Timing Drive Components: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

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

Compress the tensioner plunger, using a vise.

Fig 1: Compressing Tensioner Plunger Using Vise
Courtesy of FORD MOTOR CO.
Install a retaining clip on the tensioner to hold the plunger in during installation.

Fig 2: Installing Retaining Clip On Tensioner For Holding Plunger During Installation
Courtesy of FORD MOTOR CO.

NOTE: There are 61 links in the timing chain.

Fig 3: Identifying Timing Chain Links

Courtesy of FORD MOTOR CO.

If copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
Loosen the special tool on both camshafts.

Fig 4: Loosening Special Tool From Both Camshafts
Courtesy of FORD MOTOR CO.
Install the timing chain guides.

Fig 5: Installing Timing Chain Guides
Courtesy of FORD MOTOR CO.

CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and/or valve damage can occur.

Fig 6: Positioning Crankshaft With Special Tool And Removing Tool

Courtesy of FORD MOTOR CO.

Position the crankshaft with the special tool, and remove the tool.
Install the crankshaft sprocket, making sure the flange faces forward.

Fig 7: Installing Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the lower end of the LH (inner) timing chain, aligning the timing marks.

Fig 8: Installing Lower End Of LH (Inner) Timing Chain
Courtesy of FORD MOTOR CO.

NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel. If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment.

Fig 9: Installing Timing Chain On LH Camshaft Sprocket With Two Copper (Marked) Chain Links

Courtesy of FORD MOTOR CO.

Install the timing chain on the LH camshaft sprocket with the two copper (marked) chain links and the camshaft sprocket timing mark aligned.

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

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

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

Fig 10: Positioning RH (Outer) Timing Chain On Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

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

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

Fig 11: Aligning Copper (Marked) Links With Camshaft Sprocket Timing Mark

Courtesy of FORD MOTOR CO.

Position the timing chain on the camshaft sprocket. Make sure the two copper (marked) links align with the camshaft sprocket timing mark.
Check for correct alignment of all timing marks.

Fig 12: Checking Correct Alignment Of All Timing Marks
Courtesy of FORD MOTOR CO.

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

Fig 13: Positioning Timing Chain Tensioners And Installing Bolts

Courtesy of FORD MOTOR CO.

Position the LH and RH timing chain tensioner arms on the dowel pins. Position the timing chain tensioners and install the bolts.
Remove the retaining clips from the RH and LH timing chain tensioners.

Fig 14: Removing Retaining Clips From RH And LH Timing Chain Tensioners
Courtesy of FORD MOTOR CO.
Remove the special tools from the camshafts.

Fig 15: Removing Special Tools From Camshafts
Courtesy of FORD MOTOR CO.
Lubricate the balance shaft journals with clean engine oil.
Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.

Fig 16: Identifying Marks On Gear Tooth With Chalk
Courtesy of FORD MOTOR CO.
Position the balance shaft on the journals.

Fig 17: Positioning Balance Shaft On Journals
Courtesy of FORD MOTOR CO.

NOTE: It may be necessary to use an inspection mirror to see the marks.

Fig 18: Aligning Chalk Mark On Balance Shaft With Camshaft Timing Mark

Courtesy of FORD MOTOR CO.

Align the chalk mark on the balance shaft with the camshaft timing mark as shown.
Install the bearing caps in their original location. Install the bolts and tighten the bolts in the sequence shown.

Fig 19: Installing Bearing Caps In Their Original Location
Courtesy of FORD MOTOR CO.
Install the crankshaft sensor ring on the crankshaft.

Fig 20: Installing Crankshaft Sensor Ring On Crankshaft
Courtesy of FORD MOTOR CO.
Install the engine front cover. For additional information, refer to ENGINE FRONT COVER .