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    1994 BMW 540I 4.0L EFI DOHC 8cyl

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    Lincoln Blackwood, Ford F-Series Pick-ups, Lincoln Mark LT 2001-2006

    Timing Chain Cover, Chain & Sprockets 3

    Print

    Removal & Installation



    2004 F-150 5.4L Engine, 2005 F-150, 250, 350 5.4L Engine; 2006 Mark LT 5.4L Engine
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Raise and safely support the vehicle.
    4.  
    5. Drain the engine oil.
    6.  
    7. Remove the engine cooling fan.
    8.  
    9. Remove the right valve cover.
    10.  
    11. Remove the left valve cover.
    12.  
    13. Rotate the tensioner clockwise and remove the accessory drive belt.
    14.  
    15. Remove the nut and position aside the transmission cooler tube support bracket.
    16.  
    17. Remove the nut and position aside the power steering pressure hose support bracket.
    18.  
    19. Using the special tool, remove the power steering pump pulley.
    20.  
    21. Disconnect the power steering pressure tube. Drain the power steering fluid into a suitable container.
    22.  
    23. Remove the 3 bolts and position the power steering pump aside.
    24.  
    25. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
    26.  
    27. Using the special tool, remove the crankshaft pulley.
    28.  
    29. Using the special tool, remove the crankshaft front seal.
    30.  
    31. Remove the 3 bolts and the 3 accessory drive idler pulleys.
    32.  
    33. Remove the 4 bolts and the coolant pump pulley.
    34.  
    35. Remove the 3 bolts and the accessory drive belt tensioner.
    36.  
    37. Disconnect the right camshaft position (CMP) sensor electrical connector.
    38.  
    39. Remove the bolt and the right CMP sensor. Discard the O-ring seal.
    40.  
    41. Remove the nut and the upper radiator hose support bracket.
    42.  
    43. Remove the nut and position the right radio ignition interference capacitor aside.
    44.  
    45. Disconnect the left CMP sensor electrical connector.
    46.  
    47. Remove the bolt and the left CMP sensor. Discard the O-ring seal.
    48.  
    49. Remove the nut and position the left radio ignition interference capacitor aside.
    50.  
    51. Disconnect the crankshaft position (CKP) sensor electrical connector.
    52.  
    53. Remove the 4 front oil pan bolts.
    54.  
    55. Remove the bolts and the studs.
      WARNING
      Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

    56.  
    57. Remove the engine front cover from the front cover to cylinder block dowel.
    58.  
    59. Remove the engine front cover gaskets.
    60.  
    61. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    62.  
    63. Inspect the mating surfaces.
    64.  
    65. Remove the bolt and the CKP sensor. Discard the O-ring seal.
    66.  
    67. Remove the crankshaft sensor ring from the crankshaft.

      Click image to see an enlarged view

      Fig. Position the crankshaft keyway at the 12 o'clock position-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    68.  
    69. Position the crankshaft keyway at the 12 o'clock position.
      NOTE
      If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.



      Click image to see an enlarged view

      Fig. The number 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the number 1 cylinder-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    70.  
    71. The number 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the number 1 cylinder.
      WARNING
      If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.



      Click image to see an enlarged view

      Fig. Remove only these 3 roller followers from the right cylinder head-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    72.  
    73. Remove only the 3 roller followers shown in the illustration from the right cylinder head.
      WARNING
      Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.


      NOTE
      It may be necessary to push the valve down while compressing the spring.



      Click image to see an enlarged view

      Fig. Using special tool 303-1039-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    74.  
    75. Using special tool 303-1039, remove the 3 designated roller followers in the previous step from the right cylinder head.
      WARNING
      If the components are to be reinstalled, they must be installed in the same positions.

    76.  
    77. Mark the components for installation into their original locations.

      Click image to see an enlarged view

      Fig. Remove only these 3 roller followers from the left cylinder head-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    78.  
    79. Remove only the 3 roller followers shown in the illustration from the left cylinder head.
      WARNING
      Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.


      NOTE
      It may be necessary to push the valve down while compressing the spring.



      Click image to see an enlarged view

      Fig. Using the special tool, remove the 3 designated roller followers from the left cylinder head-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    80.  
    81. Using the special tool, remove the 3 designated roller followers in the previous step from the left cylinder head.
      WARNING
      The crankshaft cannot be moved past the 6 o'clock position once set.

    82.  
    83. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
      WARNING
      If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.



      Click image to see an enlarged view

      Fig. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine



      Click image to see an enlarged view

      Fig. Remove the bolts, the left timing chain tensioner and tensioner arm-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    84.  
    85. Remove the bolts, the left timing chain tensioner and tensioner arm.
      WARNING
      If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

    86.  
    87. Remove the bolts, the right timing chain tensioner and tensioner arm.

      Click image to see an enlarged view

      Fig. Remove the right timing chain tensioner and tensioner arm-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    88.  
    89. Remove the right timing chain from the camshaft sprocket.
    90.  
    91. Remove the right timing chain from the crankshaft sprocket.
    92.  
    93. Remove the left timing chain from the camshaft sprocket.
    94.  
    95. Remove the left timing chain and crankshaft sprocket.

      Click image to see an enlarged view

      Fig. Remove the right and left timing chains-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    96.  
    97. Remove the bolts. Remove both timing chain guides.
      WARNING
      Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.


      WARNING
      Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.



      Click image to see an enlarged view

      Fig. Remove both timing chain guides, right shown; left similar-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    98.  
    99. Using the special tool, remove the bolt and the right camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.
      WARNING
      Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.


      WARNING
      Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.



      Click image to see an enlarged view

      Fig. Using the special tool, remove the bolt and the right camshaft phaser sprocket assembly-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    100.  
    101. Using the special tool, remove the bolt and the left camshaft phaser sprocket assembly. Discard the camshaft phaser sprocket bolt.
      WARNING
      Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.


      NOTE
      The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.



      Click image to see an enlarged view

      Fig. Using the special tool, remove the bolt and the left camshaft phaser sprocket assembly-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    102.  
    103. Remove the bolts in the sequence shown and remove the right cylinder head front camshaft bearing cap and then the remaining bearing caps.

      Click image to see an enlarged view

      Fig. Camshaft bearing cap removal/installation sequence-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    104.  
    105. Clean and inspect the right camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.

      Click image to see an enlarged view

      Fig. The camshaft front thrust bearing cap contains an oil metering groove-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    106.  
    107. Remove the right camshaft.
      WARNING
      Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.


      NOTE
      The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.

    108.  
    109. Remove the bolts in the sequence shown and remove the left cylinder head front camshaft bearing cap and then the remaining bearing caps.
    110.  
    111. Clean and inspect the left camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
    112.  
    113. Remove the left camshaft.
      WARNING
      If the components are to be reinstalled, they must be installed in the same positions.

    114.  
    115. Mark the components for installation into their original locations.
    116.  
    117. Remove all of the remaining roller followers from the cylinder heads.
    118.  

    To install:

    1. Install the left and right camshafts. Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
    2.  
    3. Lubricate the camshaft bearing caps with clean engine oil.
    4.  
    5. Position the front camshaft bearing cap.
    6.  
    7. Position the remaining camshaft bearing caps.
    8.  
    9. Install the bolts loosely.
    10.  
    11. Tighten to 10 Nm (89 inch lbs.) in the sequence shown.
      WARNING
      Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

    12.  
    13. Install the camshaft phaser sprockets and new camshaft phaser bolts finger tight.
      WARNING
      Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.


      WARNING
      Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.

    14.  
    15. Using the special tool, tighten the left and right camshaft phaser sprocket bolts in 2 stages.

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

      Click image to see an enlarged view

      Fig. Position the crankshaft with the special tool-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

       

    16.  
    17. Position the crankshaft with the special tool, then remove the tool.
      WARNING
      Timing chain procedures must be followed exactly or damage to valves and pistons will result.


      WARNING
      Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

    18.  
    19. Compress the tensioner plunger, using a vise.
    20.  
    21. Install a retaining clip on the tensioner to hold the plunger in during installation.
    22.  
    23. Remove the tensioner from the vise.
    24.  
    25. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
    26.  
    27. Install the crankshaft sprocket, making sure the flange faces forward.

      Click image to see an enlarged view

      Fig. Right and left timing chain guides installed-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    28.  
    29. Install the 4 bolts and the left and right timing chain guides. Tighten to 10 Nm (89 inch lbs.).

      Click image to see an enlarged view

      Fig. Position the lower end of the left (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    30.  
    31. Position the lower end of the left (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.
      NOTE
      Make sure the upper half of the timing chain is below the tensioner arm dowel.



      Click image to see an enlarged view

      Fig. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 copper (marked) chain links-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    32.  
    33. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 copper (marked) chain links.
      NOTE
      The left timing chain tensioner arm has a bump near the dowel hole for identification.

    34.  
    35. Position the left timing chain tensioner arm on the dowel pin and install the left timing chain tensioner and bolts. Tighten to 25 Nm (18 ft. lbs.).
    36.  
    37. Remove the retaining clip from the left timing chain tensioner.

      Click image to see an enlarged view

      Fig. Position the lower end of the right (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    38.  
    39. Position the lower end of the right (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
      NOTE
      The lower half of the timing chain must be positioned above the tensioner arm dowel.



      Click image to see an enlarged view

      Fig. Position the right timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 copper (marked) chain links-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    40.  
    41. Position the right timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 copper (marked) chain links.
    42.  
    43. Position the right timing chain tensioner arm on the dowel pin and install the right timing chain tensioner and bolts. Tighten to 25 Nm (18 ft. lbs.).
    44.  
    45. Remove the retaining clip from the right timing chain tensioner.
    46.  
    47. As a post-check, verify correct alignment of all timing marks.

      Click image to see an enlarged view

      Fig. As a post-check, verify correct alignment of all timing marks-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    48.  
    49. Install the crankshaft sensor ring on the crankshaft.
      WARNING
      If the components are to be reinstalled, they must be installed into their original locations.

    50.  
    51. Using the special tool, install all of the camshaft roller followers. Lubricate the roller followers with clean engine oil prior to installation.
    52.  
    53. Install the crankshaft position (CKP) sensor and the bolt. Tighten to 10 Nm (89 inch lbs.).
      WARNING
      Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.


      NOTE
      If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.


      NOTE
      Make sure that the engine front cover gasket is in place on the engine front cover before installation.



      Click image to see an enlarged view

      Fig. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine



      Click image to see an enlarged view

      Fig. Front cover fastener identification-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    54.  
    55. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
    56.  
    57. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.
    58.  
    59. Tighten the engine front cover fasteners in sequence in 2 stages.

      Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 ft. lbs.).
       
      Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 ft. lbs.).
       

    60.  
    61. Loosely install the oil pan-to-front cover bolts, then tighten the bolts in 2 stages, in the sequence shown.

      Stage 1: Tighten to 20 Nm (15 ft. lbs.).
       
      Stage 2: Tighten an additional 60 degrees.
       

    62.  
    63. Connect the CKP sensor electrical connector.
    64.  
    65. Position the power steering pump assembly and install the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
    66.  
    67. Using the special tool, install a new O-ring seal on the pressure line fitting.
    68.  
    69. Connect the power steering pressure tube. Tighten to 65 Nm (48 ft. lbs.).
    70.  
    71. Using an installer, install the power steering pump pulley.
    72.  
    73. Position the power steering pressure hose support bracket and install the nut. Tighten to 10 Nm (89 inch lbs.).
    74.  
    75. Position the transmission cooler tube support bracket and install the nut. Tighten to 10 Nm (89 inch lbs.).
      NOTE
      Lubricate the O-ring seal with clean engine oil prior to installation.

    76.  
    77. Using a new O-ring seal, install the right camshaft position (CMP) sensor and the bolt. Tighten to 10 Nm (89 inch lbs.).
    78.  
    79. Connect the right CMP sensor electrical connector.
    80.  
    81. Install the left radio ignition interference capacitor and the nut. Tighten to 10 Nm (89 inch lbs.).
      NOTE
      Lubricate the O-ring seal with clean engine oil prior to installation.

    82.  
    83. Using a new O-ring seal, install the left CMP sensor and the bolt. Tighten to 10 Nm (89 inch lbs.).
    84.  
    85. Connect the left CMP sensor electrical connector.
    86.  
    87. Install the right radio ignition interference capacitor and the nut. Tighten to 10 Nm (89 inch lbs.).
    88.  
    89. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
    90.  
    91. Install the coolant pump pulley and the 4 bolts. Tighten to 25 Nm (18 ft. lbs.).
    92.  
    93. Install the 3 accessory drive idler pulleys and the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
    94.  
    95. Position the upper radiator hose support bracket and install the nut. Tighten to 10 Nm (89 inch lbs.).
    96.  
    97. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

      Click image to see an enlarged view

      Fig. Front seal installation-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    98.  
    99. Using the special tools, install the crankshaft seal into the engine front cover.
      NOTE
      If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

    100.  
    101. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. Use the special tool to install the crankshaft pulley.

      Click image to see an enlarged view

      Fig. Crankshaft pulley installation-2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

    102.  
    103. Tighten the new crankshaft pulley bolt in 4 stages.

      Stage 1: Tighten to 90 Nm (66 ft. lbs.).
       
      Stage 2: Loosen 360 degrees.
       
      Stage 3: Tighten to 50 Nm (37 ft. lbs.).
       
      Stage 4: Tighten an additional 90 degrees.
       

    104.  
    105. Rotate the tensioner clockwise and install the accessory drive belt.
    106.  
    107. Install the right valve cover.
    108.  
    109. Install the left valve cover.
    110.  
    111. Install the engine cooling fan.
    112.  
    113. Fill the crankcase with clean engine oil.
    114.  

    4.2L Engine
    1. Before servicing the vehicle, refer to the Precautions Section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Accessory drive belt
       
      Coolant
       
      Radiator, fan blade assembly and fan shroud
       
      Water pump
       
      Exhaust Gas Recirculation (EGR) valve vacuum hose
       
      EGR tube upper fitting
       
      EGR valve and adapter assembly
       
      Wiring harness from the heater water outlet tube
       
      Heater water outlet bolt and position the outlet tube aside
       
      Camshaft Position (CMP) sensor electrical harness connector and mark the position of the connector for proper installation.

      Click image to see an enlarged view

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

       

    4.  
    5. Rotate the crankshaft until the Top Dead Center (TDC) timing mark lines up with the timing mark.
      NOTE
      The oil pump drive shaft may come out with the camshaft synchronizer.



      The 2 bolts retaining the CMP and remove the CMP from the camshaft synchronizer.
       
      Camshaft synchronizer adjustment bolt and remove the camshaft synchronizer.
       



      Engine oil
       
      Crankshaft pulley and damper
       
      Engine oil pan
       
      The 2 engine front cover stud bolts, front cover bolt and cap screw
       
      Engine front cover and gasket off the dowels and discard the gasket.
       
      CMP sensor drive gear bolt and drive gear
       

    6.  
    7. Be sure the timing marks and keyways align.
    8.  
    9. Compress and install a retaining pin to hold the timing chain tensioner.
    10.  
    11. Slide both sprockets and timing chain forward and remove as an assembly.
    12.  
    13. Remove the 3 bolts retaining the timing chain tensioner and remove the tensioner.
    14.  
    15. Check the timing chain and sprockets for excessive wear. Replace if necessary.
    16.  

    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 3 retaining bolts. Tighten the bolts to 72-120 inch 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.

      Click image to see an enlarged view

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

    10.  
    11. Inspect the engine front cover seal for wear or damage and replace if necessary.
    12.  
    13. Install or connect the following:
      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.



      Engine front cover gasket and front cover onto the guide studs
       
      The 2 engine front cover stud bolts, front cover bolt and cap screw. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
       
      Engine oil pan
       
      Crankshaft damper and pulley
       

    14.  
    15. 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.
    16.  
    17. Install the camshaft synchronizer housing assembly so that the arrow on the tool is 54 degrees from the centerline of the engine.
    18.  
    19. Install the adjustment bolt and tighten to 15-22 ft. lbs. (21-30 Nm).
    20.  
    21. 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.
    22.  
    23. Install or connect the following:

      Water pump
       
      Fan shroud, fan blade assembly and radiator
       
      Accessory drive belt
       

    24.  
    25. Fill the crankcase with the correct amount and type of engine oil.
    26.  
    27. Fill and bleed the engine cooling system.
    28.  
    29. Connect the negative battery cable.
    30.  
    31. Start the engine and check for coolant and oil leaks.
    32.  
    33. Road test the vehicle and check for proper engine operation.
    34.  

     
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