Thursday, March 15, 2012

How To Replace Timing Chain, Sprockets & Front Cover on Ford Expedition and Lincoln Navigator?


The procedure is similar for both ford and Lincoln car models:-----

The details to replace Timing Chain, Sprockets & Front Cover are as follows:------

  

Removal & Installation



  1. Before servicing the vehicle, refer to the precautions section.
  2. Drain the engine oil.
  3. Remove the engine cooling fan.
  4. Remove the valve covers.
  5. Remove the accessory drive belt.
  6. Remove the nut and the power steering pressure hose support bracket.
  7. Remove the nut and the transmission cooler tube support bracket.
  8. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
  9. Using the tool 303-009, remove the crankshaft pulley.
  10. Using the tool 303-107, remove the crankshaft front seal.
  11. Remove the bolts and the accessory drive idler pulleys.
  12. Remove the bolts and the coolant pump pulley.
  13. Remove the bolts and the accessory drive belt tensioner.
  14. Disconnect the right hand Camshaft Position (CMP) sensor. Discard the O-ring seal.
  15. Disconnect the A/C compressor electrical connector.
  16. Disconnect the radio ignition interference capacitor electrical connectors.
  17. Remove the nut and the right hand radio ignition interference capacitor.
  18. Disconnect the left CMP sensor. Discard the O-ring seal.
  19. Remove the nut and the left hand radio ignition interference capacitor.
  20. Remove the bolts and position the power steering pump assembly aside.
  21. Disconnect the wiring harness position retainer and the engine oil pressure (EOP) switch electrical connector and position the wiring harness aside.
  22. Disconnect the Crankshaft Position (CKP) sensor connector.
  23. Remove the 4 front oil pan bolts.
  24. Remove the bolt and the CKP sensor. Discard the O-ring seal.
  25. Remove the bolts and the studs from the front cover.
    CAUTION
    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.
  26. Remove the engine front cover from the front cover to cylinder block dowel.
  27. Remove the engine front cover gaskets.
  28. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  29. Inspect the mating surfaces.
  30. Remove the crankshaft sensor ring from the crankshaft.
  31. Position the crankshaft keyway at the 12 o'clock position.
    NOTE
    If the camshaft lobes are not exactly positioned at the 12 o'clock position, the crankshaft will require one full additional rotation to 12 o'clock. 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.


    NOTE
    If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
  32. Remove only the 3 roller followers shown in the illustration from the right hand cylinder head.
    CAUTION
    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. Remove only the 3 roller followers shown from the right hand cylinder head
  33. Using the tool illustrated, remove the 3 designated roller followers in the previous step from the right hand cylinder head.

    Click image to see an enlarged view
    Fig. Remove the 3 designated roller followers from the right hand cylinder head
  34. Remove only the 3 roller followers shown in the illustration from the left hand cylinder head.

    Click image to see an enlarged view
    Fig. Remove only the 3 roller followers shown from the left hand cylinder head
  35. Using the tool 303-1039, remove the 3 designated roller followers in the previous step from the left hand cylinder head.
    WARNING
    The crankshaft cannot be moved past the 6 o'clock position once set.
  36. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    CAUTION
    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, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
  37. Remove the bolts, the left hand timing chain tensioner and tensioner arm.
  38. Remove the bolts, the right hand timing chain tensioner and tensioner arm.
  39. Remove the right hand and left hand timing chains and the crankshaft sprocket.
  40. Remove the right hand timing chain from the camshaft sprocket.
  41. Remove the right hand timing chain from the crankshaft sprocket.
  42. Remove the left hand timing chain from the camshaft sprocket.
  43. Remove the left hand timing chain and crankshaft sprocket.
  44. Remove the left hand and right hand timing chain guides.
To install:

CAUTION
Timing chain procedures must be followed exactly or damage to valves and pistons will result.


CAUTION
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.

  1. Compress the tensioner plunger, using a vise.
  2. Install a retaining clip on the tensioner to hold the plunger in during installation.
  3. Remove the tensioner from the vise.
  4. If the copper links are not visible, mark two links 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 two links on one end and one link on the other end, and use as timing marks


    Click image to see an enlarged view
    Fig. Install the crankshaft sprocket, making sure the flange faces forward
  5. Install the crankshaft sprocket, making sure the flange faces forward.
  6. Install the 4 bolts and the left hand and right hand timing chain guides. Tighten to 89 inch lbs. (10 Nm).
  7. Position the lower end of the left hand (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 lower end of the left hand (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


    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 two copper (marked) chain links
  8. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
    NOTE
    The left hand timing chain tensioner arm has a bump near the dowel hole for identification.
  9. Position the left hand timing chain tensioner arm on the dowel pin and install the left hand timing chain tensioner and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  10. Remove the retaining clip from the left hand timing chain tensioner.
  11. Position the lower end of the right hand (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 lower end of the right hand (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link


    Click image to see an enlarged view
    Fig. Position the right hand timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links
  12. Position the right hand timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.
  13. Position the right hand timing chain tensioner arm on the dowel pin and install the right hand timing chain tensioner and bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  14. Remove the retaining clip from the right hand timing chain tensioner.
  15. As a final-check, verify correct alignment of all timing marks.

    Click image to see an enlarged view
    Fig. Verify correct alignment of all timing marks
  16. Install the crankshaft sensor ring on the crankshaft.
  17. Lubricate the roller followers with clean engine oil prior to installation.
  18. Using tool 303-1039, install all of the camshaft roller followers.
    CAUTION
    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. 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.
  19. 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 illustrated.

    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, at the locations shown
  20. 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.
  21. Tighten the engine front cover fasteners in sequence in 2 steps:
    1. Step 1: Tighten fasteners 1 through 15 to 18 ft. lbs. (25 Nm).
    2. Step 2: Tighten fasteners 6 and 7 to 35 ft. lbs. (48 Nm).

      Click image to see an enlarged view
      Fig. Engine front cover fastener location and torque sequence
  22. Install the 4 front oil pan bolts in the sequence shown in 2 steps.
    1. Step 1: Tighten to 15 ft. lbs. (20 Nm).
    2. Step 2: Tighten an additional 60 degrees.
      CAUTION
      Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.



      Click image to see an enlarged view
      Fig. Front oil pan bolts torque sequence
  23. Connect the CKP sensor electrical connector.
  24. Position the power steering pump assembly and install the bolts. Tighten to 18 ft. lbs. (25 Nm).
  25. Position the power steering pressure hose support bracket and install the nut.
  26. Position the transmission cooler tube support bracket and install the nut.
    NOTE
    Lubricate the O-ring seal with clean engine oil prior to installation.
  27. Using a new O-ring seal, install the right hand CMP sensor and the bolt.
  28. Connect the right hand CMP sensor electrical connector.
  29. Install the left hand radio ignition interference capacitor and the nut.
    NOTE
    Lubricate the O-ring seal with clean engine oil prior to installation.
  30. Using a new O-ring seal, install the left hand CMP sensor and the bolt.
  31. Connect the left hand CMP sensor electrical connector.
  32. Install the right hand radio ignition interference capacitor and the nut.
  33. Connect the radio ignition interference capacitor electrical connectors.
  34. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts. Tighten the bolts to 18 ft. lbs. (25 Nm).
  35. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
  36. Use the tools illustrated to 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. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.



    Click image to see an enlarged view
    Fig. Install the crankshaft seal into the engine front cover
  37. Apply a 0.32 inch (8mm) bead of silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

    Click image to see an enlarged view
    Fig. Apply a 0.32 inch (8mm) bead of silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley


    Click image to see an enlarged view
    Fig. Install the crankshaft pulley
  38. Use the tool illustrated to install the crankshaft pulley.
  39. Tighten the new crankshaft pulley bolt in 4 steps:
    1. Step 1: Tighten to 66 ft. lbs. (90 Nm).
    2. Step 2: Loosen 360 degrees.
    3. Step 3: Tighten to 37 ft. lbs. (50 Nm).
    4. Step 4: Tighten an additional 90 degrees.
  40. Install the accessory drive belt.
  41. Clean the valve cover mating surface with silicone gasket remover and metal surface prep.
    NOTE
    If 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. Failure to follow this procedure can cause future oil leakage.
  42. Apply a 0.32 inch (8mm) bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
    CAUTION
    When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.



    Click image to see an enlarged view
    Fig. Apply a 0.32 inch (8mm) bead of silicone gasket and sealant in 2 places where the engine front cover meets the right cylinder head
  43. Install the right hand valve cover and gasket on the cylinder head and tighten the bolts in sequence and tighten to 89 inch lbs. (10 Nm).
    NOTE
    If 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. Failure to follow this procedure can cause future oil leakage.
  44. Apply a 0.32 inch (8mm) bead of silicone gasket and sealant in 2 places where the engine front cover meets the left cylinder head.
  45. Install the left hand valve cover and gasket on the cylinder head and tighten the bolts in sequence shown and tighten to 89 inch lbs. (10 Nm).
  46. Install the engine cooling fan.
  47. Fill the crankcase with clean engine oil.
  48. Check steering and transmission fluid, top off if needed.
  49. Check all connections for leaks



These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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