Timing Drive Components: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. 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.

Fig 1: Compressing Tensioner Plunger

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.

NOTE: There are 61 links in each timing chain.

Fig 3: Locating Timing Chain Marks

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If copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
On engines equipped with bolt-on sprockets, install the camshaft sprocket (2).
1. Install the bolt (1).
2. Tighten the bolt.
  - M10 bolt: Tighten in two stages.
    - Stage 1: Tighten to 40 Nm (30 lb-ft).
    - Stage 2: Tighten an additional 90 degrees.
  - M12 bolt: Tighten to 120 Nm (90 lb-ft).
    
    Fig 4: Installing Camshaft Sprocket
    Courtesy of FORD MOTOR CO.
Install the timing chain guides.

Fig 5: Identifying Tightening Torque Of Timing Chain Guides
Courtesy of FORD MOTOR CO.

NOTE: Slightly loosen the Camshaft Holding Tool to allow slight camshaft movement.

Preposition the camshafts.
1. Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock.
2. Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock.
  - Tighten the Camshaft Holding Tool to maintain camshaft prepositioning.
    
    Fig 6: Positioning Camshafts
    Courtesy of FORD MOTOR CO.

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

Fig 7: Positioning Crankshaft With Special Tool

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Position the crankshaft with the special tool, then remove the tool.
Install the crankshaft sprocket, marking sure the flange faces forward.

Fig 8: Installing Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the lower end of the LH timing chain, aligning the timing marks.

Fig 9: Installing Lower End Of LH Timing Chain
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NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel. If necessary, use the Camshaft Positioning Tool to adjust.

Fig 10: Installing LH Timing Chain On Camshaft Sprocket

Courtesy of FORD MOTOR CO.

Fig 11: Aligning Timing Marks

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Install the LH timing chain on the camshaft sprocket with the two chain (marked) links and the timing marks aligned.

CAUTION: The camshaft sprocket can jump time if the Camshaft Holding Tool is not secured.

NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned.

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

Fig 12: Installing RH (Outer) Timing Chain On Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

Install the RH (outer) timing chain on the crankshaft sprocket.
Position the timing chain on the camshaft sprocket. Make sure the two copper-colored (marked) links align with the camshaft sprocket timing mark.

Fig 13: Aligning Copper-Colored (Marked) Links With Camshaft Sprocket Timing Mark
Courtesy of FORD MOTOR CO.

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

Fig 14: Identifying Tightening Torque Of Timing Chain Tensioners Bolts

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Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioners and install the bolts.
Remove the retaining clips from the RH and LH timing chain tensioners.

Fig 15: Removing Retaining Clips From Rh And LH Timing Chain Tensioners
Courtesy of FORD MOTOR CO.
Check for correct alignment of all timing marks.

Fig 16: Checking Correct Alignment Of All Timing Marks
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Remove the special tools from the camshafts.

Fig 17: Removing Special Tools From Camshafts
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Install the crankshaft sensor ring on the crankshaft.

Fig 18: Installing Crankshaft Sensor Ring On Crankshaft
Courtesy of FORD MOTOR CO.
Lubricate the balance shaft journals with clean engine oil.
Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.

Fig 19: Identifying Balance Shaft And Gear Tooth Marks
Courtesy of FORD MOTOR CO.
Position the balance shaft on the journals.

Fig 20: Positioning Balance Shaft On Journals
Courtesy of FORD MOTOR CO.

NOTE: It may be necessary to use an inspection mirror to see the marks.

Fig 21: Aligning Chalk Mark On Balance Shaft With Camshaft Timing Mark

Courtesy of FORD MOTOR CO.

Align the chalk mark on the balance shaft with the camshaft timing mark as shown.
Install the bearing caps in their original locations. Install the bolts and tighten the bolts in the sequence shown.

Fig 22: Identifying Tightening Sequence Of Bearing Caps Bolts
Courtesy of FORD MOTOR CO.
Install engine front cover. Refer to ENGINE FRONT COVER .