REMOVAL & INSTALLATION
See Figure 1
- Drain the cooling system and crankcase.
- Disconnect the upper radiator hose from the intake manifold and the lower hose from the water pump. On cars with automatic transmission, disconnect the fluid cooler lines from the radiator.
- Remove the radiator, fan and pulley, and engine drive belts. On models with air conditioning, remove the condenser retaining bolts and position the condenser forward. Do not disconnect the refrigerant lines.
- Remove the cylinder front cover retaining bolts and front oil pan bolts, and gently pry the cover away from the block.
- Remove the crankshaft pulley bolt and use a puller to remove the vibration damper.
- With a socket wrench of the proper size on the crankshaft pulley bolt, gently rotate the crankshaft in a clockwise direction until all slack is removed from the left side of the timing chain. Scribe a mark on the engine block parallel to the present position on the left side of the chain. Next, turn the crankshaft in a counterclockwise direction to remove all the slack from the right side of the chain. Force the left side of the chain outward with your fingers and measure the distance between the reference point and the present position of the chain. If the distance exceeds 1 / 2 in. (13mm), replace the chain and sprockets.
- Crank the engine until the timing marks are aligned as shown in the illustration. Remove the bolt, slide the sprocket and chain forward and remove them as an assembly.
- Position the sprockets and chain on the engine, making sure that the timing marks are aligned, dot-to-dot.
- Install the front cover, applying oil resistant sealer to the new gasket. Trim away the exposed portion of the old oil pan gasket flush with the front of the engine block. Cut and position the required portion of a new gasket to the oil pan, applying sealer to both sides of it.
- Install the cylinder front cover retaining bolts and front oil pan bolts, and tighten them to 6-9 ft. lbs. (8-12 Nm).
- Install the vibration damper or pulley on the crankshaft and torque the bolt to 85-100 ft. lbs. (110-130 Nm).
- Install the fan, pulley and belts. Adjust the belt tension.
- Install the radiator and connect the radiator hoses and transmission cooling lines, if applicable. If equipped with air conditioning, install the condenser.
- Fill the crankcase and cooling system. Start the engine and check for leaks.
See Figures 2 and 3
- Disconnect the negative battery cable from the battery. Drain the cooling system.
- Remove the air cleaner and air duct assemblies.
- Remove the radiator fan shroud and position it back over the water pump. Remove the fan clutch assembly and shroud.
- Remove the drive belt(s). If equipped with power steering, remove the pump with the hoses attached and position it out of the way. Be sure to keep the pump upright to prevent fluid leakage.
- If your car is equipped with air conditioning, remove the front compressor mounting bracket. It is not necessary to remove the compressor.
- Disconnect the coolant bypass hose and the heater hose at the water pump.
- Disconnect the upper radiator hose at the thermostat housing.
- Remove the distributor.
- If your car is equipped with a trip reminder, remove the flow meter support bracket and allow the meter to be supported by the hoses.
- Raise the front of the car and support on jackstands.
- Remove the crankshaft pulley using a suitable puller. Remove the fuel pump shield.
- If carburetor equipped, disconnect the fuel line from the carburetor at the fuel pump, then remove the mounting bolts and the fuel pump. Position pump out of the way with the tank line still attached.
- Drain the engine oil and remove the oil filter.
- Disconnect the lower radiator hose at the water pump.
- Remove the oil pan mounting bolts and lower the oil pan.
The front cover cannot be removed unless the oil pan is lowered.
- Lower the car from the jackstands.
- Remove the front cover mounting bolts. It is not necessary to separate the water pump.
A front cover mounting bolt is located behind the oil filter adapter. If this bolt is not removed and the cover is pried upon, breakage will occur.
- Remove the timing indicator. Remove the front cover and water pump as an assembly.
- Remove the camshaft thrust button and spring from the end of the camshaft. Remove the camshaft sprocket attaching bolts.
- Remove the camshaft sprocket, crankshaft sprocket and timing chain by pulling forward evenly on both sprockets. If the crankshaft sprocket is difficult to remove, position two small prybars, one on each side, behind the sprocket and pry forward.
- Clean all gasket surfaces on the front cover, cylinder block, fuel pump and oil pan.
Install a new front cover oil seal. If a new front cover is to be installed:
- Install the oil pump, oil filter adapter and intermediate shaft from the old cover.
- Remove the water pump from the old cover.
- Clean the mounting surface, and install a new mounting gasket with the water pump on the new front cover. Tighten the pump attaching bolts to 15-22 ft. lbs. (19-29 Nm).
- Rotate the crankshaft, if necessary, to bring No. 1 piston to TDC with the crankshaft keyway at the 12 o'clock position.
- Lubricate the timing chain with motor oil. Install the chain over the two sprockets making sure that the marks on both sprockets are positioned across from each other. Install the sprockets and chain on the cam and crankshaft. Install the camshaft mounting bolts. Tighten the bolts to 15-22 ft. lbs. (19-29 Nm)
- Install the camshaft thrust button and spring. Lubricate the thrust button with polyethylene grease before installation.
- Position a new cover gasket on the front of the engine and install the cover and water pump assemblies. Install the timing indicator. Torque the front cover bolts to 15-22 ft. lbs. (19-29 Nm).
- Install the oil pan.
- Connect the lower radiator hose at the water pump.
- Install the oil filter.
- Fill the crankcase.
- Install the fuel pump, if removed.
- Connect the fuel line at the carburetor and at the fuel pump, if removed.
- Install the crankshaft pulley.
- Install the fuel pump shield.
- Lower the front of the car.
- If your car is equipped with a trip reminder, install the flow meter support bracket.
- Connect the upper radiator hose at the thermostat housing.
- Install the distributor.
- Connect the coolant bypass hose and the heater hose at the water pump.
- If your car is equipped with air conditioning, install the front compressor mounting bracket.
- If equipped with power steering, install the pump. Be sure to keep the pump upright to prevent fluid leakage.
- Install the drive belt(s) and adjust to the proper tension.
- Install the fan clutch assembly.
- Install the radiator fan shroud.
- Install the air cleaner and air duct assemblies.
- Connect the negative battery cable at the battery.
- Fill the cooling system.
EXCEPT 7.5L ENGINES
See Figures 4 through 17
- Disconnect the negative battery cable, and drain the cooling system.
- Remove the air cleaner assembly, if mounted above the intake manifold.
- Disconnect the radiator hoses and transmission cooler lines, if so equipped, 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 so 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 and remove the engine oil dipstick.
- 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 carburetor equipped engines, disconnect the fuel outlet line at the fuel pump, then remove the fuel pump retaining bolts and lay the pump to the side.
- Remove the front cover attaching bolts.
- Remove the crankshaft oil slinger, if so equipped.
- Check timing chain deflection, using the procedure outlined in Step 6 of the 6-200 engine Timing Chain Removal.
- Rotate the engine until the sprocket timing marks are aligned as shown in the valve timing illustration.
- Remove the camshaft sprocket bolt or capscrew, washers, and fuel pump eccentric or spacer. Slide the cam sprocket with the chain forward and off as an assembly.
- If removing the crankshaft gear, use a gear puller to separate the gear from the crankshaft and keyway.
- If both the camshaft and crankshaft sprockets were removed, position the sprockets and chain on the camshaft and crankshaft with both timing marks facing dot-to-dot on a centerline. If only one sprocket was removed, you will have to carefully align the chain and removed sprocket in relation to the installed sprocket. In most cases, it is easier to remove the sprocket and align all the dots and install. Position the fuel pump eccentric or spacer, washers and sprocket attaching bolt or capscrew. Torque the sprocket attaching bolt or capscrew to 40-45 ft. lbs. (52-58 Nm).
- Install the crankshaft front oil slinger, if applicable.
- 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. Torque the attaching bolts to 12-18 ft. lbs. (16-23 Nm).
- If removed, install the fuel pump and connect the fuel pump outlet tube.
- Install the crankshaft pulley adapter and torque the attaching bolt. Install the crankshaft pulley.
- 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.
- Install the engine oil dipstick. Refill the cooling system and the crankcase.
- Connect the negative battery cable.
- Start the engine and operate it at fast idle. Check for leaks.
- Install the air cleaner assembly, if removed. Adjust the ignition timing and make all final adjustments.
- Disconnect the negative battery cable.
- Drain the cooling system.
- 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 18
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).