Ford C8SZ-6268-A Timing Chain

To remove the components, first disconnect the cable from the negative battery terminal and position the engine at TDC compression for the number one cylinder. Drain the cooling system and engine oil, then remove the air cleaner assembly and air intake duct. Next, take out the fan shroud attaching screws, followed by the fan/clutch assembly attaching bolts, and then the fan/clutch assembly and shroud. Loosen the accessory drivebelt idler pulley and remove the drivebelt. If equipped with power steering, remove the pump mounting bracket attaching bolts while keeping the hoses connected, and set the pump bracket assembly aside to prevent fluid leakage. For air conditioning, remove the compressor front support bracket while leaving the compressor in place. Disconnect the engine coolant bypass hose, heater hose, and radiator upper hose. Remove the distributor cap with the coil wire attached, then lift the distributor out of the timing cover after removing the hold-down clamp. Raise the vehicle securely on jackstands and remove the crankshaft damper using a puller. Disconnect the fuel pump-to-carburetor fuel line and remove the fuel pump, oil filter, and radiator lower hose. The oil pan must be removed to access the timing cover, which requires careful removal of all attaching bolts, including one behind the oil filter adapter. Remove the ignition timing indicator, then take off the timing cover and water pump as an assembly, followed by the camshaft thrust button and spring, camshaft sprocket attaching bolts, and the sprockets and timing chain. If a new timing cover is being installed, remove the necessary components from the old cover. For installation, if re-using the timing cover, replace the crankshaft front oil seal; if using a new cover, install the oil pump and other components. Rotate the crankshaft to position piston no. 1 at TDC, lubricate the timing chain, and install the camshaft sprocket, crankshaft sprocket, and timing chain, ensuring the timing marks align. Install the camshaft sprocket attaching bolts and lubricate the thrust button and spring before installing them. Position a new cover gasket and install the timing cover/water pump assembly, then attach the ignition timing indicator and coat the attaching bolts with pipe sealant before tightening. Raise the vehicle again to install the oil pan, connect the lower radiator hose, and install the oil filter. Turn the crankshaft clockwise to position the fuel pump eccentric away from the actuating arm, then install the fuel pump with a new gasket and connect the fuel line. Coat the crankshaft damper sealing surface with clean engine oil, position the crankshaft pulley key, and install the crankshaft damper and its washer and bolt. Install the crankshaft pulley, turn the crankshaft to bring piston no. 1 back to TDC, and lower the vehicle. The remaining installation procedures follow the reverse order of removal, ensuring the distributor rotor points at the no. 1 cap tower. Finally, start the engine and check for leaks, adjusting the ignition timing and idle speed as necessary.

Before performing a component swap, it is necessary to discharge the cooling system and crankcase; fully remove the oil pan and the radiator; collect the coolant in a sealable vessel so that pets will not be harmed. Next, remove on cylinder front cover, water pump, drive belt and camshaft timing gear. Depending on the model, employ the services of a clutch aligner to have the crankshaft sprocket pulled off. As for the installation, you need to place the keyway in the gear and than slide it onto the shaft and fit the timing chain around the crankshaft sprocket and camshaft sprocket when all the timing marks should coincide. Satisfy yourself there is the appropriate camshaft end play and replace the thrust plate if required. Rotating the crankshaft until both the key and timing marks are in their correct positions, fit gear into the crankshaft with a special tool. Reconnect the cylinder front cover, oil pan and the radiator, add coolants to the engine and but air into it, switch on the engine and set the ignition timing and look for any signs of leakage. For example for timing chain deflection, first, then release the tensioner, turn the crankshaft to eat up the chain travel, put a scribe mark, and then again measure the deflection. If still higher replace the timing chain and sprockets and if the wear of the tensioner is beyond 1.5mm, replace it. During the installation of the crankshaft sprocket, one should use the thread lock and sealer to fill the keyway chamfer cavity. For 4.0L engine to 2006: Detach the front cover and radiator, turn the engine to TDC of the compression stroke at No. 1 cylinder, peel off the camshaft sprocket bolt, the sprocket retaining key and also the sprockets and the timing chains. If necessary, then unbolt the tensioner and the guide, then bolt the timing chain guide in the right position and make sure that the bolts are tightened. Check which timing mark coincides with the other on the sprockets, fit the sprockets and chain as well as tighten the camshaft sprocket bolt. The tensioner with the clip should be fitted and the alignment of the sprockets and their relative position to the chain should be tested before the camshaft sprocket bolt is tightened. Last but not the least, provide the tensioner clip, measure camshaft end-play, and then put front cover alongwith the bolts.

To service the 2.2L Diesel Engine, first bring the engine to No. 1 piston at TDC on the compression stroke, then disconnect the ground cables from the batteries and drain the cooling system, ensuring to use a sealable container for the coolant to prevent harm to pets. Next, remove the radiator fan shroud and cooling fan, and drain the engine oil from the crankcase while wearing protective gloves to minimize exposure to used oil. Loosen the idler pulley to remove the NC compressor belt and the power steering belt, then take out the power steering pump and mounting bracket. Continue by loosening and removing the alternator and vacuum pump drive belts, followed by the water pump and crankshaft pulley using a suitable puller. Remove the timing case cover by taking out the retaining nuts and bolts, and installation is the reverse of removal. For the 2.8L and 2.9L engines, start by removing the oil pan and draining the coolant, again using a sealable container. Remove the radiator, NC compressor, and power steering bracket without disconnecting the refrigerant lines, then take out the alternator, Thermactor pump, and drive belts, followed by the fan, water pump, and hoses. Remove the drive pulley from the crankshaft and the front cover retaining bolts, tapping lightly if necessary to break the gasket seal. If the front cover oil seal needs replacement, support the cover while driving out the old seal and install a new one coated with Lubriplate®. Clean the mating surfaces, apply sealer, and install the front cover with the gasket, ensuring proper alignment and torque specifications. Finally, reinstall the oil pan, water pump, hoses, NC compressor, alternator, and drive belts, adjusting tension as needed, then fill and bleed the cooling system, operating the engine to check for leaks. For the 4.0L engine, disconnect the negative battery cable, remove the oil pan, and drain the cooling system while following the same precautions for coolant disposal. Remove the air conditioning compressor and power steering pump without disconnecting the lines, then take out the alternator, fan, water pump, drive pulley/damper, and crankshaft timing sensor. After removing the front cover, reinstall it along with the timing sensor, drive pulley/damper, water pump, fan, alternator, and power steering pump. Fill the cooling system, install the oil pan, fill the crankcase, reconnect the battery, start the engine, and check for leaks while road testing the vehicle for proper operation.

To dismantle the components, turn and plug the fuel inlet line at the fuel pump, also the fuel line at the carburetor and remove the fuel feed line from the fuel pump. Next, it is necessary to unbolt the radiator and a water pump. There are bolts and washers securing the crankshaft pulley to the vibration damper, remove the crankshaft pulley and large bolt and washer joining the vibration damper to the crankshaft. Remove the vibration damper with the help of a puller, then, if it is possible, the damper key and the crankshaft pulley spacer if it exists. Go ahead and take out the oil pan-to-front cover bolts and the timing cover retaining bolts. Trim the oil pan seal to be level with the engine block mating surface and remove the timing cover. Inspect the condition of the timing chain; measure the deflection, if found to be beyond the manufacturers requirement, replace the timing chain and sprockets. If removal is required, position the timing marks, then take out the camshaft sprocket retaining bolt together with the washer, and the eccentric of the fuel pump if there is, as well as the front oil slinger if there is any. You have to slide the timing chain and sprockets in one piece out of the way and the timing gasket cover and the oil pan seal should be removed at this time in order to clean all the gasket material. For installation, it is advisable that at the outer circumference of the additional crankshaft oil seal, coil of engine oil before the seal fits into the cover until it snaps in fully. Reconnect the timing chain and sprockets so that the timing marks match with one another, then fit the chain and sprockets on the camshaft and crankshaft to have the timing marks aligned. In the case of car with this feature, fit the oil slinger and the fuel pump eccentric, camshaft sprocket retaining bolt and washer then tighten the bolt to the required torque. Place the pan gasket on the surface of the oil pan, apply RTV sealant on the gasket surface of the oil pan, install new front cover to oil pan seal and lastly apply the RTV sealant on the four corners of the mating surfaces of the two parts. Paint the gasket surfaces of the cover and fit the new gasket; paint the surface of the block that mates with the cover with sealant. Set the timing cover on the block correctly, without rubbing front seal or misplacing any of the gasket. The cover alignment tool/harmonic balancer is used to align; it's alternatively advisable to coat the bolts' threads with RTV sealant. While holding the cover in alignment tighten the cover bolts and the oil pan-to-front cover retaining bolts to the specified torque then remove the alignment tool or punch. Put some thin oil on the crank shaft contact area of the seal, fit the crank shaft spacer if used, then fit the vibration damper. Specify the damper and its retaining bolt and washer, tightening to the amount of torque required as appropriate. Fit the crankshaft anti-vibration pulley, tighten the crankshaft anti-vibration pulley bolts. The rest of the installation is the exact opposite of removal; it means that all bolts need to be tightened to the right standard. If coolant has leaked into the oil pan during the process, then discharge the crankcase oil, remove the oil filter, replace it with the new one and then add the correct grade and quantity of oil. Lastly, crank the engine at a fast idle speed, check for any anti freeze leaks and oil leaks and ensure the engine idle speed is correct and the ignition timing is right.