshaft Positioning Tool T93P-6256-A.
23. Remove Camshaft Holding Tool T93P-6256-AH.
NOTE: When cleaning sealing surfaces of the engine front cover and oil pan-to-cylinder block joints, use extreme caution not to damage the rubber bead of the oil pan gasket (6710). If a leak should occur upon reassembly, remove the oil pan and replace the oil pan gasket.
24. Install engine front cover.
25. Start engine and check for leaks and proper operation.