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Installation (Windsor Engine)

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CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. DO NOT push timing chain ratchet assembly in without releasing ratchet mechanism.
  1. Using edge of a vise, compress tensioner plunger. Using a small screwdriver, push back and hold the ratchet mechanism and retract ratchet arm. While holding ratchet arm in, install paper clip to hold ratchet assembly and plunger in place during installation. See Fig 1 Remove the tensioner from the vise.
  2. If copper links are not visible, fold timing chain in half and mark 2 links on one end and one link on other end of timing chains. See Fig 2.
  3. Install timing chain guides. See Fig 3.
  4. Lightly loosen the camshaft holding tools to allow slight camshaft movement. Rotate the left camshaft with the camshaft positioning tool until the timing mark is approximately at 12 o'clock. See Fig 4. Rotate the right camshaft with the camshaft positioning tool until the timing mark is approximately at 11 o'clock. Tighten the camshaft holding tools to maintain camshaft pre-positioning.
    CAUTION: DO NOT turn the engine over with the camshaft sprocket positioning tool still attached to the cam shaft sprocket. Damage to the camshaft sprocket of the bolt may occur if positioning tool is left on.
    CAUTION: Rotate the crankshaft counterclockwise only. DO NOT rotate past position shown or severe piston and/or valve damage can occur.
  5. Position the crankshaft to TDC. TDC is obtained when slot in crankshaft holding tool aligns with engine front cover dowel pin. See Fig 5
  6. Remove crankshaft holding tool.
  7. Position the inner crankshaft sprocket with the long hub facing outward. See Fig 6.
  8. Install left timing chain. Ensure timing marks and copper link are properly aligned.
    NOTE: Be sure upper half of left timing chain is below, and lower half of right timing chain is above, timing chain tensioner guide dowels. See Fig 7. If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.
  9. The single colored link should align with the notch on the crankshaft sprocket. The 2 colored links should be positioned on either side of the notch on the camshaft sprockets. See Fig 8.
  10. Position the outer camshaft sprocket and the right timing chain with the long hub of the sprocket facing inward.
    WARNING: The shoulder of inner crankshaft sprocket must face outward and shoulder of outer sprocket must face inward. See Fig 9.
  11. Position the right timing chain on the camshaft sprocket.
  12. Position left and right timing chain tensioner arms on the dowel pins. Install timing chain tensioners and bolts. Remove paper clip from timing chain tensioners.
  13. Remove the Camshaft Holding Tool.
  14. Position the crankshaft sensor ring on the crankshaft.
  15. Apply a bead of silicone along the head-to-block surface and the oil pan-to-block surface. Use Silicone Gasket and Sealant (F6AZ-19562-A) or equivalent meeting Ford specification WSE-M4G323-A6.
  16. Install the engine front cover. See FRONT COVER .
  17. Tighten all fasteners to specification. See TORQUE SPECIFICATIONS .
Fig 1: Setting Timing Chain Tensioner Plunger
G91C07210Courtesy of FORD MOTOR CO.
Fig 2: Identifying Or Marking Timing Chain Links
G97F03845Courtesy of FORD MOTOR CO.
Fig 3: Installing Of Timing Chain Guides
G00117968Courtesy of FORD MOTOR CO.
Fig 4: Identifying Camshaft Timing Marks
G00117969Courtesy of FORD MOTOR CO.
Fig 5: Positioning Crankshaft With Crankshaft Holding Tool
G00117970Courtesy of FORD MOTOR CO.
Fig 6: Installation Of Inner Crankshaft Sprocket
G00117971Courtesy of FORD MOTOR CO.
Fig 7: Installing Timing Chain & Components
G97J03847Courtesy of FORD MOTOR CO.
Fig 8: Identifying Crankshaft Sprocket & Camshaft Sprocket Timing Chain Marks & Positions (Left Side Shown; Right Side Is Similar)
G00030414Courtesy of FORD MOTOR CO.
Fig 9: Showing Correct Installation of Inner (Right) & Outer (Left Crankshaft Sprockets
G00132584Courtesy of FORD MOTOR CO.
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