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[pic][pic]PATH: Engine Mechanical > Engine Mechanical Components > Timing Chain Cover, Chain & Sprockets > Removal & Installation > 4.6L & 5.4L Engine
4.6L & 5.4L Engine
1. Before servicing the vehicle, refer to the Precautions Section.
2. Raise and safely support the vehicle.
3. Disconnect the battery ground cable.
4. Drain the engine oil.
5. Remove the cooling fan.
6. Remove the right valve cover.
7. Remove the left valve cover.
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|Using special tool 303-D055, remove the bolt and washer—4.6L and 5.4L engine |
8. Rotate the tensioner clockwise and remove the drive belt. Using special tool 303-D055, remove the bolt and washer and discard the bolt.
|WARNING |
|This bolt is torque-to-yield and cannot be reused. |
9.
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|Using special tool 303-099, remove the crankshaft pulley—4.6L and 5.4L engine |
10. Using special tool 303-099, remove the crankshaft pulley.
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|Using special tool 303-107, remove the crankshaft front seal—4.6L and 5.4L engine |
11. Using special tool 303-107, remove the crankshaft front seal.
12. Remove the 4 coolant pump pulley bolts and the coolant pump pulley.
13. Remove the accessory drive belt idler pulley bolt and the accessory drive belt idler pulley.
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|Using special tool 211-016, remove the power steering pump pulley—4.6L and 5.4L engine |
14. Using special tool 211-016, remove the power steering pump pulley.
15. Disconnect the power steering pressure tube. Drain the power steering fluid into a suitable container.
16. Remove the nut and position aside the power steering pressure tube.
17. Remove the power steering pump bolts and position the power steering pump assembly aside.
18. Disconnect the camshaft position (CMP) sensor electrical connector.
19. Remove the CMP sensor bolt and the CMP sensor.
20. Remove the left radio interference capacitor nut and position the left radio interference capacitor aside.
21. Remove the nut and the upper radiator hose bracket.
22. Remove the right radio interference capacitor nut and position the right radio interference capacitor aside.
23. Disconnect the crankshaft position (CKP) sensor electrical connector.
24. Remove the 4 oil pan bolts.
25. Remove the nut and the A/C manifold and tube assembly support bracket.
26. If equipped, remove the nut and the transmission cooler tube support bracket.
27. 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. |
28. Remove the engine front cover from the front cover-to-cylinder block dowel.
29. Remove the engine front cover gaskets.
30. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
31. Inspect the mating surfaces.
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|Crankshaft sensor ring—4.6L and 5.4L engine |
32. Remove the CKP sensor bolt and the CKP sensor.
33. Remove the crankshaft sensor ring from the crankshaft.
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|Rotate the crankshaft until the timing mark on the right camshaft sprocket is approximately|
|at the 11 o'clock position and the timing mark on the left camshaft sprocket is |
|approximately at the 12 o'clock position—4.6L and 5.4L engine |
34. Rotate the crankshaft until the timing mark on the right camshaft sprocket is approximately at the 11 o'clock position and the timing mark on the left camshaft sprocket is approximately at the 12 o'clock position.
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|Install the special tools on the camshaft—4.6L and 5.4L engine |
35. Install the special tools on the camshaft as shown.
|WARNING |
|If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be |
|inspected for seat integrity. If cracks, tears or separation from the tensioner body or permanent compression of|
|the seal bead is observed, install a new tensioner. |
36.
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|Removing the tensioners and tensioner arms—4.6L and 5.4L engine |
37. Remove the bolts (1). Remove the timing chain tensioners (2). Remove the timing chain tensioner arms (3).
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|Timing chain and sprocket removal—4.6L and 5.4L engine |
38. Remove the timing chains and crankshaft sprocket.
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|Timing chain guides—4.6L and 5.4L engine |
39. Remove the bolts (1). Remove the left timing chain guide (2).
40. Remove the bolts (3). Remove the right timing chain guide (4).
To install:
|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. |
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|Compress the tensioner plunger, using a vise—4.6L and 5.4L engine |
1. Compress the tensioner plunger, using a vise.
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|Install a retaining clip on the tensioner to hold the plunger in during installation—4.6L |
|and 5.4L engine |
2. Install a retaining clip on the tensioner to hold the plunger in during installation.
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|Copper links—4.6L and 5.4L engine |
3. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
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|Install the crankshaft sprocket, making sure the flange faces forward—4.6L and 5.4L engine |
4. Install the crankshaft sprocket, making sure the flange faces forward.
5. Position the left timing chain guide.
6. Install and tighten the left bolts. Tighten to 10 Nm (89 inch lbs.).
7. Position the right timing chain guide.
8. Install and tighten the right bolts. Tighten to 10 Nm (89 inch lbs.).
|WARNING |
|Unless otherwise instructed, do not rotate either the crankshaft or the camshafts, when the timing chains are |
|removed and the cylinder heads are installed. Severe piston and valve damage will occur. |
9.
|NOTE |
|The number one cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the |
|handle of the special tool. |
10.
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|Using the special tool, position the crankshaft so the number one cylinder is at TDC—4.6L |
|and 5.4L engine |
11. Remove the Crankshaft Holding Tool.
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|Position the left (inner) timing chain on the crankshaft sprocket, aligning the copper |
|(marked) link with the timing mark on the sprocket—4.6L and 5.4L engine |
12. Position the left (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
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|Install the left timing chain on the camshaft sprocket, aligning the copper (marked) link |
|with the timing marks on the sprocket—4.6L and 5.4L engine |
13. Install the left timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
|NOTE |
|The left timing chain tensioner arm has a bump near the dowel hole for identification. |
14.
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|Position the left timing chain tensioner arm on the dowel pin and install the left timing |
|chain tensioner—4.6L and 5.4L engine |
15. Position the left timing chain tensioner arm on the dowel pin and install the left timing chain tensioner. Tighten to 25 Nm (18 ft. lbs.).
16. Remove the retaining clip from the left timing chain tensioner.
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|Position the right (outer) timing chain on the crankshaft sprocket, aligning the copper |
|(marked) link with the timing mark on the sprocket—4.6L and 5.4L engine |
17. Position the right (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
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|Install the right timing chain on the camshaft sprocket, aligning the copper (marked) link |
|with the timing marks on the sprocket—4.6L and 5.4L engine |
18. Install the right timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
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|Position the right timing chain tensioner arm on the dowel pin and install the right timing|
|chain tensioner—4.6L and 5.4L engine |
19. Position the right timing chain tensioner arm on the dowel pin and install the right timing chain tensioner. Tighten to 25 Nm (18 ft. lbs.).
20. Remove the retaining clip from the right timing chain tensioner.
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|Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft|
|sprockets and the camshaft sprocket—4.6L and 5.4L engine |
21. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
22. Remove the special tools from the camshaft.
23. Install the crankshaft sensor ring on the crankshaft.
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|Front cover and related parts—4.6L and 5.4L engine |
24. Install the CKP sensor and the CKP sensor 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. |
25.
|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. |
26.
|NOTE |
|Make sure that the engine front cover gasket is in place on the engine front cover before installation. |
27.
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|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 indicated—4.6L and 5.4L|
|engine |
|Click to Enlarge |
28. 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.
29. Install the engine front cover with the engine front cover gasket on the front cover-to-cylinder block dowel and loosely install the bolts.
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|Front cover fastener identification—4.6L and 5.4L engine |
30. Tighten the engine front cover fasteners in the sequence shown.
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|Oil pan-to-front cover bolt torque sequence—4.6L and 5.4L engine |
31. Loosely install the oil pan-to-front cover bolts, then tighten the bolts in 2 steps, in the sequence shown.
o Step 1: Tighten to 20 Nm (15 ft. lbs.).
o Step 2: Tighten an additional 60 degrees.
1. If equipped, install the transmission cooler tube support bracket and nut. Tighten to 10 Nm (89 inch lbs.).
2. Install the A/C manifold and tube assembly support bracket and nut. Tighten to 10 Nm (89 inch lbs.).
3. Connect the CKP sensor electrical connector.
4. Position the right radio interference capacitor and install the nut. Tighten to 10 Nm (89 inch lbs.).
5. Position the upper radiator hose bracket and install the nut. Tighten to 10 Nm (89 inch lbs.).
6. Install the left radio interference capacitor and install the left radio interference capacitor nut. Tighten to 10 Nm (89 inch lbs.).
7. Install the CMP sensor and the bolt. Tighten to 10 Nm (89 inch lbs.).
8. Connect the CMP sensor electrical connector.
9. Position the power steering pump and install the bolts. Tighten to 25 Nm (18 ft. lbs.).
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|Power steering pressure line fitting connection—4.6L and 5.4L engine |
10. Using special tool 211-D207, install a new O-ring seal on the pressure line fitting.
11. Connect the power steering pressure tube. Tighten to 65 Nm (48 ft. lbs.).
12. Position the power steering pressure tube support bracket and install the nut. Tighten to 10 Nm (89 inch lbs.).
|WARNING |
|If the pulley has been removed and installed twice, install a new power steering pump pulley. |
13. Using special tool 211-185, install the power steering pump pulley. Inspect the pulley for paint marks in the web area near the hub. If there are 2 paint marks, install a new pulley. If there is 1 paint mark or none at all, use a pencil to mark the web area of the pulley near the hub.
14. Install the accessory drive belt idler pulley and the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
15. Install the coolant pump pulley and the 4 bolts. Tighten to 25 Nm (18 ft. lbs.).
16. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
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|Crankshaft front seal installation—4.6L and 5.4L engine |
17. Using the special tools shown, install the crankshaft front seal.
|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. Follow the directions on the packaging. Failure to |
|follow this procedure can cause future oil leakage. |
18.
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|Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley—4.6L |
|and 5.4L engine |
19. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
20. Using special tool 303-102, install the crankshaft pulley.
21. Using a new crankshaft pulley bolt, install the crankshaft pulley bolt and washer.
22. Using the special tool to hold the crankshaft pulley, tighten the bolt in 4 steps:
o Step 1: Tighten the bolt to 90 Nm (66 ft. lbs.).
o Step 2: Loosen the bolt one full turn.
o Step 3: Tighten the bolt to 50 Nm (37 ft. lbs.).
o Step 4: Tighten the bolt an additional 90 degrees without exceeding 200 Nm (148 ft. lbs.).
23. Rotate the tensioner clockwise and install the drive belt.
24. Install the left valve cover.
25. Install the right valve cover.
26. Install the cooling fan.
27. Connect the battery ground cable.
28. Fill the engine with clean engine oil.
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