Removal and Replacement

Timing Drive Components - 5.4L (2V)









Removal

NOTICE: 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. For additional information, refer to Engine Front Cover Service and Repair.

2. Remove the crankshaft sensor ring from the crankshaft.





3. NOTICE: 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 Camshaft Position Aligners on both camshafts.





5. NOTICE: 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 or engine damage may occur.

Remove the timing chain tensioning system from both timing chains.

1. Remove the 4 bolts.

2. Remove the 2 timing chain tensioners.

3. Remove the 2 timing chain tensioner arms.





6. Remove the 2 timing chains and crankshaft sprocket.





7. Remove the timing chain guides.

1. Remove the 2 bolts.

2. Remove the LH timing chain guide.

3. Remove the 2 bolts.

4. Remove the RH timing chain guide.





Installation

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

NOTICE: 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 or engine damage may occur.

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 lb-in).

3. Position the RH timing chain guide.

4. Install the 2 RH bolts.
- Tighten to 10 Nm (89 lb-in).





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

Install the Camshaft Alignment Set.





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

Pre-position the camshafts.

1. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock.
- Tighten the Camshaft Position Aligner tools to maintain camshaft pre-positioning.

2. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
- Tighten the Camshaft Position Aligner tools to maintain camshaft pre-positioning.





7. NOTICE: 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.

NOTICE: 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 Crankshaft Holding Tool.

Position the crankshaft so the No. 1 cylinder is at TDC with the Crankshaft Holding 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 and the 2 bolts.

- Tighten to 25 Nm (18 lb-ft).





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 and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).





16. Remove the retaining clip from the RH timing chain tensioner.





17. Remove the Camshaft Alignment Set.





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





19. Remove the Camshaft Position Aligner.





20. Position the crankshaft sensor ring on the crankshaft.





21. Install the engine front cover. For additional information, refer to Engine Front Cover Service and Repair.