AutoZone 2004 Dodge/Ram Truck Grand Caravan AWD 3.8L SFI OHV 6cyl | Repair Guides | Engine And Engine Overhaul | Engine Mechanical | Timing Chain, Sprockets And Front Cover | AutoZone.com

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    2004 Dodge/Ram Truck Grand Caravan AWD 3.8L SFI OHV 6cyl

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    Ford Pick-Ups/Expedition/Navigator 1997-2000

    Timing Chain, Sprockets and Front Cover

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    REMOVAL & INSTALLATION



    4.2L Engine
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the accessory drive belt.
    4.  
    5. Drain the coolant into a suitable clean container.
    6.  
    7. Remove the radiator, fan blade assembly and fan shroud.
    8.  
    9. Remove the water pump.
    10.  
    11. Remove the EGR valve vacuum hose.
    12.  
    13. Remove the EGR tube upper fitting.
    14.  
    15. Remove the EGR valve and adapter assembly.
    16.  
    17. Detach the wiring harness from the heater water outlet tube.
    18.  
    19. Remove the heater water outlet bolt and position the outlet tube aside.
    20.  
    21. Remove the Camshaft Position (CMP) sensor electrical harness connector and mark the position of the connector for proper installation.
    22.  



    Click image to see an enlarged view

    Fig. Fig. 1 After removing the CMP drive gear, be sure the timing marks (A) and key-ways (B) are aligned-4.2L engine



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    Fig. Fig. 2 Compress the tensioner assembly and install a pin into the hole in the tensioner body



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    Fig. Fig. 3 Turn the balance shaft so that the timing mark (B) on the gear(A) is in alignment



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    Fig. Fig. 4 After the timing chains are installed, remove the retaining pin from the tensioner

    1. Rotate the crankshaft until the TDC timing mark lines up with the timing mark.
    2.  
    3. Remove the two bolts retaining the CMP and remove the CMP from the camshaft synchronizer.
    4.  
    5. Remove the camshaft synchronizer adjustment bolt and remove the camshaft synchronizer.
    6.  

    The oil pump drive shaft may come out with the camshaft synchronizer.

    1. Raise and safely support the vehicle.
    2.  
    3. Remove the oil pan drain plug and drain the engine oil in a suitable container.
    4.  
    5. Remove the crankshaft pulley and damper using appropriate tools.
    6.  
    7. Remove the engine oil pan.
    8.  
    9. Remove the two engine front cover stud bolts, front cover bolt and cap screw.
    10.  
    11. Slide the engine front cover and gasket off the dowels and discard the gasket.
    12.  
    13. Remove the CMP sensor drive gear bolt and remove the drive gear.
    14.  
    15. Be sure the timing marks and key-ways align.
    16.  
    17. Compress and install a retaining pin to hold the timing chain tensioner.
    18.  
    19. Slide both sprockets and timing chain forward and remove as an assembly.
    20.  
    21. Remove the three bolts retaining the timing chain tensioner and remove the tensioner.
    22.  
    23. Check the timing chain and sprockets for excessive wear. Replace if necessary.
    24.  

    To install:

    1. Before installation, clean and inspect all parts. Clean the gasket material from the engine oil pan, cylinder block and engine front cover.
    2.  
    3. Place the timing chain tensioner in position and install the three retaining bolts. Tighten the bolts to 6-10 ft. lbs. (8-14 Nm).
    4.  
    5. Verify that the balance shaft timing gears are in correct alignment.
    6.  
    7. Slide both sprockets and the timing chain onto the camshaft and crankshaft with the timing marks aligned. Install the CMP sensor drive gear and bolt. Tighten the bolt to 30-36 ft. lbs. (40-50 Nm).
    8.  
    9. Remove the retaining pin.
    10.  



    Click image to see an enlarged view

    Fig. Fig. 5 Install the camshaft synchronizer (A) in the orientation shown (white arrow points to front of engine)-4.2L engines

    1. Inspect the engine front cover seal for wear or damage and replace if necessary.
    2.  
    3. Install the engine front cover gasket and front cover onto the guide studs.
    4.  
    5. Install the two engine front cover stud bolts, front cover bolt and cap screw. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
    6.  
    7. Install the engine oil pan.
    8.  
    9. Install the crankshaft damper and pulley.
    10.  


    WARNING
    A Synchro Positioning Tool must be used prior to installation. Failure to using this procedure will result in the fuel system being out of time, possibly causing engine damage.

    1. Install Synchro Positioning Tool T89P-12200-A or equivalent, on the camshaft synchronizer by rotating the tool until it engages the notch in the housing.
    2.  
    3. Install the camshaft synchronizer housing assembly so that the arrow on the tool is 54 degrees from the centerline of the engine.
    4.  
    5. Install the adjustment bolt and tighten to 15-22 ft. lbs. (21-30 Nm).
    6.  
    7. Remove the tool and position the CMP sensor. Install the 2 bolts and 40-70 inch lbs. (5-8 Nm) and install the CMP electrical harness connector.
    8.  
    9. Install the water pump.
    10.  
    11. Install the fan shroud, fan blade assembly and radiator.
    12.  
    13. Install the accessory drive belt.
    14.  
    15. Fill the crankcase with the correct amount and type of engine oil.
    16.  
    17. Fill and bleed the engine cooling system.
    18.  
    19. Connect the negative battery cable.
    20.  
    21. Start the engine and check for coolant and oil leaks.
    22.  
    23. Road test the vehicle and check for proper engine operation.
    24.  

    4.6L Engine


    Click image to see an enlarged view

    Fig. Fig. 6 Remove the driver's side ignition coil bracket bolts



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    Fig. Fig. 7 Remove the passenger side ignition coil bracket bolts along with the belt tensioner retaining bolts and the idler pulley retaining bolt



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    Fig. Fig. 8 Remove the power steering pump mounting bolts and position the pump to the side



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    Fig. Fig. 9 Remove the four front oil pan-to-timing cover retaining bolts



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    Fig. Fig. 10 Once the necessary components are removed, the timing cover bolts are accessible, remove the bolts and ...



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    Fig. Fig. 11 ... remove the cover from the engine



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    Fig. Fig. 12 Install the camshaft holding tool



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    Fig. Fig. 13 Remove the crankshaft position sensor trigger wheel from the crankshaft



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    Fig. Fig. 14 Remove the timing chain tensioner retaining bolts and ...



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    Fig. Fig. 15 ... remove the tensioner from the engine



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    Fig. Fig. 16 Remove the tensioner arm from the engine



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    Fig. Fig. 17 Remove the timing chain from around the camshaft pulley



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    Fig. Fig. 18 When removing the timing chains, rotate the crankshaft so that the camshaft key-ways are positioned as shown-4.6L engines



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    Fig. Fig. 19 Remove the timing chain guide retaining bolts and remove the guides from the engine



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    Fig. Fig. 20 Place the tensioner into a bench vise or other suitable device and retract the plunger



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    Fig. Fig. 21 Using a small screwdriver or other suitable tool, push back and hold the ratchet mechanism



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    Fig. Fig. 22 While holding the ratchet mechanism, push the ratchet arm back into the tensioner assembly



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    Fig. Fig. 23 After the ratchet mechanism is retracted, place a paper clip or other suitable tool into the hole in the tensioner body to hold the ratchet arm and plunger during installation



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    Fig. Fig. 24 Place the tensioner assembly onto the engine and tighten the retaining bolts



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    Fig. Fig. 25 Remove the paper clip from the tensioner assembly

    1. Disconnect the negative battery cable.
    2.  
    3. Remove the radiator, fan blade and fan shroud assembly.
    4.  
    5. Remove the accessory drive belt.
    6.  
    7. Remove the water pump pulley.
    8.  
    9. Detach the electrical harness connectors from both ignition coils.
    10.  
    11. Remove both ignition coils with their brackets attached.
    12.  
    13. Remove the left-hand and right-hand cylinder head covers.
    14.  
    15. Raise and safely support the vehicle.
    16.  
    17. Remove the two upper power steering pump retaining bolts.
    18.  
    19. Remove the two lower power steering pump retaining bolts and move the pump aside.
    20.  
    21. Detach the Crankshaft Position (CKP) sensor electrical harness connector. Remove the retaining bolt and remove the CKP sensor.
    22.  
    23. Drain the engine oil into a suitable container.
    24.  
    25. Remove the four oil pan-to-engine front cover retaining bolts.
    26.  
    27. Lower the vehicle.
    28.  
    29. Remove the crankshaft damper retaining bolt and washer from the crankshaft.
    30.  
    31. Install Crankshaft Damper Remover T58P-6316-D or equivalent and pull the damper from the crankshaft.
    32.  
    33. Remove the Camshaft Position (CMP) sensor retaining bolt and remove the CMP sensor.
    34.  
    35. Remove the idler pulley bolt and remove the pulley.
    36.  
    37. Remove the three belt tensioner retaining bolts and remove the tensioner.
    38.  
    39. Remove the eight engine front cover retaining bolts and the seven nuts. Swing the top of the cover out off the dowel pins and remove the cover.
    40.  
    41. Remove the sensor ring from the crankshaft.
    42.  
    43. Use Camshaft Positioning Tool T91P-6256-A and Camshaft Positioning Adapters T92P-6256-A or equivalents, to position the camshaft.
    44.  
    45. Rotate the crankshaft until both camshaft key-ways are 90 degrees from the cam cover surface. Be sure the copper links line up with the dots on the camshaft sprockets.
    46.  


    WARNING
    At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or the camshaft be rotated. Severe piston and valve damage will occur.

    1. Remove the two left-hand and right-hand tensioner bolts and remove the timing chain tensioners.
    2.  
    3. Slide the left-hand and right-hand tensioner guides off the dowel pins.
    4.  
    5. Remove the right-hand timing chain from the camshaft sprocket.
    6.  
    7. Remove the left-hand timing chain from the camshaft sprocket.
    8.  
    9. Remove the left-hand and right-hand timing chain guide bolts and remove the timing chain guides.
    10.  
    11. If necessary, remove the camshaft gear bolt and remove the camshaft gear.
    12.  

    To install:



    Click image to see an enlarged view

    Fig. Fig. 26 When installing the timing chains, make certain that the copper colored links (A) are aligned with the timing marks-4.6L engine



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    Fig. Fig. 27 Tighten the first five front cover fasteners in the sequence shown-4.6L engine



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    Fig. Fig. 28 Continue tightening the remaining fasteners in the sequence shown here-4.6L engine

    1. Examine the timing chains, looking for the copper links. If the copper links are not visible, lay the chain on a flat surface and pull the chain taught until the opposite sides of the chain contact one another. Mark the links at each end of the chain and use these marks in place of the copper links.
    2.  

    If the engine jumped time, damage has been done to valves and possibly pistons and/or connecting rods. Any damage must be corrected before installing the timing chains.

    1. If removed, install the camshaft gears and tighten the retaining bolt to 81-95 ft. lbs. (110-130 Nm).
    2.  
    3. Install the left-hand and right-hand timing chain guides and retaining bolts. Tighten the retaining bolts to 71-106 inch lbs. (8-12 Nm).
    4.  
    5. If removed, install the left-hand crankshaft sprocket with the tapered part of the sprocket facing away from the engine block.
    6.  

    The crankshaft sprockets are identical. They may only be installed one way, with the tapered part of the sprockets facing each other. Ensure that the key-way and timing marks on the crankshaft sprockets are aligned.

    1. Install the left-hand timing chain on the camshaft and crankshaft sprockets. Be sure the copper links of the timing chain line up with the timing marks on both sprockets.
    2.  
    3. If removed, install the right-hand crankshaft sprocket with the tapered part of the sprocket facing the left-hand crankshaft sprocket.
    4.  
    5. Install the right-hand timing chain on the camshaft and crankshaft sprockets. Be sure the copper links of the timing chain line up with the timing marks on both sprockets.
    6.  
    7. It is necessary to bleed the timing chain tensioners before installation. Proceed as follows:
      1. Place the timing chain tensioner in a soft-jawed vise.
      2.  
      3. Using a small pick or similar tool, hold the ratchet lock mechanism away from the ratchet stem and slowly compress the tensioner plunger by rotating the vise handle.
      4.  

    8.  


    WARNING
    The tensioner must be compressed slowly or damage to the internal seals will result.

    1. Once the tensioner plunger bottoms in the tensioner bore, continue to hold the ratchet lock mechanism and push down on the ratchet stem until flush with the tensioner face.
    2.  
    3. While holding the ratchet stem flush to the tensioner face, release the ratchet lock mechanism and install a paper clip or similar tool in the tensioner body to lock the tensioner in the collapsed position.
    4.  
    5. The paper clip must not be removed until the timing chain, tensioner, tensioner arm and timing chain guide are completely installed on the engine.
    6.  

    1. Install the left-hand and right-hand timing chain tensioner guides on the dowel pins.
    2.  
    3. Place the left-hand and right-hand timing chain tensioners in position and install the retaining bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
    4.  
    5. Remove the retaining pins from the timing chain tensioners.
    6.  
    7. Remove Camshaft Positioning Tool T91P-6256-A and Camshaft Positioning Adapters T92P-6256-A or equivalents. from the camshaft.
    8.  
    9. Install the crankshaft sensor ring on the crankshaft.
    10.  
    11. Apply a bead of silicone sealer along the cylinder head-to-cylinder block and the oil pan-to-cylinder block sealing surfaces.
    12.  
    13. Install the engine front cover carefully onto the dowel pins.
    14.  
    15. Tighten the engine front cover bolts, in sequence, to 15-22 ft. lbs. (20-30 Nm).
    16.  
    17. Place the idler pulley in position and install the retaining bolt. Tighten the bolt to 15-22 ft. lbs. (20-30 Nm).
    18.  
    19. Install the drive belt tensioner and the three retaining bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
    20.  
    21. Install the CMP sensor and the retaining bolt. Tighten the bolt to 106 inch lbs. (12 Nm).
    22.  
    23. Place the damper on the crankshaft. Ensure the crankshaft key and key-way are aligned.
    24.  
    25. Using Crankshaft Damper Replacer T74P-6316-B or equivalent, install the crankshaft damper.
    26.  
    27. Raise and safely support the vehicle.
    28.  
    29. Install the four oil pan-to-engine front cover bolts and tighten, in sequence, in 2 steps:
      1. Tighten the bolts to 15 ft. lbs. (20 Nm).
      2.  
      3. Rotate the bolts an additional 60 degrees.
      4.  

    30.  
    31. Install the CKP sensor and the retaining bolt. Tighten the bolt to 106 inch lbs. (12 Nm). Connect the CKP sensor electrical harness connector.
    32.  
    33. Install the power steering pump and the two upper and two lower retaining bolts. Tighten the bolts to 15-20 ft. lbs. (20-30 Nm).
    34.  
    35. Lower the vehicle.
    36.  
    37. Place the ignition coil and brackets on the engine front cover and install the bracket bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
    38.  
    39. Connect the ignition coil and capacitor electrical harness connectors.
    40.  
    41. Connect the CMP electrical harness connector.
    42.  
    43. Install the water pump pulley and tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
    44.  
    45. Install the radiator, fan blade and fan shroud assembly.
    46.  
    47. Install the accessory drive belt.
    48.  
    49. Connect the negative battery cable.
    50.  
    51. Start the engine and check for leaks.
    52.  
    53. Road test the vehicle and check for proper engine operation.
    54.  

    5.4L and 6.8L Engines
    1. Disconnect the negative battery cable.
    2.  
    3. Remove the radiator, fan blade and fan shroud assembly.
    4.  
    5. Remove the accessory drive belt.
    6.  
    7. Remove the water pump pulley.
    8.  
    9. Detach the electrical harness connectors from both ignition coils.
    10.  
    11. Remove both ignition coils with their brackets attached.
    12.  
    13. Raise and safely support the vehicle.
    14.  
    15. Remove the two upper power steering pump retaining bolts.
    16.  
    17. Remove the two lower power steering pump retaining bolts and move the pump aside.
    18.  
    19. Detach the Crankshaft Position (CKP) sensor electrical harness connector. Remove the retaining bolt and remove the CKP sensor.
    20.  



    Click image to see an enlarged view

    Fig. Fig. 29 Timing chains and related components-5.4L and 6.8L engines

    1. Drain the engine oil into a suitable container.
    2.  
    3. Remove the four oil pan-to-engine front cover retaining bolts.
    4.  
    5. Lower the vehicle.
    6.  
    7. Remove the crankshaft damper retaining bolt and washer from the crankshaft.
    8.  
    9. Install Crankshaft Damper Remover T58P-6316-D or equivalent and pull the damper from the crankshaft.
    10.  
    11. Remove the Camshaft Position (CMP) sensor retaining bolt and remove the CMP sensor.
    12.  
    13. Remove the idler pulley bolt and remove the pulley.
    14.  
    15. Remove the three belt tensioner bolts and remove the tensioner.
    16.  
    17. Remove the eight engine front cover retaining bolts and the seven nuts. Swing the top of the cover out off the dowel pins and remove the cover.
    18.  
    19. Remove the sensor ring from the crankshaft.
    20.  
    21. Use Camshaft Positioning Tool T96T-6256-A or equivalent, to position the camshaft.
    22.  
    23. Rotate the crankshaft until both camshaft key-ways are 90 degrees from the cam cover surface. Be sure the copper links line up with the dots on the camshaft sprockets.
    24.  


    WARNING
    At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or the camshaft be rotated. Severe piston and valve damage will occur.

    1. Install Camshaft Holding Tool T96T-6256-B or equivalent, on the camshaft.
    2.  
    3. Remove 2 left-hand and right-hand tensioner bolts and remove the timing chain tensioners.
    4.  
    5. Slide the left-hand and right-hand tensioner guides off the dowel pins.
    6.  
    7. Remove the right-hand timing chain from the camshaft sprocket.
    8.  
    9. Remove the left-hand timing chain from the camshaft sprocket.
    10.  
    11. Remove the left-hand and right-hand timing chain guide bolts and remove the timing chain guides.
    12.  

    To install:

    1. Examine the timing chains, looking for the copper links. If the copper links are not visible, lay the chain on a flat surface and pull the chain taught until the opposite sides of the chain contact one another. Mark the links at each end of the chain and use these marks in place of the copper links.
    2.  



    Click image to see an enlarged view

    Fig. Fig. 30 If the copper links are not visible, mark one link on one end of the chain and two links on the opposite end of the chain-5.4L and 6.8L engines

    If the engine jumped time, damage has been done to valves and possibly pistons and/or connecting rods. Any damage must be corrected before installing the timing chains.

    1. Install the left-hand and right-hand timing chain guides and retaining bolts. Tighten the retaining bolts to 71-106 inch lbs. (8-12 Nm).
    2.  
    3. If removed, install the left-hand crankshaft sprocket with the tapered part of the sprocket facing away from the engine block.
    4.  

    The crankshaft sprockets are identical. They may only be installed one way, with the tapered part of the sprockets facing each other. Ensure that the key-way and timing marks on the crankshaft sprockets are aligned.

    1. Install the left-hand timing chain on the camshaft and crankshaft sprockets. Be sure the one copper link aligns with the mark on the crankshaft sprocket and the two copper links align with the mark on the camshaft sprocket.
    2.  
    3. Install the right-hand crankshaft sprocket with the tapered part of the sprocket facing the left-hand crankshaft sprocket.
    4.  
    5. Install the right-hand timing chain on the camshaft and crankshaft sprockets. Be sure the copper links of the timing chain line up with the timing marks on both sprockets.
    6.  
    7. It is necessary to bleed the timing chain tensioners before installation. Proceed as follows:
      1. Place the timing chain tensioner in a soft-jawed vise.
      2.  
      3. Using a small pick or similar tool, hold the ratchet lock mechanism away from the ratchet stem and slowly compress the tensioner plunger by rotating the vise handle.
      4.  

    8.  


    WARNING
    The tensioner must be compressed slowly or damage to the internal seals will result.

    1. Once the tensioner plunger bottoms in the tensioner bore, continue to hold the ratchet lock mechanism and push down on the ratchet stem until flush with the tensioner face.
    2.  
    3. While holding the ratchet stem flush to the tensioner face, release the ratchet lock mechanism and install a paper clip or similar tool in the tensioner body to lock the tensioner in the collapsed position.
    4.  
    5. The paper clip must not be removed until the timing chain, tensioner, tensioner arm and timing chain guide are completely installed on the engine.
    6.  

    1. Install the left-hand and right-hand timing chain tensioner guides on the dowel pins.
    2.  
    3. Place the left-hand and right-hand timing chain tensioners in position and install the retaining bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
    4.  
    5. Remove the retaining pins from the timing chain tensioners.
    6.  
    7. Remove Cam Holding Tool T96T-6256-B or equivalent, from the camshaft.
    8.  
    9. Install the crankshaft sensor ring on the crankshaft.
    10.  
    11. Apply silicone gasket along the cylinder head-to-cylinder block and engine oil pan-to-cylinder block sealing surfaces.
    12.  
    13. Install the engine front cover carefully onto the dowel pins.
    14.  
    15. Tighten the engine front cover bolts, in sequence, in the following manner:
      1. Tighten bolts 1 through 5 to 15-22 ft. lbs. (20-30 Nm).
      2.  
      3. Tighten bolts 6 through 15 to 29-40 ft. lbs. (40-55 Nm).
      4.  

    16.  
    17. Place the idler pulley in position and install the retaining bolt. Tighten the bolt to 15-22 ft. lbs. (20-30 Nm).
    18.  
    19. Place the drive belt tensioner in position and install 3 retaining bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
    20.  
    21. Place the CMP sensor in position and install the retaining bolt. Tighten the bolt to 106 inch lbs. (12 Nm).
    22.  
    23. Install the damper on the crankshaft. Ensure the crankshaft key and key-way are aligned.
    24.  
    25. Using Crankshaft Damper Replacer T74P-6316-B or equivalent, install the crankshaft damper.
    26.  
    27. Raise and safely support the vehicle.
    28.  
    29. Install 4 front oil pan-to-engine front cover retaining bolts and tighten in sequence in 2 steps:
      1. Tighten the bolts to 15 ft. lbs. (20 Nm).
      2.  
      3. Rotate the bolts an additional 60 degrees.
      4.  

    30.  
    31. Place the CKP sensor in position and install the retaining bolt. Tighten the bolt to 106 inch lbs. (12 Nm).
    32.  
    33. Connect the CKP sensor electrical harness connector.
    34.  
    35. Install the power steering pump with 2 upper and 2 lower retaining bolts. Tighten the bolts to 15-20 ft. lbs. (20-30 Nm).
    36.  
    37. Lower the vehicle.
    38.  
    39. Place the ignition coil and brackets on the engine front cover and install the bracket bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
    40.  
    41. Connect the ignition coil and capacitor electrical harness connectors.
    42.  
    43. Connect the CMP electrical harness connector.
    44.  
    45. Install the water pump pulley and tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
    46.  
    47. Install the radiator.
    48.  
    49. Connect the negative battery cable.
    50.  
    51. Start the engine and check for leaks.
    52.  
    53. Road test the vehicle and check for proper engine operation.
    54.  

    5.8L Engine
    1. Drain the cooling system and the crankcase.
    2.  
    3. Disconnect the upper and lower radiator hoses and the transmission oil cooler lines and remove the radiator.
    4.  
    5. Disconnect the heater hose from the water pump. Slide the water pump bypass hose clamp toward the water pump.
    6.  
    7. Loosen the alternator pivot bolt and the bolt which secures the alternator adjusting arm to the water pump. Position the alternator out of the way.
    8.  
    9. Remove the power steering pump and air conditioning compressor from their mounting brackets, if so equipped.
    10.  
    11. Remove the fan, spacer, pulley and drive belts.
    12.  
    13. Remove the crankshaft pulley from the crankshaft damper. Remove the damper attaching bolt and washer and remove the damper with a puller.
    14.  
    15. If equipped with a manual fuel pump, disconnect the fuel pump outlet line at the fuel pump. Disconnect the vacuum inlet and outlet lines from the fuel pump. Remove the fuel pump attaching bolts and lay the pump to one side with the fuel inlet line still attached.
    16.  
    17. If necessary, remove the oil level dipstick and the bolt holding the dipstick tube to the exhaust manifold.
    18.  
    19. Remove the oil pan-to-cylinder front cover attaching bolts. Use a sharp, thin cutting blade to cut the oil pan gasket flush with the cylinder block. Remove the front cover and water pump as an assembly.
    20.  
    21. Discard the front cover gasket. If necessary, properly support the cover and carefully drive the oil seal out towards the front of the cover.
    22.  
    23. Rotate the crankshaft counterclockwise to take up the slack on the left side of the chain.
    24.  
    25. Establish a reference point on the cylinder block and measure from this point to the chain.
    26.  
    27. Rotate the crankshaft in the opposite direction to take up the slack on the right side of the chain.
    28.  
    29. Force the left side of the chain out with your fingers and measure the distance between the reference point and the chain. The timing chain deflection is the difference between the two measurements. If the deflection exceeds 1 / 2 in. (13mm), replace the timing chain and sprockets.
    30.  
    31. Turn the crankshaft until the timing marks on the sprockets are aligned vertically.
    32.  
    33. Remove the camshaft sprocket retaining screw, if equipped, remove the fuel pump eccentric and washers.
    34.  
    35. Alternately slide both of the sprockets and timing chain off the crankshaft and camshaft until free of the engine.
    36.  

    To install:

    1. Clean the front cover mating surfaces of all gasket material and/or sealer. If the front cover seal is being replaced, support the cover to prevent damage and drive out the seal. Coat the new seal with heavy SJ engine oil and install it in the cover, making sure it is not cocked.
    2.  
    3. Position the timing chain on the sprockets so that the timing marks on the sprockets are aligned vertically. Alternately slide the sprockets and chain onto the crankshaft and camshaft sprockets.
    4.  
    5. If equipped with a manual fuel pump, install the fuel pump eccentric washers and attaching bolt on the camshaft sprocket. Tighten to 40-45 ft. lbs.
    6.  
    7. Cut the new oil pan gasket as needed for a correct fit. Apply sealing compound to the oil pan and fit the gasket into place.
    8.  
    9. Apply sealing compound to the gasket surfaces on the cylinder block and back side of the front cover. Position the gasket onto the cylinder block and fit the front cover onto the engine.
    10.  
    11. Coat the screw threads with sealing compound and start all the screws. Center the cover by inserting an alignment tool (T74P-6019-a or equivalent) in the oil seal.
    12.  
    13. Tighten the oil pan screws first to 12-18 ft. lbs. (17-24 Nm), then tighten the front cover screws to the same torque.
    14.  
    15. Apply Lubriplate® or equivalent to the oil seal lip and to the vibration damper to prevent damage to the seal. Coat the front of the crankshaft with engine oil for damper installation.
    16.  
    17. Line up the damper key-way with the key on the crankshaft and push the damper onto the crankshaft. Install the bolt and washer and tighten to 80 ft. lbs. Install the crankshaft pulley.
    18.  
    19. Install the fan, spacer, pulley and drive belts.
    20.  
    21. Install the bolts holding the fan shroud to the radiator, if so equipped.
    22.  
    23. Install the power steering pump and air conditioning compressor.
    24.  
    25. Install the alternator and adjust the belt tension.
    26.  
    27. Connect the heater hose at the water pump.
    28.  
    29. Install the radiator.
    30.  
    31. Connect the upper and lower radiator hoses, and transmission oil cooler lines.
    32.  
    33. Fill the cooling system and the crankcase.
    34.  



    Click image to see an enlarged view

    Fig. Fig. 31 Align the marks when installing the timing chain-5.8L and 7.5L engines

    7.5L Engine


    Click image to see an enlarged view

    Fig. Fig. 32 Align the timing marks on the pulleys



    Click image to see an enlarged view

    Fig. Fig. 33 Alternately slide both of the sprockets and timing chain off the crankshaft and camshaft until free of the engine

    1. Drain the cooling system and crankcase.
    2.  
    3. Remove the radiator shroud and fan.
    4.  
    5. Disconnect the upper and lower radiator hoses and the automatic transmission oil cooler lines from the radiator.
    6.  
    7. Remove the radiator upper support and remove the radiator.
    8.  
    9. Loosen the alternator attaching bolts and air conditioning compressor idler pulley and remove the drive belts with the water pump pulley. Remove the bolts attaching the compressor support to the water pump and remove the bracket (support), if equipped.
    10.  
    11. Remove the crankshaft pulley from the vibration damper. Remove the bolt and washer attaching the crankshaft damper and remove the damper with a puller. Remove the woodruff key from the crankshaft.
    12.  
    13. Loosen the bypass hose at the water pump and disconnect the heater return tube at the water pump.
    14.  
    15. Disconnect and plug the fuel inlet and outlet lines at the fuel pump and remove the fuel pump.
    16.  
    17. Remove the bolts attaching the front cover to the cylinder block. Cut the oil pan seal flush with the cylinder block face with a thin knife blade prior to separating the cover from the cylinder block. Remove the cover and water pump as an assembly. Discard the front cover gasket and oil pan seal.
    18.  
    19. Rotate the crankshaft counterclockwise to take up the slack on the left side of the chain.
    20.  
    21. Establish a reference point on the cylinder block and measure from this point to the chain.
    22.  
    23. Rotate the crankshaft in the opposite direction to take up the slack on the right side of the chain.
    24.  
    25. Force the left side of the chain out and measure the distance between the reference point and the chain. The timing chain deflection is the difference between the two measurements. If the deflection exceeds 1 / 2 in. (13mm), replace the timing chain and sprockets.
    26.  
    27. Turn the crankshaft until the timing marks on the sprockets are aligned vertically.
    28.  
    29. Remove the camshaft sprocket retaining screw and remove the fuel pump eccentric and washers.
    30.  
    31. Alternately slide both of the sprockets and timing chain off the crankshaft and camshaft until free of the engine.
    32.  

    To install:

    1. Position the timing chain on the sprockets so the timing marks on the sprockets are aligned vertically. Alternately slide the sprockets and chain onto the crankshaft and camshaft sprockets.
    2.  
    3. Install the fuel pump eccentric washers and attaching bolt on the camshaft sprocket. Tighten to 40-45 ft. lbs. (54-61 Nm).
    4.  
    5. Transfer the water pump if a new cover is going to be installed. Clean all of the gasket sealing surfaces on both the front cover and the cylinder block.
    6.  
    7. Coat the gasket surface of the oil pan with sealer. Cut and position the required sections of a new seal on the oil pan. Apply sealer to the corners.
    8.  
    9. Drive out the old front cover oil seal with a pin punch. Clean out the seal recess in the cover. coat a new seal with Lubriplate® or equivalent grease. Install the seal, making sure the seal spring remains in the proper position. A front cover seal tool, Ford part no. T72J-117 or equivalent, makes installation easier.
    10.  
    11. Coat the gasket surfaces of the cylinder block and cover with sealer and position the new gasket on the block.
    12.  
    13. Position the front cover on the cylinder block. Use care not to damage the seal and gasket or misplace them.
    14.  
    15. Coat the front cover attaching screws with sealer and install them.
    16.  

    It may be necessary to force the front cover downward to compress the oil pan seal in order to install the front cover attaching bolts. Use a prybar or drift to engage the cover screw holes through the cover and pry downward.

    1. Install the fuel pump.
    2.  
    3. Connect the fuel inlet and outlet lines at the fuel pump.
    4.  
    5. Tighten the bypass hose at the water pump.
    6.  
    7. Connect the heater return tube at the water pump.
    8.  
    9. Install the woodruff key from the crankshaft.
    10.  
    11. Install the damper.
    12.  
    13. Install the crankshaft pulley on the vibration damper.
    14.  
    15. Install the compressor support on the water pump and install the bracket (support), if equipped.
    16.  
    17. Install the drive belts with the water pump pulley.
    18.  
    19. Install the radiator and upper support.
    20.  
    21. Connect the upper and lower radiator hoses and the automatic transmission oil cooler lines.
    22.  
    23. Install the radiator shroud and fan.
    24.  
    25. Fill the cooling system and crankcase.
    26.  

    Tighten the fasteners to the following specifications:



    Front cover bolts: 15-20 ft. lbs. (20-27 Nm)
     
    Water pump attaching screws: 12-15 ft. lbs. (16-20 Nm)
     
    Crankshaft damper: 70-90 ft. lbs. (95-122 Nm)
     
    Crankshaft pulley: 35-50 ft. lbs. (47-68 Nm)
     
    Fuel pump: 19-27 ft. lbs. (26-37 Nm)
     
    Oil pan bolts: 9-11 ft. lbs. (12.2-15.0 Nm) for the 5 / 16 in. (7.9mm) screws and to 7-9 ft. lbs. (9.5-12.2 Nm) for the 1 / 4 in. (6.3mm) screws
     
    Alternator pivot bolt: 45-57 ft. lbs. (61-77 Nm)
     

     
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