Timing Drive Components

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1 of 27 3/9/2012 8:26 AM Timing Drive Components Special Tool(s) Material

LLDATA Online - 2006 Ford Truck Expedition 4WD V8-5.4L VIN 5 -... 2 of 27 3/9/2012 8:26 AM Material Removal 1. Remove the engine front cover. 2. Remove the crankshaft sensor ring from the crankshaft. 3. Position the crankshaft keyway at the 12 o'clock position.

3 of 27 3/9/2012 8:26 AM 4. NOTE: If the camshaft lobes are not exactly positioned as shown, 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.

4 of 27 3/9/2012 8:26 AM 5. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Remove only the 3 roller followers shown in the illustration from the RH cylinder head. 6. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove the 3 designated roller followers in the previous step from the RH cylinder head.

5 of 27 3/9/2012 8:26 AM 7. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Remove only the 3 roller followers shown in the illustration from the LH cylinder head.

6 of 27 3/9/2012 8:26 AM 8. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. NOTE: It may be necessary to push the valve down while compressing the spring. Using the special tool, remove the 3 designated roller followers in the previous step from the LH cylinder head.

7 of 27 3/9/2012 8:26 AM 9. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position. 10. 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 or engine damage may occur. Remove the bolts, the LH timing chain tensioner and tensioner arm.

8 of 27 3/9/2012 8:26 AM 11. 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 or engine damage may occur. Remove the bolts, the RH timing chain tensioner and tensioner arm. 12. Remove the RH and LH timing chains and the crankshaft sprocket. Remove the RH timing chain from the camshaft sprocket. Remove the RH timing chain from the crankshaft sprocket. Remove the LH timing chain from the camshaft sprocket. Remove the LH timing chain and crankshaft sprocket.

9 of 27 3/9/2012 8:26 AM 13. NOTE: RH shown, LH similar. Remove the LH and RH timing chain guides. Remove the bolts. Remove both timing chain guides. 14. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. Using the special tool, remove the bolt and the RH camshaft phaser sprocket assembly. 15. Discard the camshaft phaser sprocket bolt. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. Using the special tool, remove the bolt and the LH camshaft phaser and sprocket assembly. Discard the camshaft phaser sprocket bolt.

10 of 27 3/9/2012 8:26 AM 16. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from sideloading. Remove the 2 bolts and the RH cylinder head camshaft front bearing cap. 17. NOTICE : The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining 8 bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.

LLDATA Online - 2006 Ford Truck Expedition 4WD V8-5.4L VIN 5 -... 11 of 27 3/9/2012 8:26 AM 18. Clean and inspect the RH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.

12 of 27 3/9/2012 8:26 AM 19. Remove the RH camshaft. 20. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from sideloading. Remove the 2 bolts and the LH cylinder head camshaft bearing cap. 21. NOTICE : The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining 8 bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps.

LLDATA Online - 2006 Ford Truck Expedition 4WD V8-5.4L VIN 5 -... 13 of 27 3/9/2012 8:26 AM 22. Clean and inspect the LH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.

14 of 27 3/9/2012 8:26 AM 23. Remove the LH camshaft. 24. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Failure to follow these instructions may result in engine damage. Remove all of the remaining roller followers from the cylinder heads. Installation 1. Install the LH and RH camshafts. Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.

15 of 27 3/9/2012 8:26 AM 2. NOTE: LH shown, RH similar. Install the LH and RH camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts loosely. Tighten to 10 Nm (89 inch lbs.). in the sequence shown.

16 of 27 3/9/2012 8:26 AM 3. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: LH shown, RH similar. Install the camshaft phaser sprockets and new camshaft phaser bolts finger tight. 4. CAUTION: Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. CAUTION: Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit. NOTE: LH shown, RH similar. Using the special tool, tighten the LH and RH camshaft phaser sprocket bolts in 2 stages.

LLDATA Online - 2006 Ford Truck Expedition 4WD V8-5.4L VIN 5 -... 17 of 27 3/9/2012 8:26 AM Stage 1: Tighten to 40 Nm (30 ft. lbs.). Stage 2: Tighten an additional 90 degrees. 5. Using the special tool, position the crankshaft keyway at the 11 o'clock position. 6. 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.

LLDATA Online - 2006 Ford Truck Expedition 4WD V8-5.4L VIN 5 -... 18 of 27 3/9/2012 8:26 AM Compress the tensioner plunger, using a vise. 7. 8. Install a retaining clip on the tensioner to hold the plunger in during installation. Remove the tensioner from the vise. 9. 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.

19 of 27 3/9/2012 8:26 AM 10. Install the crankshaft sprocket, making sure the flange faces forward. 11. Install the 4 bolts and the LH and RH timing chain guides. Tighten to 10 Nm (89 inch lbs.).

LLDATA Online - 2006 Ford Truck Expedition 4WD V8-5.4L VIN 5 -... 0 of 27 3/9/2012 8:26 AM 12. Position the lower end of the LH (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. 13. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.

LLDATA Online - 2006 Ford Truck Expedition 4WD V8-5.4L VIN 5 -... 21 of 27 3/9/2012 8:26 AM 14. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts. Tighten to 25 Nm (18 ft. lbs.). 15. Remove the retaining clip from the LH timing chain tensioner.

22 of 27 3/9/2012 8:26 AM 16. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.

23 of 27 3/9/2012 8:26 AM 17. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel. NOTE :The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft. Position the RH timing chain on the camshaft phaser and sprocket wil the timing mark positioned between the 2 copper (marked) chain links.

LLDATA Online - 2006 Ford Truck Expedition 4WD V8-5.4L VIN 5 -... 24 of 27 3/9/2012 8:26 AM 18. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts. Tighten to 25 Nm (18 ft. lbs.). 19. Remove the retaining clip from the RH timing chain tensioner.

LLDATA Online - 2006 Ford Truck Expedition 4WD V8-5.4L VIN 5 -... 5 of 27 3/9/2012 8:26 AM 20. As a post-check, verify correct alignment of all timing marks.

26 of 27 3/9/2012 8:26 AM 21. Install the crankshaft sensor ring on the crankshaft. 22. NOTICE : If the components are to be reinstalled, they must be installed into their

27 of 27 3/9/2012 8:26 AM original locations. Failure to follow these instructions may result in engine damage. NOTE : Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valave drops into the cylinder, the cylinder head must be removed. NOTE : It may be necessary to push the valve down while compressing the spring. Using the speical tool, install all of the camshaft roller followers. Lubricate the roller followers with clean engine oil prior to installation. 23. Install the engine front cover.

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