TIMING CHAIN REMOVAL/INSTALLATION[AJ (3.0L Duratec)]

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Warning

•  Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.

•  Fuel line spills and leakage are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedure”. (See BEFORE SERVICE PRECAUTION[AJ (3.0L Duratec)].)

Removal

1.  Remove the engine front cover. (See ENGINE FRONT COVER REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)

2.  Remove the ignition CKP sensor pulse wheel.

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3.  Install the crankshaft pulley lock bolt.

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Note

•  The RH side is shown, however, the LH side is the same.

4.  Remove the LH and RH spark plugs.

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5.  Rotate the crankshaft clockwise to position the crankshaft keyway to the 11 o’clock position and position the camshafts in the correct position. This will position the number one cylinder at top dead center (TDC).

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Caution

•  Do not rotate the crankshaft counterclockwise. The timing chains may bind, causing engine damage.

6.  Rotate the crankshaft clockwise 120° to the 3 o’clock position to locate the RH camshafts in the neutral position.

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7.  Place alignment marks on the timing chain corresponding to each of the alignment marks on the timing sprocket.

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8.  Remove the RH timing chain and tensioner arm.

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(1)  Remove the bolt.

(2)  Remove the tensioner.

(3)  Remove the tensioner arm.

9.  Remove the bolts, RH timing chain guide and the timing chain.

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10.  Rotate the crankshaft clockwise 1and 2/3 turns to position the crankshaft keyway to the 11 o’clock position. This will position the LH camshafts to the neutral position.

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11.  Place alignment marks on the timing chain corresponding to each of the alignment marks on the timing sprocket.

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12.  Remove the LH timing chain and tensioner arm.

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(1)  Remove the bolt.

(2)  Remove the tensioner.

(3)  Remove the tensioner arm.

13.  Remove the LH timing chain and timing chain guide.

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14.  Remove the crankshaft pulley lock bolt and the crankshaft sprockets.

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Installation

1.  Install the crankshaft sprockets.

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Note

•  The RH side is shown, however, the LH side is the same.

2.  Position the chain tensioner in a soft-jawed vise.

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Note

•  The RH side is shown, however, the LH side is the same.

3.  Hold the chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.

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Note

•  During tensioner compression, do not release the ratchet stem until the tensioner piston is fully set to the bottom of its bore. Otherwise damage to the ratchet stem will result.

4.  Slowly compress the timing chain tensioner.

5.  Retain the tensioner piston with a 1.5 mm {0.059 in} wire or paper clip.

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6.  If timing marks on the timing chains are not evident, use a permanent-type marker to mark on the LH and RH timing chains.

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(1)  Mark any link to use as the crankshaft timing mark.

(2)  Count 29 links from the crankshaft timing mark and mark as the exhaust cam sprocket timing mark.

(3)  Continue counting to 42 and mark the link as the intake sprocket timing mark.

7.  Position the guide and install the bolts.

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8.  Position the mark on the intake camshaft to 9 o’clock position.

9.  Position the mark on the exhaust camshaft to 12 o’clock position.

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10.  Install the LH timing chain.

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(1)  Position number one link on the crankshaft timing mark.

(2)  Count 29 links from the number one link, and position on the exhaust cam sprocket.

(3)  Continue counting to 42 and position the link on the intake sprocket timing mark.

11.  Install the LH timing chain and tensioner arm.

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(1)  Install the tensioner arm.

(2)  Position the tensioner.

(3)  Install the bolt.

12.  Install the crankshaft pulley lock bolt and rotate the crankshaft keyway to the 3 o’clock position.

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13.  Position the mark on the exhaust camshaft to 12 o'clock position.

14.  Position the mark on the intake camshaft to 3 o'clock position.

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15.  Position the RH timing chain and chain guide and install the bolts.

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(1)  Align the marks on the timing chain with the marks on the camshaft and crankshaft sprockets.

16.  Install the RH timing chain tensioner and tensioner arm.

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(1)  Install the tensioner arm.

(2)  Position the tensioner.

(3)  Install the bolt.

17.  Remove the LH and RH timing chain tensioner piston retaining wires or paper clip.

18.  Remove the crankshaft pulley lock bolt.

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19.  Install the CKP sensor pulse wheel with the colored code area pointed towards the front of the vehicle.

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20.  Install the LH and RH spark plugs. (RH shown. LH similar.)

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21.  Install the engine front cover. (See ENGINE FRONT COVER REMOVAL/INSTALLATION[AJ (3.0L Duratec)].)

22.  Start the engine and:

•  Inspect for the engine oil, engine coolant, transaxle oil and fuel leakage.

•  Verify the ignition timing, idle speed and idle mixture.