Procedures
Timing Drive Components - Windsor Engine (5.4L)Special Tool(s):
Material:
Removal
CAUTION: Since the engine is not free-wheeling, the timing procedures must be followed exactly or piston and valve damage can occur.
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. CAUTION: If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
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. Remove the timing chains and crankshaft sprocket.
7. Remove the timing chain guides.
1 Remove the bolts.
2 Remove the LH timing chain guide.
3 Remove the bolts.
4 Remove the RH timing chain guide.
Installation
1. 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.
Compress the tensioner plunger, using a vise.
2. Install a retaining clip on the tensioner to hold the plunger in during installation.
3. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
4. Install the timing chain guides.
1 Position the LH timing chain guide.
2 Install the 2 LH bolts.
^ Tighten to 10 Nm (89 inch lbs).
3 Position the RH timing chain guide.
4 Install the 2 RH bolts.
^ Tighten to 10 Nm (89 inch lbs).
5. CAUTION: Do not turn the engine over with the special tool installed or damage to the camshaft sprocket or the bolt can occur.
Install the special tool.
6. NOTE: Slightly loosen the Camshaft Position Aligner tools to allow slight camshaft movement.
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.
7. 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 No. 1 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.
Position the crankshaft so the No. 1 cylinder is at top dead center (TDC) with the special tool.
8. Install the crankshaft sprocket, making sure the flange faces forward.
9. 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.
10. 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.
Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 copper (marked) chain links.
11. 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.
^ Tighten to 25 Nm (18 ft. lbs).
12. Remove the retaining clip from the LH timing chain tensioner.
13. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.
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.
14. NOTE: If necessary, use the Camshaft Alignment Set 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 2 copper (marked) chain links.
15. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
^ Tighten to 25 Nm (18 ft. lbs).
16. Remove the retaining clip from the RH timing chain tensioner.
17. Remove the special tool.
18. As a post-check, verify correct alignment of all timing marks.
19. Remove the special tool.
20. Position the crankshaft sensor ring on the crankshaft.
21. Install the engine front cover.