Timing Drive Components: Installation

Install the timing chain onto the 2 camshaft phaser and sprockets and the crankshaft sprocket.
- Install the timing chain guide and the 2 bolts.
  - Tighten to 10 Nm (89 lb-in).
- Install the timing chain arm.
Courtesy of FORD MOTOR COMPANY

NOTE: If equipped with aluminum timing chain tensioner.

NOTE: If the timing chain tensioner plunger is not pinned in the compressed position, follow the next step.
Reset the timing chain tensioner.
1. Position the timing chain tensioner in a soft-jawed vise.
2. Spread the ends of the ratchet wire clip apart.
3. Using the soft-jawed vise, compress the plunger to the reset position.
4. Install a locking pin in the 2 holes of the timing chain tensioner body to hold the plunger in place.
Courtesy of FORD MOTOR COMPANY
NOTE: If equipped with aluminum timing chain tensioner.

NOTE: Do not remove the locking pin until the tensioner bolts are tightened.

Install the timing chain tensioner.
1. Install the bolts.
  - Tighten to 10 Nm (89 lb-in).
2. Remove the locking pin.
Courtesy of FORD MOTOR COMPANY

NOTE: If equipped with cast iron timing chain tensioner.

NOTE: If the timing chain tensioner plunger and ratchet assembly are not pinned in the compressed position, follow the next 4 steps.
NOTE: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Using the edge of a vise, compress the timing chain tensioner plunger.

Courtesy of FORD MOTOR COMPANY
Using a small pick, push back and hold the ratchet mechanism.

Courtesy of FORD MOTOR COMPANY
While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

Courtesy of FORD MOTOR COMPANY
Install a locking pin into the hole in the tensioner housing to hold the ratchet assembly and the plunger in during installation.

Courtesy of FORD MOTOR COMPANY
NOTE: If equipped with cast iron timing chain tensioner.

NOTE: Do not remove the locking pin until the tensioner bolts are tightened.

Install the timing chain tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
Courtesy of FORD MOTOR COMPANY
NOTE: If equipped with cast iron timing chain tensioner.

Remove the locking pin.

Courtesy of FORD MOTOR COMPANY
NOTE: Do not rely on the Camshaft Alignment Tool to prevent camshaft rotation. Damage to the tool or the camshaft can occur.

Using a wrench on the flats of the exhaust camshaft to prevent camshaft rotation, tighten the exhaust camshaft phaser and sprocket bolt.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
Courtesy of FORD MOTOR COMPANY
NOTE: The Camshaft Alignment Tool is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Using a wrench on the flats of the intake camshaft to prevent camshaft rotation, tighten the intake camshaft phaser and sprocket bolt.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
Courtesy of FORD MOTOR COMPANY
Install the front cover. For additional information, refer to Engine Front Cover .
Using the crankshaft pulley bolt, rotate the engine clockwise until the fuel injection cam lobe is at zero lift.

Courtesy of FORD MOTOR COMPANY
Inspect the fuel injection pump housing gasket and replace as necessary.

Courtesy of FORD MOTOR COMPANY
Install the fuel injection pump housing and the 4 bolts.
- Tighten to 15 Nm (133 lb-in) plus an additional 60 degrees.
Courtesy of FORD MOTOR COMPANY
Install the tappet and fuel injection pump. For additional information, refer to Fuel Charging and Controls - 2.0L GTDI .
Install the RH fender splash shield. For additional information, refer to Front End Body Panels .