Windsor Engine

Timing Drive Components





Special Tool(s) Windsor Engine

Removal

CAUTION: Since the engine is not free-wheeling, if the crankshaft or the camshafts are moved in any manner during removal and installation the crankshaft and camshafts must be re-synchronized. These steps are located in Engine Assembly Steps 35 to 48.

1. Remove the engine front cover.





2. Remove the crankshaft sensor ring from the crankshaft.





3. 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.

Position the crankshaft with the keyway at the 12 o'clock position.





4. Install and fully tighten the special tools on both camshafts.





5. Remove the timing chain tensioning system from both timing chains.
1. Remove the bolts.
2. Remove the timing chain tensioners.
3. Remove the timing chain tensioner arms.





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

Remove the LH and RH timing chains and the crankshaft sprocket.
^ Remove the RH timing chain from the camshaft sprocket.
^ Remove the RH timing chain and from the crankshaft sprocket.
^ Remove the LH timing chain from the camshaft sprocket.
^ Remove the LH timing chain and crankshaft sprocket.





7. Remove both timing chain guides.
^ Remove the bolts.
^ Remove both timing chain guides.

Installation





1. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. Compress the tensioner plunger, using a vise.





2. Install a retaining clip on the tensioner to hold the plunger in during installation.
3. Remove the tensioner from the vise.





4. 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.





5. Install the timing chain guides.





6. Slightly loosen the camshaft holding tools to allow slight camshaft movement. Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock.

Rotate the RH 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.

7. CAUTION: Do not turn the engine over with the camshaft positioning tool or damage to the camshaft sprocket or the bolt may occur. Use the Camshaft Positioning Tool to position the camshaft.





8. 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/or valve damage can occur.

Position the crankshaft with the special tool.

9. Remove the Crankshaft Holding Tool.





10. Position the crankshaft sprocket and lower end of the LH (inner) timing chain, aligning the timing marks.





11. NOTE: Make sure the upper half of the timing chain is below the tensioner guide dowel. If necessary, use the Camshaft Positioning Tool to adjust.

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

Position the timing chain on the camshaft sprocket with the two copper chain links and the camshaft sprocket timing mark aligned.





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

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

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

Position the RH (outer) timing chain on the crankshaft sprocket.

13. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment with the Camshaft Positioning Tool.

Position the RH timing chain on the camshaft sprocket. Make sure the two copper-colored links align with the camshaft sprocket timing mark.





14. As a post-check, verify correct alignment of all timing marks.





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

Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioner assemblies, and install the timing bolts.





16. Remove the retaining clips from the RH and LH timing chain tensioners.





17. Remove the special tool.





18. Position the crankshaft sensor ring on the crankshaft.
19. Install the engine front cover.