Friday, March 16, 2012

How To Replace Timing Chain, Cover & Sprockets On Ford Ranger?

Timing Chain, Cover & Sprockets replacing on Ford Ranger:---


Timing Chain, Cover & Sprockets
REMOVAL & INSTALLATION Details are as follows:---

2.3L Engine
Specific to:
Ford Ranger 2008-2009

WARNING
Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Negative battery cable
    Fan and shroud
    Drive belt
    Valve cover
  3. Set No. 1 piston to TDC and install the Camshaft Alignment Plate 303-376, or equivalent.
  4. Remove the plug for the crankshaft timing peg.
  5. Install the Crankshaft Timing Peg 303-507, or equivalent.
  6. Install an M6 bolt into the crankshaft pulley to verify the engine timing. Refer to Crankshaft Damper Removal & Installation in this section.
  7. Remove or disconnect the following:
    NOTE
    This step is needed only if a new front cover is being installed.



    Camshaft pulley
    Crankshaft position sensor
    Belt tensioner
    Water pump pulley
    Power steering high pressure hose. Remove the nylon O-ring.
    Power steering return hose
    Power steering pump
  8. Using a three-jaw puller, remove the fan drive pulley.
    NOTE
    There is one bolt behind the cooling fan drive pulley. This bolt can be accessed by lining up one of the holes in the pulley with the bolt.
  9. Remove the bolts and the engine front cover.
  10. Compress the timing chain tensioner and remove the tensioner.
  11. Remove the right-hand timing chain guide.
  12. Remove the timing chain.
  13. Remove the bolts and the left-hand timing chain guide.
    WARNING
    Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshaft can occur.
  14. If necessary, remove the bolts and the camshaft sprockets. Use the flats on the camshaft to prevent camshaft rotation. 

    image
    Fig. Timing chain tensioner removal; 1-paper clip, 2-bolts-2.3L engine


    Click image to see an enlarged view
    Fig. Right side timing chain guide-2.3L engine


    Click image to see an enlarged view
    Fig. Timing chain removal-2.3L engine


    Click image to see an enlarged view
    Fig. Left timing chain guide-2.3L engine


    Click image to see an enlarged view
    Fig. Camshaft alignment plate installed-2.3L engine
To install:
  1. Remove the special tool.
    WARNING
    Do not rotate the camshafts. Damage to the valves and pistons can occur.
If the camshaft sprockets were not removed, use the flats on the camshafts to prevent camshaft rotation and loosen the sprocket bolts.
  1. If removed, install the camshaft sprockets and the bolts. Do not tighten the bolts at this time.

    Click image to see an enlarged view
    Fig. Front cover torque sequence-2.3L engine
  2. Install or connect the following:

    Left-hand timing chain guide and bolts
    Timing chain
    Right-hand timing chain guide
    Timing chain tensioner and release the piston
    Timing chain tensioner and the bolts
  3. Remove the drill rod to release the piston.
  4. Install the special tool.
    WARNING
    Do not rely on the Camshaft Alignment Plate to prevent camshaft rotation. Damage to the tool or the camshafts can result. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.


    NOTE
    This step is needed only if a new front cover is being installed.
  5. Install the fan drive pulley using a nut and bolt with flat washers.
  6. Clean and inspect the mounting surfaces of the engine and the front cover.
    NOTE
    The engine front cover must be installed and the bolts tightened within four minutes of applying the silicone gasket and sealant.
  7. Apply a 2.5 mm bead of silicone gasket and sealant to the cylinder head and oil pan joint areas. Apply a 2.5 mm bead of silicone gasket and sealant to the front cover.
  8. Install the front cover. Tighten the bolts in the sequence shown, to the following specifications:

    Step 1: 8 mm bolts to 89 inch lbs. (10 Nm)
    Step 2: 10 mm bolts to 18 ft. lbs. (25 Nm)
    Step 3: 13 mm bolts to 35 ft. lbs. (48 Nm)
  9. Install or connect the following:
    NOTE
    Do not reuse the crankshaft damper bolt.



    Power steering pump and lower retaining bolt
    Power steering return hose
    New nylon O-ring and install the high pressure line.
    Water pump pulley
    Belt tensioner



    Crankshaft pulley and hand-tighten the bolt
  10. Install an M6 bolt in the crankshaft pulley.
  11. Install a new crankshaft pulley bolt. Using the Crankshaft Damper Holding Tool and a suitable 1/2-in drive hand tool to hold the crankshaft pulley in place, tighten the crankshaft pulley bolt in 2 stages:

    Step 1: 74 ft. lbs. (100 Nm)
    Step 2: Rotate the bolt an additional 90 degrees.
  12. Install the crankshaft position sensor, do not tighten the bolts at this time.
  13. Adjust the crankshaft position sensor with the Alignment Tool, and tighten the mounting bolts.
  14. Connect the crankshaft position sensor electrical connector.
  15. Remove the M6 bolt from the crankshaft pulley.
  16. Remove the Crankshaft Timing Peg 303-507.
  17. Install the plug.
  18. Remove the Camshaft Alignment Plate 303-376.
  19. Install the valve cover.
  20. Install the drive belt.
  21. Install the fan and shroud.
  22. Connect the battery ground cable.
3.0L Engine
Specific to:
Ford Ranger 2008
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the engine coolant.
  3. Remove the accessory drive belt.
  4. Remove the fan and shroud assembly. Remove the bolts and the coolant pump pulley.
  5. Remove the nut and detach the wiring harness bracket.
  6. Remove the nut and position the A/C hose and bracket assembly aside.
  7. Remove the stud bolts from the A/C compressor mounting bracket.
  8. Remove the bolt and the accessory drive belt tensioner.
  9. Remove the bolts and position the power steering bracket and compressor aside.
  10. Disconnect the heater hose at the coolant pump.
  11. Disconnect the lower radiator hose assembly at the coolant pump outlet and lower intake manifold.
  12. Remove the crankshaft front seal.
  13. Remove the oil pan
  14. Remove the crankshaft position (CKP) sensor.
  15. Disconnect the CKP sensor electrical connector.
  16. Remove the 2 bolts and the CKP sensor.
  17. Remove the bolts and the stud bolts, and remove the engine front
  18. Remove and discard the front cover gasket.

    Click image to see an enlarged view
    Fig. Engine front cover-3.0L engine
  19. Rotate the crankshaft and align the timing marks.

    Click image to see an enlarged view
    Fig. Timing marks-3.0L engine
  20. Remove the camshaft bolt.
  21. Remove the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
To install:
  1. Align the timing marks.
  2. Install the timing chain, the camshaft sprocket and the crankshaft sprocket as an assembly.
  3. Install the camshaft bolt and tighten to 46 ft. lbs. (63 Nm).
  4. Clean all sealing surfaces and position a new front cover gasket.
  5. Position the engine front cover.
  6. Apply pipe sealant with PTFE to the bolts to be installed in the locations shown.

    Click image to see an enlarged view
    Fig. Apply pipe sealant with PTFE to the bolts to be installed in the locations shown
  7. Install the engine front cover bolts and tighten to 18 ft. lbs. (25 Nm).

    Click image to see an enlarged view
    Fig. Install the engine front cover bolts and tighten to 18 ft. lbs. (25 Nm).
  8. Position the CKP and install the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  9. Connect the CKP sensor electrical connector.
  10. Install the oil pan.
  11. Install the crankshaft front seal.
  12. Connect the lower radiator hose assembly at the coolant pump outlet and lower intake manifold.
  13. Connect the heater hose at the coolant pump.
  14. Position the A/C compressor and power steering bracket. Install the bolts and tighten to 35 ft. lbs. (47 Nm).
  15. Install the accessory drive belt tensioner and install the bolt to 20 ft. lbs. (27 Nm).
  16. Install the stud bolts to the A/C compressor mounting bracket and tighten to 35 ft. lbs. (47 Nm).
  17. Position the A/C hose and bracket assembly and install the nut. Tighten to 96 inch lbs. (11 Nm).
  18. Position the wiring harness bracket and install the nut. Tighten to 89 inch lbs. (10 Nm).
  19. Install the coolant pump pulley and the bolts. Tighten to 18 ft. lbs. (25 Nm).
  20. Install the fan and shroud assembly.
  21. Install the accessory drive belt.
  22. Fill and bleed the cooling system.
  23. Start the vehicle and check for leaks, repair if necessary.
4.0L Engine
Left Camshaft Drive Chain Cassette-4.0L Engine
Specific to:
Ford Ranger 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Release the fuel system pressure.
  3. Disconnect the negative battery cable.
  4. Drain the cooling system.
  5. Remove the valve covers.
  6. Remove the fuel rail.
  7. Remove the engine front cover.
  8. Remove the thermostat housing.
  9. Remove all of the roller followers.
    WARNING
    The LH and RH camshafts must be retimed when either camshaft is disturbed.
  10. Turn the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC).
  11. Remove the LH hydraulic chain tensioner. Discard the washer.
  12. Remove the LH camshaft sprocket bolt.
  13. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 and tighten the bolts to 10 Nm (89 lb-in).

    Click image to see an enlarged view
    Fig. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564
  14. Remove the LH camshaft sprocket bolt.
  15. Using the Crankshaft Holding Tool to prevent the crankshaft from turning, remove the jackshaft sprocket bolt.

    Click image to see an enlarged view
    Fig. Using the Crankshaft Holding Tool to prevent the crankshaft from turning, remove the jackshaft sprocket bolt
  16. Remove the 2 bolts and the primary chain tensioner.
  17. Remove the primary chain and sprockets as an assembly.
  18. Remove the LH cassette upper bolt.

    Click image to see an enlarged view
    Fig. Remove the LH cassette upper bolt
  19. Remove the LH cassette lower bolt and the LH cassette.

    Click image to see an enlarged view
    Fig. Remove the LH cassette lower bolt


    Click image to see an enlarged view
    Fig. Left timing cassette-4.0L engine-exploded view
To install:

NOTE
The camshaft chain sprockets must be oriented correctly.

  1. Position the LH cassette.
  2. Install the LH cassette lower bolt and tighten to 168 inch lbs. (19 Nm).
  3. Install the LH cassette upper bolt and tighten to 106 inch lbs. (12 Nm).
  4. Install the jackshaft chain and sprockets as an assembly.
  5. Install the jackshaft chain tensioner and the bolts. Tighten to 80 inch lbs. (9 Nm).
  6. Using the Crankshaft Holding Tool to prevent the crankshaft from turning, tighten the jackshaft sprocket bolt in 2 stages:

    Stage 1: Tighten to 33 ft. lbs. (45 Nm).
    Stage 2: Tighten an additional 90 degrees.
  7. Loosely install the camshaft sprocket bolt.
  8. Install the engine front cover
    NOTE
    The LH and RH camshafts must be retimed when either camshaft is disturbed. Refer to Camshaft Removal & Installation in this section. (Camshaft Timing)
  9. Install the LH hydraulic chain tensioner during camshaft timing.
  10. Time the LH and RH camshafts. Refer to Camshaft Removal & Installation in this section. (Camshaft Timing)
  11. Install the camshaft roller followers. Refer to Camshaft Removal & Installation in this section.
  12. Install the thermostat housing.
  13. Install the fuel rail.
  14. Install the valve covers.
  15. Connect the negative battery cable.
  16. Fill and bleed the cooling system.
    WARNING
    The LH and RH camshafts must be retimed when either camshaft is disturbed.
  17. Start the vehicle and check for leaks, repair if necessary.
Right Camshaft Drive Chain Cassette-4.0L Engine
Specific to:
Ford Ranger 2008-2009
The engine must be removed to service the RH Camshaft drive chain cassette.

These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html




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