Timing Chain: Service and Repair

CAUTION: The timing arrows/flags on the back of the camshaft sprocket(s) are mis-marked by as much as 30° rotation. The arrows or flags should not be used for engine service procedures, including timing diagnostics.

CAUTION: The 2.5L Duratec engines are not "free-wheeling." An error in timing chain installation may result in severe valve/piston damage. Use extreme care during timing chain installation.

REMOVAL
1. Remove the camshaft oil seal.
2. Remove the engine front cover.





3. Remove the camshaft oil seal retainer.





4. Remove the crankshaft position sensor pulse wheel.
- Install the pulse wheel with the keyway in the 2.5L slot.

NOTE: The pulse ring has two keyways, one for the 3.0L engine and one for the 2.5L engine.





5. Install the crankshaft pulley and bolt.

CAUTION: Rotate the crankshaft clockwise to position the crankshaft keyway to the 11 o'clock position and the engine to top dead center (TDC) No. 1 cylinder prior to the removal and installation of the camshafts and the roller followers or damage to the engine may occur.

NOTE:
- Do not rotate the crankshaft counterclockwise. The timing chains may bind causing engine damage.
- If the camshaft sprockets do not align, rotate the crankshaft one complete revolution. Testing and Inspection





6. Position the crankshaft.
1 To place the crankshaft at TDC Cylinder # 1, compression stroke, rotate the crankshaft clockwise and place the crankshaft keyway at the 11 o'clock position. Rotate the crankshaft an additional full turn if the front camshaft timing marks are not on the top side of the camshaft sprockets.






2 To check camshaft timing you must count the number of timing chain links between the camshaft front timing marks, and the timing marks on the crankshaft sprockets as shown in illustration. Ignore the timing flags on the rear of the camshaft sprockets.





7. Rotate the crankshaft clockwise to position the crankshaft keyway in the 3 o'clock position.
- The RH camshafts are in the neutral position.

NOTE: Mark the position of all chain drive components to be sure they are assembled in their original positions.





8. Remove the RH chain tensioner and tensioner arm.
1 Remove the bolts and the chain tensioner.
2 Remove the tensioner arm.





9. Remove the RH timing chain.
1 Remove the bolts and the timing chain guide.
2 Remove the RH timing chain.

CAUTION: The cylinder head and the camshaft bearing caps are numbered to make sure they are reassembled in their original position. When removed, keep the bearing caps with the cylinder head they were removed from. Do not mix the caps.

NOTE:
- Remove the camshaft bearing thrust caps Nos. 1 and 5 first. Do not loosen any of the other bolts until the thrust caps are removed.
- Camshaft bearing caps are dowelled to cylinder head. If necessary use a plastic mallet to loosen the caps.





10. Loosen the camshafts (RH cylinder head).
- Loosen the remaining bolts and bearing caps in the indicated sequence in several passes to allow the camshafts to gradually raise from the cylinder head.
- Remove the roller finger followers (RFF).

NOTE: Verify that the LH camshaft sprockets are aligned after rotating the crankshaft. Testing and Inspection





11. Rotate the crankshaft clockwise two revolutions until the keyway is in the 11 o'clock position.





12. Remove the crankshaft pulley bolt and washer.





13. Remove the LH chain tensioner and tensioner arm.
1 Remove the chain tensioner bolts.
2 Remove the chain tensioner.
3 Remove the timing chain tensioner arm.





14. Remove the LH timing chain.
1 Remove the bolts and the fixed chain guide.
2 Remove the LH timing chain.

CAUTION: The cylinder head and the camshaft bearing caps are numbered to make sure they are reassembled in their original position. When removed, keep the bearing caps with the cylinder head they were removed from. Do not mix the caps.

NOTE: Remove the camshaft bearing thrust caps Nos. 1 and 5 first. Do not loosen any of the other bolts until the thrust caps are removed.






15. Loosen the camshafts (LH cylinder head).
- Loosen the remaining bolts and bearing caps in the indicated sequence in several passes to allow the camshafts to gradually raise from the cylinder head.
- Remove the roller finger followers (RFF).






16. Remove the RH and LH timing chain sprockets.

INSTALLATION





1. Install the crankshaft pulley washer and bolt.
- Install the LH timing chain sprocket.
- Install the RH timing chain sprocket.
- Install the washer and bolt.





2. POSITION THE CRANKSHAFT.
- Turn the crankshaft clockwise to position the key to the 11 o'clock position.
- Remove the crankshaft pulley and bolt.

NOTE: Lubricate the camshafts with engine assembly lubricant D9A2-19579-D.





3. Align the LH camshaft sprockets. Testing and Inspection

NOTE: The colored links of the timing chain and the marks on the timing sprockets must line up.





4. Install the LH timing chain.
1 Install the LH chain guide and bolts (black material).
2 Install the timing chain.





5. Position the LH timing chain tensioner in a softjawed vise.

CAUTION: During tensioner compression, do not release ratchet stem until tensioner piston is fully bottomed in its bore or damage to the ratchet stem will result.





6. Hold the LH timing chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.

NOTE: Piston should retract with minimal force. If binding occurs, reposition the tensioner to eliminate side loading.

7. Slowly compress the LH timing chain tensioner.

NOTE: Wire must remain in the timing chain tensioner until the tensioner is installed onto the engine with the piston bottomed in the bore.

Timing Chain Tensioner:

8. Retain piston with a 1.5 mm wire or paper clip.





9. Install the LH timing chain tensioner.
1 Install the LH tensioner arm (black material).
2 Install the timing chain tensioner and bolts.

NOTE: The colored links of the timing chain and the marks on the timing sprockets must line up





10 Install the RH timing chain.
1 Install the timing chain guide and bolts (tan material).
2 Install the crankshaft sprocket.
3 Install the timing chain.





11. Position the RH timing chain tensioner in a softjawed vise.

CAUTION: During tensioner compression, do not release ratchet stem until tensioner piston is fully bottomed in its bore, or damage to the ratchet stem will result.





12. Hold the RH timing chain tensioner ratchet lock mechanism away from the ratchet stem with a small pick.

NOTE: Piston should retract with minimal force. If binding occurs, reposition the tensioner to eliminate side loading.

13. Slowly compress the RH timing chain tensioner.

NOTE: Wire must remain in the timing chain tensioner until the tensioner is installed with the piston bottomed in the bore.

Timing Chain Tensioner:

14. Retain piston with a 1.5 mm wire or paper clip.





15. Install the RH timing chain tensioner.
1 Install the RH tensioner arm (tan material).
2 Install the timing chain tensioner and bolts.

CAUTION: The crankshaft keyway must be in the 11 o'clock position prior to installation of the LH cylinder roller finger followers.
Failure to do so may lead to engine damage.

NOTE:
- Verify that all timing marks are in the correct position before installing the roller finger followers.
- Roller finger followers must be installed in their original locations.
- Lubricate the roller finger follower with engine assembly lubricant D9AZ-19579-D.





16. Install the LH roller finger followers.

CAUTION: Do not install LH cylinder head camshaft journal thrust caps until camshaft journal caps are installed or damage to the thrust caps may occur.

NOTE: With LH cylinder head roller finger followers installed, align camshaft endplay using thrust caps as a guide prior to torquing journal caps.






17. Tighten the LH camshaft cap bolts in the indicted sequence in several passes.





18. Install the crankshaft pulley and bolt.

CAUTION: Rotating the crankshaft counter-clockwise may cause the timing chains to bind and may cause engine damage.






19. Rotate the engine clock-wise to locate the crankshaft keyway to the 3 o'clock position.

CAUTION: The crankshaft keyway must be in the 3 o'clock position prior to installation of the RH cylinder head roller finger followers. Failure to do so may lead to engine damage.

NOTE:
- Roller finger followers must be installed in their original locations.
- Lubricate the roller finger follower with engine assembly lubricant D9AZ-19579-D.





20. Install the RH roller finger followers.

CAUTION: Do not install RH cylinder head camshaft journal thrust caps until camshaft journal caps are installed, or damage to the thrust caps may occur.

NOTE: With RH cylinder head roller finger followers installed, align camshaft endplay using thrust caps as a guide prior to torquing journal caps.





21. Tighten the RH camshaft cap bolts in the indicated sequence in several passes.

NOTE: LH shown, RH similar.





22. Remove the RH and LH chain tensioner retaining wires.





23. Remove the crankshaft pulley bolt and washer.





24. Install the camshaft oil seal retainer.
25. Install the camshaft oil seal.
26. Install the engine front cover.