2004 Ford F-150 : Engine Mechanical > Engine Mechanical Components > Timing Chain Cover, Chain & Sprockets > Removal & Installation > 2004 F-150 5.4L Engine, 2005 F-150, 250, 350 5.4L Engine; 2006 Mark LT 5.4L Engine 2004 F-150 5.4L Engine, 2005 F-150, 250, 350 5.4L Engine; 2006 Mark LT 5.4L Engine 1. Before servicing the vehicle, refer to the Precautions Section. 2. Raise and safely support the vehicle. 3. Drain the engine oil. 4. Remove the engine cooling fan. 5. Remove the right valve cover. 6. Remove the left valve cover. 7. Rotate the tensioner clockwise and remove the accessory drive belt. 8. Remove the nut and position aside the transmission cooler tube support bracket. 9. Remove the nut and position aside the power steering pressure hose support bracket. 10. Using the special tool, remove the power steering pump pulley. 11. Disconnect the power steering pressure tube. Drain the power steering fluid into a suitable container. 12. Remove the 3 bolts and position the power steering pump aside. 13. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt. 14. Using the special tool, remove the crankshaft pulley. 15. Using the special tool, remove the crankshaft front seal. 16. Remove the 3 bolts and the 3 accessory drive idler pulleys. 17. Remove the 4 bolts and the coolant pump pulley. 18. Remove the 3 bolts and the accessory drive belt tensioner. 19. Disconnect the right camshaft position (CMP) sensor electrical connector. 20. Remove the bolt and the right CMP sensor. Discard the O-ring seal. 21. Remove the nut and the upper radiator hose support bracket. 22. Remove the nut and position the right radio ignition interference capacitor aside. 23. Disconnect the left CMP sensor electrical connector. 24. Remove the bolt and the left CMP sensor. Discard the O-ring seal. 25. Remove the nut and position the left radio ignition interference capacitor aside. 26. Disconnect the crankshaft position (CKP) sensor electrical connector. Page 1 of 24 2004 Ford F-150 - Engine Mechanical > Engine Mechanical Components > Timing Chain Cover, ... 8/8/2014 http://content.chiltonsonline.com/(S(cch11k55pq5g0o55i540s055))/Repair/FreshView.aspx?key=6kA...
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
WARNINGDo 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.
29. Remove the engine front cover from the front cover to cylinder block
dowel.
30. Remove the engine front cover gaskets.
31. Clean the mating surfaces with silicone gasket remover and metal
surface prep. Follow the directions on the packaging.
32. Inspect the mating surfaces.
33. Remove the bolt and the CKP sensor. Discard the O-ring seal.
34. Remove the crankshaft sensor ring from the crankshaft.
Position the crankshaft keyway at the 12 o'clock position—2004 F-150 5.4L Engine, Exc.
36. 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.
WARNINGIf the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
Page 3 of 242004 Ford F-150 - Engine Mechanical > Engine Mechanical Components > Timing Chain Cover, ...
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 or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
Page 8 of 242004 Ford F-150 - Engine Mechanical > Engine Mechanical Components > Timing Chain Cover, ...
43. Remove the bolts, the left timing chain tensioner and tensioner arm.
WARNING
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 or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
44. Remove the bolts, the right timing chain tensioner and tensioner arm.
Remove the right timing chain tensioner and tensioner arm—2004 F-150 5.4L Engine, Exc.
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.
10. Compress the tensioner plunger, using a vise.
11. Install a retaining clip on the tensioner to hold the plunger in during
installation.
12. Remove the tensioner from the vise.
13. If the copper links are not visible, mark 2 links on one end and 1 link
on the other end, and use as timing marks.
14. Install the crankshaft sprocket, making sure the flange faces forward.
Right and left timing chain guides installed—2004 F-150 5.4L Engine, Exc. Heritage Edition;
25. Install the crankshaft sensor ring on the crankshaft.
WARNING
If the components are to be reinstalled, they must be installed into their original locations.
26. Using the special tool, install all of the camshaft roller followers.
Lubricate the roller followers with clean engine oil prior to installation.
27. Install the crankshaft position (CKP) sensor and the 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.
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.
Page 19 of 242004 Ford F-150 - Engine Mechanical > Engine Mechanical Components > Timing Chain Cover...
46. Install the coolant pump pulley and the 4 bolts. Tighten to 25 Nm (18
ft. lbs.).
47. Install the 3 accessory drive idler pulleys and the 3 bolts. Tighten to 25
Nm (18 ft. lbs.).
48. Position the upper radiator hose support bracket and install the nut.
Tighten to 10 Nm (89 inch lbs.).
49. Lubricate the engine front cover and the crankshaft seal inner lip with
clean engine oil.
Front seal installation—2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350
5.4L Engine, 2006 Mark LT 5.4L Engine
50. Using the special tools, 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 with metal surface prep and silicone gasket remover. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
51. Apply silicone gasket and sealant to the Woodruff key slot on the
crankshaft pulley. Use the special tool to install the crankshaft pulley.
Page 23 of 242004 Ford F-150 - Engine Mechanical > Engine Mechanical Components > Timing Chain Cover...