REMOVAL & INSTALLATION
See Figures 1, 2 and 3
This procedure applies to the 8 cylinder engines only. 6 cylinder models use timing gears.Except 7.5L Engines
- Drain the cooling system, remove the air cleaner and disconnect the battery.
- Disconnect the transmission cooler lines and radiator hoses and remove the radiator.
- Disconnect the heater hose at the water pump. Slide the water pump bypass hose clamp toward the pump.
- Loosen the alternator mounting bolts at the alternator. Remove the alternator support bolt at the water pump. Remove the Thermactor® pump on all engines equipped. If equipped with power steering or air conditioning, unbolt the component, remove the belt, and lay the pump or compressor aside with the lines attached.
- Remove the fan, spacer, pulley, and drive belt.
- Drain the crankcase oil.
- Remove the pulley from the crankshaft pulley adapter. Remove the capscrew and washer from the front end of the crankshaft. Remove the crankshaft pulley adapter with a puller.
- On 6.4L and 7.0L engines, use a suitable tool to pull the crankshaft sleeve away from the cylinder front cover. Remove the sleeve from the engine.
- On carbureted models, disconnect the fuel pump outlet line at the pump. Remove the fuel pump retaining bolts and lay the pump to the side. Remove the engine oil dipstick.
- Remove the front cover attaching bolts. Remove the front cover assembly.
- Remove the crankshaft oil slinger, if equipped.
- Check timing chain deflection if required.
- Rotate the engine until the sprocket timing marks are aligned and engine is at TDC on compression stroke and distributor rotor is in No. 1 cylinder firing position.
- Remove the camshaft sprocket capscrew, washers, and fuel pump eccentric. Slide both sprockets and chain forward and off as an assembly.
- Position the sprockets and chain on the camshaft and crankshaft with both timing marks dot-to-dot on a centerline. Refer to the illustration in this section. The engine timing gear marks must be aligned and engine must be at TDC on compression stroke and distributor rotor at No. 1 cylinder firing position. Install the fuel pump eccentric, washers and sprocket attaching bolt. Tighten the sprocket attaching bolt to 40-45 ft. lbs. (54-61 Nm).
- Install the crankshaft front oil slinger.
- Clean the front cover and mating surfaces of old gasket material. Install a new oil seal in the cover. Use a seal driver tool, if available.
- Coat a new cover gasket with sealer and position it on the block.
Trim away the exposed portion of the oil pan gasket flush with the cylinder block. Cut and position the required portion of a new gasket to the oil pan, applying sealer to both sides of it.
- Install the front cover, using a crankshaft-to-cover alignment tool. Coat the threads of the attaching bolts with sealer. Tighten the attaching bolt evenly to 12-15 ft. lbs. (16-20 Nm).
- Install the fuel pump and connect the fuel pump outlet tube.
- Install the crankshaft pulley adapter and tighten the attaching bolt. Install the crankshaft pulley. Refer to the Torque Specification chart in this section.
- Install the water pump pulley, drive belt, spacer and fan.
- Install the alternator support bolt at the water pump. Tighten the alternator mounting bolts. Adjust the drive belt tension. Install the Thermactor® pump if so equipped.
- Install the radiator and connect all coolant and heater hoses. Connect the battery cables.
- Refill the cooling system and the crankcase. Install the dipstick.
- Start the engine. Check for leaks. Adjust the ignition timing and make all final adjustments.
- Disconnect the negative battery cable.
- Drain the cooling system and crankcase oil.
- Remove the radiator shroud and fan.
- Disconnect the upper and lower radiator hoses, and the automatic transmission oil cooler lines from the radiator.
- Remove the radiator upper support and remove the radiator.
- 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 so equipped.
- 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.
- Loosen the bypass hose at the water pump, and disconnect the heater return tube at the water pump.
- Disconnect and plug the fuel inlet and outlet lines at the fuel pump, and remove the fuel pump.
- 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.
- Turn the crankshaft until the timing marks on the sprockets are aligned vertically.
- Remove the camshaft sprocket retaining bolt and remove the fuel pump eccentric and washers.
- Alternately slide both of the sprockets and timing chain off the crankshaft and camshaft until free of the engine.
- The engine timing gear marks (refer to the illustration in this section) must be aligned and the engine must be at TDC on compression stroke and distributor rotor pointed at No. 1 cylinder firing position. 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.
- Install the fuel pump eccentric washers and attaching bolt on the camshaft sprocket. Tighten to 40-45 ft. lbs. (54-61 Nm).
- 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.
- 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.
- 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.
- Coat the gasket surfaces of the cylinder block and cover with sealer and position the new gasket on the block.
- Position the front cover on the cylinder block. Use care not to damage the seal and gasket or mis-align them.
- Coat the front cover attaching screws with sealer and install them.
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 screwdriver or drift to engage the cover screw holes through the cover and pry downward.
- Assemble and install the remaining components in the reverse order of removal.
CHECKING TIMING CHAIN DEFLECTION
See Figure 4
To measure timing chain deflection, rotate the crankshaft clockwise to take up any slack on the left side of the chain. Choose a reference point and measure the distance from this point to the chain. Rotate the crankshaft in the opposite direction to take up slack on the right side of the chain. Force the left (slack) side of the chain out and measure the distance from the chain to the reference point chosen earlier. The difference between the two measurements is the deflection. The timing chain should be replaced if the deflection measurement exceeded the specified limit of 1 / 2 in. (13mm).