Friday, October 14, 2011

How to replace Timing chain sprockets on 2005 Ford Explorer?


Timing Chain & Sprockets



Camshaft Timing Procedure



4.0L (VIN E) SOHC Engine

NOTE
You must retime both camshafts when either camshaft is disturbed.

  1. If installed, remove the camshaft roller followers.
  2. On the RH side, perform the following:
    1. Turn the crankshaft clockwise to position the number one cylinder at top dead center (TDC).
    2. Remove the retainer and position the A/C manifold tube aside.
      CAUTION
      Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in incorrect timing of the engine.


      NOTE
      The special tool must be installed on the damper and should contact the engine block, this positions the engine at TDC.
    3. Install the special tool on the crankshaft pulley.

      Click image to see an enlarged view
      Fig. Install the special tool on the crankshaft pulley-4.0L (VIN E) SOHC engine
    4. Install the special tools to the RH cylinder head and tighten the 2 top clamp bolts to 89 inch lbs. (10 Nm).

      Click image to see an enlarged view
      Fig. Install the RH camshaft sprocket special holding tools-4.0L (VIN E) SOHC engine
    5. Using the special tool with the Camshaft Sprocket Nut Socket 303-565, loosen the RH camshaft sprocket bolt.

      Click image to see an enlarged view
      Fig. Using the special tool with the Camshaft Sprocket Nut Socket 303-565, loosen the RH camshaft sprocket bolt-4.0L (VIN E) SOHC engine
    6. Loosen the top 2 special tool sprocket clamp bolts.
      NOTE
      The camshaft timing slots are off-center.
    7. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools and install the special tools on the front of the RH cylinder head.

      Click image to see an enlarged view
      Fig. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the special tools and install the special tools on the front of the RH cylinder head-4.0L (VIN E) SOHC engine
    8. Remove the RH camshaft tensioner.
    9. Install the special tool, 303-571, in place of the RH camshaft tensioner.
      CAUTION
      The RH camshaft sprocket bolt is a LH-threaded bolt.
    10. Tighten the sprocket special tool top 2 clamp bolts to 89 inch lbs. (10 Nm).
    11. Using the special tool with the Camshaft Sprocket Nut Socket 303-565, tighten the camshaft bolt to 45 ft. lbs. (61 Nm).
    12. Remove the special tool from the RH camshaft tensioner hole.
    13. Install the RH camshaft tensioner, with a new, lubricated O-ring. Tighten the tensioner to 32 ft. lbs. (44 Nm).
    14. Remove the special tools from the RH cylinder head.
  3. Repeat the above procedure for the LH cylinder head, using the appropriate special tools where needed.
  4. Install the camshaft roller followers.
4.6L (VIN H) DOHC Engine
  1. Before servicing the vehicle, refer to the -Precautions- section.
  2. Remove the crankshaft sensor ignition pulse ring.
    WARNING
    Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage can occur.


    WARNING
    Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage will occur.
  3. Using special tool 303-448, position the crankshaft with the keyway at the 12 o'clock position.
  4. Install special tool 303-446.

    Click image to see an enlarged view
    Fig. Timing chains and related parts-4.6L DOHC engine


    Click image to see an enlarged view
    Fig. Secondary timing chains and related parts-4.6L DOHC engine
  5. Remove the timing chain tensioning system from both timing chains.
    1. Remove the bolts.
    2. Remove the timing chain tensioners.
    3. Remove the timing chain tensioner arms.
  6. Remove the right timing chain tensioner arm.
  7. Remove the left timing chain tensioner arm.
  8. Remove the right camshaft sprocket mounting bolt.
  9. Remove the right camshaft sprocket washer.
  10. Remove the right camshaft sprocket.
  11. Remove the left camshaft sprocket mounting bolt.
  12. Remove the left camshaft sprocket washer.
  13. Remove the crankshaft gear.
  14. Remove the left timing chain.
  15. Remove the left camshaft sprocket.
  16. Remove the left timing chain guide.
  17. Remove the right timing chain guide.
  18. Remove the right intake camshaft gear mounting bolt.
  19. Remove the right intake camshaft gear washer.
  20. Remove the right intake camshaft gear spacer.
  21. Remove the left intake camshaft gear mounting bolt.
  22. Remove the left intake camshaft gear washer.
  23. Remove the left intake camshaft gear spacer.
  24. Remove the left secondary timing chain tensioner.
  25. Remove the right secondary timing chain tensioner.
  26. Remove the right exhaust secondary camshaft sprocket.
  27. Remove the right secondary camshaft timing chain.
  28. Remove the right intake secondary camshaft sprocket.
  29. Remove the left intake secondary camshaft sprocket.
  30. Remove the left exhaust secondary camshaft sprocket.
  31. Remove the left secondary camshaft timing chain.
To install:
  1. Installation is the reverse of the removal procedure. Observe the following notes:
Timing Drive Components Installation
  1. Compress the tensioner and install the retaining pin. Install the tensioners.
    CAUTION
    Timing marks must be at the 12 o'clock position and indexed at the 6 o'clock position.
  2. Install the camshaft sprockets and chain as an assembly.
  3. Install special tool 303-446.

    Click image to see an enlarged view
    Fig. Install special tool 303-446


    Click image to see an enlarged view
    Fig. Install the camshaft sprockets and chain as an assembly
  4. Install the camshaft spacer, washer and bolt, and hand-tighten the bolt.
  5. Install the camshaft gear, washer and bolt, and hand-tighten the bolt.
  6. Tighten the bolts in two stages:
    CAUTION
    Timing chain procedures must be followed exactly or damage to valves and pistons will result.


    CAUTION
    Do not compress the ratchet assembly. This will damage the ratchet assembly.



    Stage 1: Tighten to 30 ft. lbs. (40 Nm).
    Stage 2: Tighten an additional 90 degrees.
  7. On engine with ratcheting timing chain tensioners only.
    1. Compress each tensioner plunger, using an edge of a vise.
    2. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
    3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
    4. Install a paper clip into the hole of each tensioner housing to hold the ratchet assembly and plunger in during installation. Remove the tensioner from the vise.
      CAUTION
      The timing chain procedures must be followed exactly or damage to valves and pistons will result.
  8. On engine with non-ratcheting timing chain tensioners only.
    1. Compress each tensioner plunger, using a vise.
    2. Install a retaining clip on each tensioner to hold the plunger in during installation.
  9. 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.

    Click image to see an enlarged view
    Fig. 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<4.6L DOHC engine
  10. Install the timing chain guides.
  11. Rotate the left camshaft sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the right camshaft timing sprocket until the timing mark is approximately at the 11 o'clock position.
    CAUTION
    Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or the camshaft to be rotated. Severe piston and valve damage will occur.


    CAUTION
    Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston or valve damage will occur.


    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.



    Click image to see an enlarged view
    Fig. Rotate the left camshaft sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the right camshaft timing sprocket until the timing mark is approximately at the 11 o'clock position-4.6L DOHC engine
  12. Using special tool 303-448, position the crankshaft so the number one cylinder is at TDC.

    Click image to see an enlarged view
    Fig. Using special tool 303-448, position the crankshaft so the number one cylinder is at TDC-4.6L DOHC engine
  13. Remove the special tool.
  14. Position the left (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.

    Click image to see an enlarged view
    Fig. Position the left (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket-4.6L DOHC engine
  15. Install the left timing chain onto 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.



    Click image to see an enlarged view
    Fig. Install the left timing chain onto the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket-4.6L DOHC engine
  16. Position the left timing chain tensioner arms on the dowel pin and install the left timing chain tensioner.
  17. On engine with ratcheting timing chain tensioners only, remove the retaining clip from the left timing chain tensioner.
  18. On engine with non-ratcheting timing chain tensioners only, remove the retaining clip from the left timing chain tensioner.
  19. Position the right (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
  20. Install the right timing chain onto the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.

    Click image to see an enlarged view
    Fig. Position the right (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket-4.6L DOHC engine


    Click image to see an enlarged view
    Fig. Install the right timing chain onto the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket-4.6L DOHC engine
  21. Position the right timing chain tensioner arms on the dowel pin and install the right timing chain tensioner.
  22. On engine with ratcheting timing chain tensioners only, remove the retaining clip from the right timing chain tensioner.
  23. On engine with non-ratcheting timing chain tensioners only, remove the retaining clips from the right timing chain tensioner.
    NOTE
    Applies to all engine.
  24. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.

    Click image to see an enlarged view
    Fig. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket-4.6L engine
4.6L (VIN W) SOHC Engine
  1. Before servicing the vehicle, refer to the precautions in the beginning of this manual.
  2. Remove or disconnect the following:
    WARNING
    Since the engine is not free-wheeling, timing procedures must be followed exactly or piston and valve damage may occur.






    Front cover
    Crankshaft sensor ring from the crankshaft
  3. Rotate the crankshaft until both camshaft key ways are 90 degrees from the valve cover surface. Make sure the copper links line up with the dots on the camshaft sprocket.
  4. Install the special tools 303-380 and 303-413 on the camshaft.
  5. Remove or disconnect the following:

    Left timing chain tensioner
    Right timing chain tensioner
    Left and right timing chain tensioner arm from the dowel pins
    Timing chains and crankshaft sprocket
    Timing chain guides
To install:

WARNING
Do not compress the ratchet assembly. This will damage the ratchet assembly.

  1. Compress the tensioner plunger, using an edge of a vise.
  2. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
  3. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
  4. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
    NOTE
    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.
  5. Install or connect the following:

    Crankshaft sprocket, making sure the timing mark faces forward
    Timing chain guides
    Left (inner) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket
    Left (inner) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket

    Click image to see an enlarged view
    Fig. Copper link alignment-4.6L SOHC Engine


    Click image to see an enlarged view
    Fig. Left cylinder head bolt torque sequence 4.6L SOHC Engine
    Right (outer) timing chain on the crankshaft sprocket, aligning the copper link with the dot on the crankshaft sprocket
    Right (outer) timing chain on the camshaft sprocket, aligning the copper link with the dot on the camshaft sprocket
  6. Make sure that the copper marks on the timing chain are lined up with the corresponding dots on the crankshaft sprockets and the camshaft sprockets.

    Click image to see an enlarged view
    Fig. Sprocket alignment-4.6L SOHC Engine
  7. Make sure that the camshaft sprocket keyway is 90 degrees from the valve cover mounting surface.
    NOTE
    The left timing chain tensioner arm has a bump near the dowel hole, for identification.
  8. Position the left and right timing chain tensioner arm on the dowel pins.
  9. Position the right timing chain tensioner and install the bolts.
  10. Position the left timing chain tensioner and install the bolts.
  11. Remove both the right and left retaining pins from the timing chain tensioner.
  12. Remove the special tools from the camshaft.
  13. Install the crankshaft sensor ring on the crankshaft.
  14. Install the engine front cover.

Removal & Installation



4.0L (VIN E) SOHC Engine
  1. Before servicing the vehicle, refer to the -Precautions- section.
  2. Drain the engine oil.
  3. Remove or disconnect the following:

    Negative battery cable
    Valve covers
    Camshaft roller followers
    Cylinder heads; see -Cylinder Head- section
  4. On RH head, perform the following:
    1. Remove the hydraulic chain tensioner bolt from side of the head.
    2. Install the camshaft sprocket special holding tools.

      Click image to see an enlarged view
      Fig. Install the RH camshaft sprocket special holding tools-4.0L (VIN E) SOHC engine
    3. Install a camshaft sprocket nut tool, 303-575, on the camshaft sprocket nut.
    4. Remove the right side cassette bolt.
      NOTE
      Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.



      Click image to see an enlarged view
      Fig. Remove the right side cassette bolt-4.0L (VIN E) SOHC engine
    5. Remove the RH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
    6. Remove the timing chain.
  5. On the LH head, perform the following:
    1. Remove the LH side hydraulic chain tensioner bolt.
    2. Install the sprocket holding special tools.

      Click image to see an enlarged view
      Fig. Install the LH camshaft sprocket special holding tools-4.0L (VIN E) SOHC engine
    3. Remove the LH side camshaft sprocket bolt.
    4. Remove the LH side cassette bolt from the front of the engine.
      NOTE
      Hold the timing chain and cassette with a rubber band to aid in removal and to prevent the timing chain from falling into the cylinder block.
    5. Remove the LH camshaft sprocket from the timing chain. Install a rubber band around the cassette and the timing chain.
    6. Remove the timing chain.
To install:
  1. On the RH head, perform the following:
    1. Install the timing chain.
    2. Install the camshaft sprocket and bolt.
    3. Install the RH side cassette bolt and tighten to 9 ft. lbs. (12 Nm).
  2. On the LH head, perform the following:
    1. Install the timing chain.
    2. Install the camshaft sprocket and bolt.
    3. Install the LH side cassette bolt to 14 ft. lbs. (19 Nm).
  3. Install the following:

    Cylinder heads; see -Cylinder Head- section
  4. Perform the -Camshaft Timing Procedure- below.

    Valve covers
    Negative battery cable
  5. Fill the engine with clean oil.
  6. Start the vehicle, check for leaks and repair if necessary.



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