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

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Removal

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

2.  Remove the ignition pulse wheel.

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3.  Install the crankshaft pulley lock bolt.

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4.  Remove the LH and RH spark plugs.

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Note

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

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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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 two times 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 damper bolt and the crankshaft sprockets.

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Installation

1.  Remove the damper bolt and the crankshaft sprockets.

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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

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

4.  Slowly compress the timing chain tensioner.

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.

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

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6.  Position the guide and install the bolts.

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7.  Install the LH timing chain.

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(1)  Position number one on the crankshaft.

(2)  Count twenty-nine 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.

8.  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.

9.  Install the crankshaft damper bolt and rotate the crankshaft keyway to the 3 o’clock position.

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10.  Verify that the RH camshafts are correctly positioned.

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11.  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.

12.  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.

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

14.  Remove the crankshaft pulley lock bolt.

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15.  Install the pulse wheel with the keyway in the slot stamped 25/34Y mark (Color Blue).

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

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