Windsor Engine

Timing Drive Components - Windsor Engine





Special Tool(s)

Removal

CAUTION: Since the engine is not free-wheeling, if the crankshaft (6303) or the camshafts (6250) 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 an 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 an removed and the cylinders heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.

Remove the RH and LH 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 fall result.

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

Compress the tensioner plunger, using an edge of a vise.






2. Using a small screwdriver or pick, push back and hold the ratchet mechanism.






3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.






4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
- Remove the tensioner from the vise.






5. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.






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. Install the timing chain guides.






8. CAUTION: Unless otherwise instructed, at no time when the timing chains an 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.






9. Remove the Crankshaft Holding Tool.

10. Install the crankshaft sprocket, make sure the flange faces forward.






11. Position the lower end of the (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.






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

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

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

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13. CAUTION: The camshaft sprocket can jump if the Camshaft Aligner is not secured.

NOTE: Be sure the copper (marked) 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.ocket.






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

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.






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






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

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.

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






18. Remove the special tools.






19. Position the crankshaft sensor ring on the crankshaft.






20. Install the engine front cover.