AutoZone 1994 Ford Crown Victoria 4.6L SFI 8cyl | Repair Guides | Engine Mechanical | Engine Mechanical Components | Timing Chain Cover, Chain, Sprockets, & Seal | AutoZone.com

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    1994 Ford Crown Victoria 4.6L SFI 8cyl

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    Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005

    Timing Chain Cover, Chain, Sprockets, & Seal

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    Removal & Installation



    4.0L Engine
    SOHC Engine (VIN E)
    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    2.  
    3. Drain the engine oil.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Engine from the vehicle
       
      Oil pan
       
      Engine front cover
       
      Cylinder heads
       

    6.  
    7. Lock the jackshaft tensioner by installing a pin.

      Jackshaft sprocket and chain assembly
       
      Left front cassette retaining bolt
       
      Cassette chain and tensioner assembly
       
      Rear jackshaft plug from the engine
       
      Right rear cassette retaining bolt and spacer
       
      Right rear cassette chain and tensioner
       
      Timing chain (s)

      Click image to see an enlarged view

      Fig. Remove the jackshaft sprocket-4.0L SOHC Engine

       

    8.  

    To install:

    1. Install or connect the following:

      Timing chain(s)
       
      Right rear cassette chain, tensioner and sprocket
       
      Jackshaft sprocket and chain on the engine and remove the tensioner pin
       

    2.  
    3. Torque the jackshaft sprocket bolt in 2 stages:
      1. 32-35 ft. lbs. (43-47 Nm).
      2.  
      3. Turn an additional 65 degrees.
      4.  

    4.  
    5. Install or connect the following:

      Cylinder heads
       
      Front cover
       
      Oil pan
       
      Engine to the vehicle
       
      Negative battery cable
       

    6.  
    7. Fill the engine with clean oil.
    8.  
    9. Start the vehicle, check for leaks and repair if necessary.
    10.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. Drain the engine oil.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Engine from the vehicle
       
      Oil pan
       
      Engine front cover
       
      Cylinder heads
       

    6.  
    7. Lock the jackshaft tensioner by installing a pin.

      Jackshaft sprocket and chain assembly
       
      Left front cassette retaining bolt
       
      Cassette chain and tensioner assembly
       
      Rear jackshaft plug from the engine
       
      Right rear cassette retaining bolt and spacer
       
      Right rear cassette chain and tensioner
       
      Timing chain (s)

      Click image to see an enlarged view

      Fig. Remove the jackshaft sprocket-4.0L SOHC Engine

       

    8.  

    To install:

    1. Install or connect the following:

      Timing chain(s)
       
      Right rear cassette chain, tensioner and sprocket
       
      Jackshaft sprocket and chain on the engine and remove the tensioner pin
       

    2.  
    3. Torque the jackshaft sprocket bolt in 2 stages:
      1. 32-35 ft. lbs. (43-47 Nm).
      2.  
      3. Turn an additional 65 degrees.
      4.  

    4.  
    5. Install or connect the following:

      Cylinder heads
       
      Front cover
       
      Oil pan
       
      Engine to the vehicle
       
      Negative battery cable
       

    6.  
    7. Fill the engine with clean oil.
    8.  
    9. Start the vehicle, check for leaks and repair if necessary.
    10.  

    4.6L Engine
    VIN H DOHC Engine
    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    2.  
    3. Remove the crankshaft sensor ignition pulse ring.
      WARNING
      Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage can occur.  


      WARNING
      Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage will occur.

    4.  
    5. Using special tool 303-448, position the crankshaft with the keyway at the 12 o'clock position.
    6.  
    7. Install special tool 303-446.

      Click image to see an enlarged view

      Fig. Timing chains and related parts-4.6L DOHC engine



      Click image to see an enlarged view

      Fig. Secondary timing chains and related parts-4.6L DOHC engine

    8.  
    9. Remove the timing chain tensioning system from both timing chains.
      1. Remove the bolts.
      2.  
      3. Remove the timing chain tensioners.
      4.  
      5. Remove the timing chain tensioner arms.
      6.  

    10.  
    11. Remove the right timing chain tensioner arm.
    12.  
    13. Remove the left timing chain tensioner arm.
    14.  
    15. Remove the right camshaft sprocket mounting bolt.
    16.  
    17. Remove the right camshaft sprocket washer.
    18.  
    19. Remove the right camshaft sprocket.
    20.  
    21. Remove the left camshaft sprocket mounting bolt.
    22.  
    23. Remove the left camshaft sprocket washer.
    24.  
    25. Remove the crankshaft gear.
    26.  
    27. Remove the left timing chain.
    28.  
    29. Remove the left camshaft sprocket.
    30.  
    31. Remove the left timing chain guide.
    32.  
    33. Remove the right timing chain guide.
    34.  
    35. Remove the right intake camshaft gear mounting bolt.
    36.  
    37. Remove the right intake camshaft gear washer.
    38.  
    39. Remove the right intake camshaft gear spacer.
    40.  
    41. Remove the left intake camshaft gear mounting bolt.
    42.  
    43. Remove the left intake camshaft gear washer.
    44.  
    45. Remove the left intake camshaft gear spacer.
    46.  
    47. Remove the left secondary timing chain tensioner.
    48.  
    49. Remove the right secondary timing chain tensioner.
    50.  
    51. Remove the right exhaust secondary camshaft sprocket.
    52.  
    53. Remove the right secondary camshaft timing chain.
    54.  
    55. Remove the right intake secondary camshaft sprocket.
    56.  
    57. Remove the left intake secondary camshaft sprocket.
    58.  
    59. Remove the left exhaust secondary camshaft sprocket.
    60.  
    61. Remove the left secondary camshaft timing chain.
    62.  

    To install:

    1. Installation is the reverse of removal. Observe the following notes:
    2.  

    Timing Drive Components Installation

    1. Compress the tensioner and install the retaining pin. Install the tensioners.
      CAUTION
      Timing marks must be at the 12 o'clock position and indexed at the 6 o'clock position.

    2.  
    3. Install the camshaft sprockets and chain as an assembly.
    4.  
    5. Install special tool 303-446.

      Click image to see an enlarged view

      Fig. Install special tool 303-446



      Click image to see an enlarged view

      Fig. Install the camshaft sprockets and chain as an assembly

    6.  
    7. Install the camshaft spacer, washer and bolt, and hand-tighten the bolt.
    8.  
    9. Install the camshaft gear, washer and bolt, and hand-tighten the bolt.
    10.  
    11. Tighten the bolts in two stages:
      CAUTION
      Timing chain procedures must be followed exactly or damage to valves and pistons will result.  


      CAUTION
      Do not compress the ratchet assembly. This will damage the ratchet assembly.



      Stage 1: Tighten to 30 ft. lbs. (40 Nm).
       
      Stage 2: Tighten an additional 90 degrees.
       

    12.  
    13. On engines with ratcheting timing chain tensioners only.
      1. Compress each tensioner plunger, using an edge of a vise.
      2.  
      3. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
      4.  
      5. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
      6.  
      7. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation. Remove the tensioner from the vise.
        CAUTION
        The timing chain procedures must be followed exactly or damage to valves and pistons will result.

      8.  

    14.  
    15. On engines with non-ratcheting timing chain tensioners only.
      1. Compress each tensioner plunger, using a vise.
      2.  
      3. Install a retaining clip on each tensioner to hold the plunger in during installation.
      4.  

    16.  
    17. 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.

      Click image to see an enlarged view

      Fig. 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 4.6L DOHC engine

    18.  
    19. Install the timing chain guides.
    20.  
    21. Rotate the left camshaft sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the right camshaft timing sprocket until the timing mark is approximately at the 11 o'clock position.
      CAUTION
      Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the 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 or valve damage will occur.


      NOTE
      The number one 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.



      Click image to see an enlarged view

      Fig. Rotate the left camshaft sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the right camshaft timing sprocket until the timing mark is approximately at the 11 o'clock position-4.6L DOHC engine

    22.  
    23. Using special tool 303-448, position the crankshaft so the number one cylinder is at TDC.

      Click image to see an enlarged view

      Fig. Using special tool 303-448, position the crankshaft so the number one cylinder is at TDC-4.6L DOHC engine

    24.  
    25. Remove the special tool.
    26.  
    27. Position the left (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.

      Click image to see an enlarged view

      Fig. Position the left (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket-4.6L DOHC engine

    28.  
    29. Install the left timing chain onto the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
      NOTE
      The left timing chain tensioner arm has a bump near the dowel hole for identification.



      Click image to see an enlarged view

      Fig. Install the left timing chain onto the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket-4.6L DOHC engine

    30.  
    31. Position the left timing chain tensioner arms on the dowel pin and install the left timing chain tensioner.
    32.  
    33. On engines with ratcheting timing chain tensioners only, remove the retaining clip from the left timing chain tensioner.
    34.  
    35. On engines with non-ratcheting timing chain tensioners only, remove the retaining clip from the left timing chain tensioner.
    36.  
    37. Position the right (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    38.  
    39. Install the right timing chain onto the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.

      Click image to see an enlarged view

      Fig. Position the right (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket-4.6L DOHC engine

    40.  


    41. Click image to see an enlarged view

      Fig. Install the right timing chain onto the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket-4.6L DOHC engine

    42.  
    43. Position the right timing chain tensioner arms on the dowel pin and install the right timing chain tensioner.
    44.  
    45. On engines with ratcheting timing chain tensioners only, remove the retaining clip from the right timing chain tensioner.
    46.  
    47. On engines with non-ratcheting timing chain tensioners only, remove the retaining clips from the right timing chain tensioner.
      NOTE
      Applies to all engines.

    48.  
    49. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.

      Click image to see an enlarged view

      Fig. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket-4.6L engine

    50.  

    VIN W SOHC Engine
    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    2.  
    3. Remove or disconnect the following:
      WARNING
      Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage may occur.






      Front cover
       
      Crankshaft sensor ring from the crankshaft
       

    4.  
    5. Rotate the crankshaft until both camshaft key ways are 90 degrees from the valve cover surface. Make sure the copper links line up with the dots on the camshaft sprocket.
    6.  
    7. Install the special tools 303-380 and 303-413 on the camshaft.
    8.  
    9. Remove or disconnect the following:

      Left timing chain tensioner
       
      Right timing chain tensioner
       
      Left and right timing chain tensioner arm from the dowel pins
       
      Timing chains and crankshaft sprocket
       
      Timing chain guides
       

    10.  

    To install:


    WARNING
    Do not compress the ratchet assembly. This will damage the ratchet assembly.

    1. Compress the tensioner plunger, using an edge of a vise.
    2.  
    3. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
    4.  
    5. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    6.  
    7. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
      NOTE
      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.

    8.  
    9. Install or connect the following:

      Crankshaft sprocket, making sure the timing mark faces forward
       
      Timing chain guides
       
      Left (inner) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket
       
      Left (inner) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket

      Click image to see an enlarged view

      Fig. Copper link alignment-4.6L SOHC Engine



      Click image to see an enlarged view

      Fig. Left cylinder head bolt torque sequence 4.6L SOHC Engine

       
      Right (outer) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket
       
      Right (outer) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket
       

    10.  
    11. Make sure that the copper marks on the timing chain are lined up with the corresponding dots on the crankshaft sprockets and the camshaft sprockets.

      Click image to see an enlarged view

      Fig. Sprocket alignment-4.6L SOHC Engine

    12.  
    13. Make sure that the camshaft sprocket keyway is 90 degrees from the valve cover mounting surface.
      NOTE
      The left timing chain tensioner arm has a bump near the dowel hole, for identification.

    14.  
    15. Position the left and right timing chain tensioner arm on the dowel pins.
    16.  
    17. Position the right timing chain tensioner and install the bolts.
    18.  
    19. Position the left timing chain tensioner and install the bolts.
    20.  
    21. Remove both the right and left retaining pins from the timing chain tensioner.
    22.  
    23. Remove the special tools from the camshaft.
    24.  
    25. Install the crankshaft sensor ring on the crankshaft.
    26.  
    27. Install the engine front cover.
    28.  

    5.0L Engine
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the engine oil.
    4.  
    5. Remove or disconnect the following:

      Negative battery cable
       
      Engine front cover
       

    6.  
    7. Rotate the crankshaft and align the timing marks.
    8.  
    9. Remove or disconnect the following:

      Camshaft sprocket bolt
       
      Timing chain, camshaft sprocket and crankshaft sprocket as an assembly
       

    10.  

    To install:

    1. Install or connect the following:

      Timing chain, camshaft and crankshaft sprockets as an assembly
       

    2.  
    3. Align the timing marks.

      Camshaft sprocket bolt. Torque the bolt to 45 ft. lbs. (61 Nm).
       
      Engine front cover
       
      Negative battery cable
       

    4.  

     
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