Timing chains and sprockets — removal and installation Ford F150
Caution: These engines are difficult to work on and require some special tools. On any procedure involving the timing chains, the Steps must be read carefully and disassembly must proceed using the special tools, otherwise damage to the engine will result.
Caution: Because this is an «interference» engine design, if the timing chain has broken, there will be damage to the valves (and possibly the pistons) and will require removal of the cylinder heads.
Caution: The timing system is complex. Severe engine damage will occur if you make any mistakes. Do not attempt this procedure unless you are highly experienced with this type of repair. If you are at all unsure of your abilities, consult an expert. Double-check all your work and be sure everything is correct before you attempt to start the engine.
Removal
1. Relieve the fuel system pressure (see Fuel and exhaust systems), then disconnect the cable from the negative battery terminal (see Battery – disconnection and reconnection)
2. Remove the valve covers (see Valve covers – removal and installation).
3. Remove the engine front cover (see Engine front cover – removal and installation).
2.7L engines
4. Starting with the right-side chain, reinstall the crankshaft pulley bolt then rotate the engine until the keyway on the crankshaft is at 11 o’clock position.
5. Verify the triangle timing marks on the VCT units are at the 2 o’clock (intake unit) and 11 o’clock (exhaust unit) positions. If the circle timing marks are at these positions, the crankshaft must be turned clockwise one revolution (360 degrees).
6. Remove the right side tensioner mounting bolts and tensioner.
7. Slide the right side tensioner arm/guide off the pivot and remove the arm.
8. Remove the timing chain guide bolts and guide.
9. Lift the timing chain up and off of the VCT units then off of the crankshaft sprocket.
10. Remove the crankshaft pulley bolt and slide the crankshaft outer sprocket off of the crankshaft.
11. Starting with the left-side chain, reinstall the crankshaft pulley bolt, then rotate the engine 360-degrees until the keyway on the crankshaft is at 11 o’clock position.
12. Verify the circle timing marks on the VCT units are at the 10 o’clock (intake unit) and 12: 30 (exhaust unit) positions. If the triangle timing marks are at these positions the crankshaft must be turned clockwise one revolution (360 degrees).
13. Remove the crankshaft pulley bolt then pull the oil pump chain tensioner back until a drill bit or Allen wrench can be inserted through the holes in the tensioner. With the tensioner in this position, remove the mounting bolt and tensioner.
14. Remove the oil pump chain guide bolts and guide.
15. Lift the oil pump chain up and off of the crankshaft sprocket, then down and out of the oil pump sprocket.
16. Remove the left side tensioner mounting bolts and tensioner.
17. Slide the left side tensioner arm/guide off the pivot and remove the arm.
18. Remove the timing chain guide bolts and guide.
19. Lift the timing chain up and off of the VCT units then off of the crankshaft sprocket.
20. Slide the crankshaft inner sprocket off of the crankshaft.
VCT unit removal
Note: If the right-side VCT units are being removed at the same time as the left-side VCT units, remove the right side VCT units first.
21. Remove the timing chain(s).
22. Install special tool 303-1248 over the camshafts to lock them into place.
23. Remove the VCT unit center bolts and slide the VCT units off of the camshafts. Always replace the VCT unit center mounting bolt.
3.3L/3.5L non-turbocharged engines and 2016 and earlier turbocharged 3.5L engines
24. Turn the engine clockwise until the VCT units (camshaft sprockets) on each intake camshaft are positioned at 90-degrees (12 o’clock) in relation to the top surface of the cylinder heads.
Remove three of the camshaft cap bolts to remove the valvetrain oil tubes
25. Remove the bolts that secure the valvetrain oil tubes to each cylinder head.
26. Install the special camshaft locking tools (303-1248), with the tools holding the flats on each camshaft.
27. If you can’t see the timing marks on the timing chain, add a paint dot to align with the marks on the VCT units and the crankshaft timing sprocket.
28. Remove the two bolts and the primary timing chain tensioner arm, then unbolt and remove the two tensioners.
29. Remove the mounting bolts and the lower-left chain guide, then the lower right chain guide.
Remove the VCT oil control solenoid mounting bolts (A and B) — (C) is the exhaust VCT unit and (D) is the intake VCT unit
30. Remove the bolts securing the VCT solenoids to the cylinder heads. You may have to twist or wiggle the solenoids to disengage them.
Note: The intake solenoids are white, the exhaust solenoids are black.
31. Keep the VCT solenoids in clean plastic sandwich bags, marked with their destination.
32. Remove the primary timing chain.
33. The two camshafts on each cylinder head are jointly driven by a smaller secondary timing chain.
34. Depress and lock the secondary chain tensioner on each bank, using the factory tool (303-1530) inserted in the large hole at the camshaft first bearing cap, or a length of threaded rod and nuts to hold the tensioner down, by pushing from the camshaft bearing cap.
35. With the camshafts still locked at TDC, remove the mounting bolts from the VCT units (camshaft sprockets), and remove the sprockets and secondary timing chains from the camshafts.
36. If the primary timing chain sprocket (at the center of the front of the block) is to be replaced, remove the nine bolts securing the plate that mounts the gear to the front of the block.
2017 3.5L turbocharged engine
37. Starting with the right-side chain, reinstall the crankshaft pulley bolt, then rotate the engine 360-degrees until the keyway on the crankshaft is at 11 o’clock position.
38. Verify the timing marks on the VCT units are at the 12:30 (intake unit) and 11 o’clock (exhaust unit) positions.
39. Install special tool 303-1655 over the camshafts to lock them into place.
40. Remove the bolts from the right-side chain tensioner and remove the tensioner. It may be necessary to rotate the crankshaft slightly to take the pressure off of the tensioner before it can be removed.
41. Slide the right-side timing chain tensioner arm off of the pivot and remove the arm.
42. Remove the right-side timing chain guide bolts and guide.
43. Remove the right-hand primary chain.
44. Remove the crankshaft pulley bolt.
45. Starting with the left-side chain, verify the timing marks on the VCT units are at the 11:30 (intake unit) and 1 o’clock (exhaust unit) positions.
46. Install special tool 303-1655 over the camshafts to lock them into place.
47. Remove the stud-bolt and bolts from the left-side chain tensioner and remove the tensioner. It may be necessary to rotate the crankshaft slightly to take the pressure off of the tensioner before it can be removed.
48. Slide the left-side timing chain tensioner arm off of the pivot then remove the left-side chain guide bolt and guide.
49. Remove the left-side timing chain guide bolts and guide.
50. Remove the left-side chain.
51. Remove the crankshaft pulley bolt and slide the crankshaft sprocket off of the crankshaft.
Remove three of the camshaft cap bolts to remove the valvetrain oil tubes
52. Remove the bolts that secure the valvetrain oil tubes to each cylinder head.
VCT unit removal
Note: If the right side VCT units are being remove at the same time as the left side VCT units, remove the right side VCT units first.
53. Remove the timing chain(s).
54. Install special tool 303-1655 over the camshafts to lock them into place.
55. Remove the VCT unit center bolts and slide the VCT units off of the camshafts. Always replace the VCT unit center mounting bolt.
Installation
2.7L engine
Note: The VCT units have two timing marks on them, a triangle and a circle. When removing and installing the left-side VCT, use the circle marks.
56. Starting with the left-side chain, install the left-side VCT units on to the camshafts with the circle timing marks at the 10 o’clock (intake) and 12:30 (exhaust) positions.
57. Install new VCT unit center bolts and tighten the bolts to the torque listed in this Chapter’s Specifications.
58. Slide the inner crankshaft sprocket over the end of the crankshaft.
59. Place the left-side timing chain over the VCT units with the single colored links aligned with the circle timing marks on the VCT units at the 10 o’clock and 12:30 positions then align the double colored links on the chain so the timing mark on the crankshaft sprocket is in between both links.
60. Install the chain guide and bolts and tighten the guide bolts to the torque listed in this Chapter’s Specifications.
61. Slide the left-side timing chain tensioner arm on to the pivot.
62. Slide the tensioner piston out of the tensioner body.
63. Using a vise, cover the vise jaws with covers or towels to prevent damage to the tensioner piston then mount the piston vertically in the vise. Using a flat-blade screwdriver, push the ratchet mechanism down inside the tensioner piston then rotate the screwdriver clockwise, one full turn until a click is heard.
Note: If an audible click is not heard, the ratcheting mechanism is not locked in place.
64. Remove the tensioner piston from the vise and insert the piston into the tensioner body until a retaining pin can be inserted through the hole in the tensioner body to lock the piston in the retracted position.
65. Install the left-side tensioner and tighten the bolts to the torque listed in this Chapter’s Specifications, make sure the end of the tensioner is properly engaged with the tensioner arm.
66. With the tensioner piston properly engaged with the tensioner arm remove the retaining pin.
67. Install the oil pump chain over the crankshaft and oil pump drive sprockets.
68. Install the oil pump chain guide and bolts, then tighten the bolts to the torque listed in this Chapter’s Specifications.
69. Install the oil pump chain tensioner and bolt, then tighten the bolt to the torque listed in this Chapter’s Specifications, then remove the retaining pin.
70. Install the crankshaft mounting bolt, then rotate the crankshaft one full turn (360-degrees) until the keyway on the crankshaft is at the 11 o’clock position.
71. Remove the crankshaft bolt and replace it with a new one then side the crankshaft sprocket onto the end of the crankshaft.
72. Install the right-side VCT units on to the camshafts with the triangle timing marks at the 2 o’clock (intake) and 11 o’clock (exhaust) positions.
73. Install new VCT unit center bolts and tighten the bolts to the torque listed in this Chapter’s Specifications.
74. Place the left-side timing chain over the VCT units with the single colored links aligned with the triangle timing marks on the VCT units at the 2 o’clock and 11 o’clock positions, then align the double colored links on the chain so the timing mark on the crankshaft sprocket is in between both links.
75. Install the chain guide and bolts and tighten the guide bolts to the torque listed in this Chapter’s Specifications.
76. Slide the right-side timing chain tensioner arm on to the pivot.
77. Slide the tensioner piston out of the tensioner body.
78. Using a vise, cover the vise jaws with covers or towels to prevent damage to the tensioner piston, then mount the piston vertically in the vise. Using a flat-blade screwdriver, push the ratchet mechanism down inside the tensioner piston then rotate the screwdriver clockwise, one full turn until a click is heard.
Note: If an audible click is not heard the ratcheting mechanism is not locked in place.
79. Remove the tensioner piston from the vise and insert the piston into the tensioner body until a retaining pin can be inserted through the hole in the tensioner body to lock the piston in the retracted position.
80. Install the right-side tensioner and tighten the bolts to the torque listed in this Chapter’s Specifications, make sure the end of the tensioner is properly engaged with the tensioner arm.
81. With the tensioner piston properly engaged with the tensioner arm remove the retaining pin.
3.3L/3.5L non-turbocharged engines and 2016 and earlier turbocharged 3.5L engines
82. If the primary chain gear and its plate were removed, clean the mounting surface and the block and install the sprocket and plate with a new gasket. Prepare the primary chain tensioners by pushing in the release button and compressing the plunger until a nail or large paper clip can be inserted to hold the plunger.
83. If the secondary timing chain tensioners were removed, they cannot be reused. New tensioners must be installed.
Caution: Do not remove the plastic clip that is keeping the new tensioner compressed.
84. The tensioner is installed to the correct depth when you hear a «snap» sound. Install the tensioner shoe. The plastic clip can now be removed with pliers.
Align the colored links of the secondary timing chain with the marks on the back of the sprockets (VCT units)
85. Align the colored links with the marks on the VCT units and install the chain on the backside of the VCT units. Align the two VCT units with the dowel pins on the front of the camshafts.
86. New bolts must be used to install the VCT units. Tighten the bolts to the torque listed in this Chapter’s Specifications.
Align the colored links on the primary timing chain with the marks on the crankshaft and camshaft sprockets (VCT units)
87. When the secondary chains and VCT units are installed and aligned, install the primary timing chain, aligning the colored links with the marks on the sprockets. When all components are installed and aligned, pull the pins holding back the two primary chain tensioners.
2017 and later 3.5L turbocharged engines
Note: The VCT units have two timing marks on them: a triangle and a circle. When removing and installing the left-side VCT, use the circle marks.
88. Starting with the left-side chain, install the left-side VCT units on to the camshafts with the circle timing marks at the 11:30 (intake) and 1 o’clock (exhaust) positions.
89. Install new VCT unit center bolts and tighten the bolts to the torque listed in this Chapter’s Specifications.
90. Slide the crankshaft sprocket over the end of the crankshaft.
91. Place the left-side timing chain over the VCT units with the single colored links aligned with the timing marks on the VCT units at the 11:30 and 1 o’clock positions, then align the double colored links on the chain so the timing mark on the crankshaft sprocket is in between both links.
92. Install the chain guide and bolts and tighten the guide bolts to the torque listed in this Chapter’s Specifications.
93. Slide the left-side timing chain tensioner arm on to the pivot.
94. Place the tensioner into a soft-jawed vise, using a pair of needle nose pliers to compress the ratchet wire clip ends together, then compress the plunger while holding the ratchet wire together until a locking pin can be inserted through the body of the tensioner to hold the plunger in the compressed position.
95. Remove the tensioner from the vise and install the left-side tensioner. Tighten the bolts to the torque listed in this Chapter’s Specifications. Make sure the end of the tensioner is properly engaged with the tensioner arm.
96. With the tensioner piston properly engaged with the tensioner arm, remove the retaining pin.
97. Remove the special service tool #303-1655 from the camshafts.
98. Place the right-side timing chain over the VCT units with the single colored links aligned with the timing marks on the VCT units at the 12:30 and 11 o’clock positions, then align the double colored links on the chain so the timing mark on the crankshaft sprocket is in between both links.
99. Install the crankshaft pulley bolt and rotate the crankshaft one full turn (360-degrees) until the keyway on the crankshaft is at the 11 o’clock position.
100. Remove the crankshaft bolt and replace it with a new one.
101. Install new VCT unit center bolts and tighten the bolts to the torque listed in this Chapter’s Specifications.
102. Install the chain guide and bolts and tighten the guide bolts to the torque listed in this Chapter’s Specifications.
103. Slide the right-side timing chain tensioner arm on to the pivot.
104. Compress the right-side tensioner (see Steps 94 and 95).
105. Install the right-side tensioner and tighten the bolts to the torque listed in this Chapter’s Specifications, make sure the end of the tensioner is properly engaged with the tensioner arm.
106. With the tensioner piston properly engaged with the tensioner arm remove the retaining pin.
All models
107. Reinstall the remaining parts in the reverse order of removal.
108. Carefully rotate the crankshaft by hand through at least two full revolutions (use a socket and breaker bar on the crankshaft pulley center bolt).
Caution: If you feel any resistance, STOP! There is something wrong -most likely, valves are contacting the pistons. You must find the problem before proceeding.
109. Install a new oil filter, then add engine oil and coolant (see Tune-up and routine maintenance).
110. Run the engine and check for leaks.