Timing Drive Components - Windsor Engine (5.4L): Installation

WARNING: This page is about a different car, the 2004 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

Fig 1: Compressing Tensioner Plunger, Using Vise

Courtesy of FORD MOTOR CO.

Compress the tensioner plunger, using a vise.
Install a retaining clip on the tensioner to hold the plunger in during installation.

Fig 2: Installing Retaining Clip On Tensioner
Courtesy of FORD MOTOR CO.
Remove the tensioner from the vise.
If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.

Fig 3: Removing Tensioner From Vise
Courtesy of FORD MOTOR CO.
Install the timing chain guides.

Fig 4: Installing Timing Chain Guides
Courtesy of FORD MOTOR CO.

CAUTION: Do not turn the engine over with the Camshaft Alignment Set or damage to the camshaft sprocket or the bolt can occur.

Fig 5: Installing Special Tool

Courtesy of FORD MOTOR CO.

Install the special tool.

NOTE: Slightly loosen the Camshaft Position Aligner tools to allow slight camshaft movement.

Fig 6: Tightening Camshaft Position Aligner Tools

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Pre-position the camshafts.
1. Rotate the LH camshaft with the Camshaft Alignment Set until the timing mark is approximately at 12 o'clock.
2. Rotate the RH camshaft with the Camshaft Alignment Set until the timing mark is approximately at 11 o'clock.
  - Tighten the Camshaft Position Aligner tools to maintain camshaft pre-positioning.

CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and valve damage can occur.

NOTE: The number one cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.

Fig 7: Identifying Crankshaft Position

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Position the crankshaft so the number one cylinder is at TDC with the special tool.
Remove the special tool.
Install the crankshaft sprocket, making sure the flange faces forward.

Fig 8: Installing Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.

Fig 9: Aligning Timing Mark On Outer Flange Of Crankshaft Sprocket With Single Copper (Marked) Link
Courtesy of FORD MOTOR CO.

NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.

NOTE: If necessary, use the Camshaft Alignment Set to adjust the camshaft sprocket slightly to obtain timing mark alignment.

Fig 10: Positioning Timing Chain On Camshaft Sprocket With Camshaft Sprocket Timing Mark

Courtesy of FORD MOTOR CO.

Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.

NOTE: The LH timing chain tensioner arm has a bump near the dowel hole, for identification.

Fig 11: Positioning LH Timing Chain Tensioner Arm On Dowel Pin

Courtesy of FORD MOTOR CO.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
Remove the retaining clip from the LH timing chain tensioner.

Fig 12: Removing Retaining Clip From LH Timing Chain Tensioner
Courtesy of FORD MOTOR CO.

NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.

Fig 13: Aligning Timing Mark On Sprocket With Single Copper Mark

Courtesy of FORD MOTOR CO.

Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) link on the timing chain.

NOTE: If necessary, use the Camshaft Alignment Set to adjust the camshaft sprocket slightly to obtain timing mark alignment.

Fig 14: Positioning RH Timing Chain On Camshaft Sprocket

Courtesy of FORD MOTOR CO.

Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.

Fig 15: Positioning RH Timing Chain Tensioner Arm On Dowel Pin
Courtesy of FORD MOTOR CO.
Remove the retaining clip from the RH timing chain tensioner.

Fig 16: Removing Retaining Clip From RH Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 17: Removing Special Tool
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As a post-check, verify correct alignment of all timing marks.

Fig 18: Identifying Alignment Timing Marks Position
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Remove the special tool.

Fig 19: Removing Special Tool
Courtesy of FORD MOTOR CO.
Position the crankshaft sensor ring on the crankshaft.

Fig 20: Positioning Crankshaft Sensor Ring On Crankshaft
Courtesy of FORD MOTOR CO.
Install the engine front cover. For additional information, refer to ENGINE FRONT COVER .