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Timing Chain Replacing on 6.8L Ford Truck & Lincoln?


Timing Chain Cover, Chain & Sprockets
Its for 6.8L engine model.
F150 1/2 ton P/U 2WD/ 4WD
F250 Super Duty P/U 2WD/4WD
F350 Super Duty P/U 2WD/4WD
F450 Super Duty P/U 2WD/4WD
F550 Super Duty P/U 2WD/4WD
And Lincoln Mark LT car models.



The procedure is similar for both ford and Lincoln car models:-----

 Timing Chain Cover, Chain & Sprockets 
REMOVAL & INSTALLATION Details are mentioned below:--------

6.8L 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 3 bolts and position the power steering pump aside.
  9. Remove the nut and position the starter electrical harness support bracket aside. 

    image
    Fig. Remove these 3 bolts from the A/C compressor-6.8L engine
  10. Remove the 3 bolts and position the A/C compressor aside.
  11. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt.
  12. Using the special tool, remove the crankshaft pulley. 

    image
    Fig. Front seal removal-6.8L engine
  13. Using the special tool, remove the crankshaft front seal.
  14. Remove the bolt and the accessory drive idler pulley.
  15. Remove the 4 bolts and the coolant pump pulley.
  16. Remove the 3 bolts and the accessory drive belt tensioner.
  17. Disconnect the camshaft position (CMP) sensor electrical connector.
  18. Remove the bolt and the CMP sensor. Discard the O-ring seal.
  19. Disconnect the right and left radio ignition interference capacitor electrical connectors.
  20. Remove the nut and the right and left radio ignition interference capacitors.
  21. Disconnect the crankshaft position (CKP) sensor electrical connector.
  22. Remove the 4 front oil pan bolts.
  23. Remove the bolts and the studs.
    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.
  24. Remove the engine front cover from the front cover to cylinder block dowel.
  25. Remove the engine front cover gaskets.
  26. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  27. Inspect the mating surfaces.
  28. Remove the bolt and the CKP sensor. Discard the O-ring seal.
    WARNING
    Only use hand tools to loosen the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
  29. Loosen and back off the right camshaft sprocket bolt 1 full turn.
    WARNING
    Only use hand tools to loosen the sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
  30. Loosen the left camshaft sprocket bolt.
    NOTE
    The balance shaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.



    Click image to see an enlarged view
    Fig. Balance shaft bearing cap removal/installation sequence-6.8L engine
  31. Remove the 6 bolts in the sequence shown, the 3 bearing caps and the balance shaft.
  32. Remove the crankshaft sensor ring from the crankshaft.

    Click image to see an enlarged view
    Fig. Position the crankshaft keyway at the 12 o'clock position-6.8L engine
  33. Position the crankshaft keyway at the 12 o'clock position.
    NOTE
    If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.



    Click image to see an enlarged view
    Fig. 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-6.8L engine
  34. 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.
    WARNING
    If the components are to be reinstalled, they must be installed in the same positions.
  35. Mark the components for installation into the original locations.

    Click image to see an enlarged view
    Fig. Remove only these 3 roller followers from the right cylinder head-6.8L engine
  36. Remove only the 3 roller followers shown in the illustration from the right cylinder head.
    WARNING
    Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.


    NOTE
    It may be necessary to push the valve down while compressing the spring.



    Click image to see an enlarged view
    Fig. Using special tool 303-1039-6.8L engine
  37. Using special tool 303-1039, remove the 3 designated roller followers in the previous step from the right cylinder head.
    WARNING
    If the components are to be reinstalled, they must be installed in the same positions.
  38. Mark the components for installation into the original locations.

    Click image to see an enlarged view
    Fig. Remove only these 4 roller followers from the left cylinder head-6.8L engine
  39. Remove only the 4 roller followers shown in the illustration from the left cylinder head.
    WARNING
    Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.


    NOTE
    It may be necessary to push the valve down while compressing the spring.
  40. Using the special tool, remove the 4 designated roller followers in the previous step from the left cylinder head.
    WARNING
    The crankshaft cannot be moved past the 6 o'clock position once set.



    Click image to see an enlarged view
    Fig. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position-6.8L engine
  41. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    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, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
  42. 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, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
  43. Remove the bolts, the right timing chain tensioner and tensioner arm.
  44. Remove the right timing chain from the camshaft sprocket.
  45. Remove the right timing chain from the crankshaft sprocket.
  46. Remove the left timing chain from the camshaft sprocket.

    Click image to see an enlarged view
    Fig. Timing chain guide bolts-6.8L engine
  47. Remove the left timing chain and the crankshaft sprocket.
  48. Remove the bolts. Remove the timing chain guides.
  49. Remove the bolts and the right and left camshaft sprockets.

    Click image to see an enlarged view
    Fig. Balance shaft drive gear-6.8L engine
  50. Remove the balance shaft drive gear from the left camshaft.
    WARNING
    Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.


    NOTE
    The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
  51. Remove the bolts in the sequence shown and remove the right cylinder head front camshaft bearing cap and then the remaining bearing caps.
  52. Clean and inspect the right camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
  53. Remove the right camshaft.
    WARNING
    Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.


    NOTE
    The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.



    Click image to see an enlarged view
    Fig. Right side camshaft bearing cap removal/installation sequence-6.8L engine


    Click image to see an enlarged view
    Fig. The camshaft front thrust bearing cap contains an oil metering groove-6.8L engine


    Click image to see an enlarged view
    Fig. Left side camshaft bearing cap removal/installation sequence-6.8L engine
  54. Remove the bolts in the sequence shown and remove the left cylinder head front camshaft bearing cap and then the remaining bearing caps.
  55. Clean and inspect the left camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
  56. Remove the left camshaft.
    WARNING
    If the components are to be reinstalled, they must be installed in the same positions.
  57. Mark the components for installation into their original locations.
  58. Remove all of the remaining roller followers from the cylinder heads.
To install:

WARNING
Timing chain procedures must be followed exactly or damage to valves and pistons will result.


WARNING
If the components are to be reinstalled, they must be installed into their original locations.


NOTE
Camshaft shown installed to clarify roller follower position.

  1. Install only the identified camshaft roller followers onto the right cylinder head.
    WARNING
    If the components are to be reinstalled, they must be installed into their original locations.


    NOTE
    Camshaft shown installed to clarify camshaft roller follower position.
  2. Install only the identified camshaft roller followers onto the left cylinder head.
  3. Install the left and right camshafts.
  4. Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
  5. Lubricate the camshaft bearing caps with clean engine oil.
  6. Position the front camshaft bearing cap.
  7. Position the remaining camshaft bearing caps.
  8. Install the bolts loosely.
  9. Tighten the left camshaft bearing cap bolts in 2 steps:

    Step 1: Tighten to 8 Nm(71 inch lbs.) in the sequence shown.
    Step 2: Tighten an additional 45 degrees.
  10. Tighten the right camshaft bearing cap bolts in 2 steps:

    Step 1: Tighten to 8 Nm (71 inch lbs.) in the sequence shown.
    Step 2: Tighten an additional 45 degrees.
  11. Install the balance shaft drive gear onto the left camshaft.
  12. Install the camshaft sprockets and camshaft sprocket bolts finger tight.
    WARNING
    Timing chain procedures must be followed exactly or damage to valves and pistons will result.


    WARNING
    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.
  13. Compress the tensioner plunger, using a vise.
  14. Install a retaining clip on the tensioner to hold the plunger in during installation.
    NOTE
    There are 61 links in each timing chain.
  15. If copper links are not visible, mark 2 links on one end and one link on the other end, and use as timing marks.
  16. Install the timing chain guides and the 4 bolts. Tighten to 10 Nm (89 inch lbs.).

    Click image to see an enlarged view
    Fig. Rotate the left camshaft until the timing mark is approximately at 12 o'clock. Rotate the right camshaft until the timing mark is approximately at 11 o'clock-6.8L engine
  17. Rotate the left camshaft until the timing mark is approximately at 12 o'clock.
  18. Rotate the right camshaft until the timing mark is approximately at 11 o'clock.
    WARNING
    Rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and/or valve damage can occur.



    Click image to see an enlarged view
    Fig. Position the crankshaft with special tool 303-448-6.8L engine
  19. Position the crankshaft with special tool 303-448, then remove the tool.
  20. Install the crankshaft sprocket, marking sure the flange faces forward.

    Click image to see an enlarged view
    Fig. Install the lower end of the left timing chain, aligning the timing marks-6.8L engine
  21. Install the lower end of the left timing chain, aligning the timing marks.
    NOTE
    Be sure the upper half of the timing chain is below the tensioner guide dowel.



    Click image to see an enlarged view
    Fig. Install the left timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned-6.8L engine
  22. Install the left timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.
    NOTE
    The left timing chain tensioner arm has a bump near the dowel hole for identification.
  23. Position the left timing chain tensioner arm on the dowel pin and install the left timing chain tensioner and bolts. Tighten to 25 Nm (18 ft. lbs.).
    NOTE
    Be sure the chain link and crankshaft sprocket timing marks are aligned.


    NOTE
    The lower half of the timing chain must be positioned above the dowel.



    Click image to see an enlarged view
    Fig. Install the right (outer) timing chain on the crankshaft sprocket-6.8L engine
  24. Install the right (outer) timing chain on the crankshaft sprocket.

    Click image to see an enlarged view
    Fig. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark-6.8L engine
  25. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.
  26. Position the right timing chain tensioner arm on the dowel pin and install the right timing chain tensioner and bolts. Tighten to 25 Nm (18 ft. lbs.).
  27. Remove the retaining clips from the right and left timing chain tensioners.
  28. Check for correct alignment of all timing marks.
  29. Install the crankshaft sensor ring on the crankshaft.
  30. Lubricate the balance shaft journals with clean engine oil.
  31. Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
  32. Position the balance shaft on the journals.
    NOTE
    It may be necessary to use an inspection mirror to see the marks.



    Click image to see an enlarged view
    Fig. Position the balance shaft on the journals and align the chalk mark on the balance shaft with the camshaft timing mark-6.8L engine
  33. Position the balance shaft on the journals and align the chalk mark on the balance shaft with the camshaft timing mark as shown.
    NOTE
    Install the bearing caps in their original locations.
  34. Install the bolts and tighten the bolts in the sequence shown. Tighten to 10 Nm (89 inch lbs.).
    WARNING
    Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
  35. Tighten the right camshaft sprocket bolt in 2 steps:
    WARNING
    Only use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.



    Step 1: Tighten to 40 Nm (30 ft. lbs.) in the sequence shown.
    Step 2: Tighten an additional 90 degrees.
  36. Tighten the left camshaft sprocket bolt in 2 steps:
    WARNING
    If the components are to be reinstalled, they must be installed into their original locations.



    Step 1: Tighten to 40 Nm (30 ft. lbs.) in the sequence shown.
    Step 2: Tighten an additional 90 degrees.
  37. Using the special tool, install all of the remaining camshaft roller followers.
  38. Lubricate the roller followers with clean engine oil prior to installation.
    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. Failure to follow this procedure can cause future oil leakage.


    NOTE
    Make sure that the engine front cover gasket is in place on the engine front cover before installation.



    Click image to see an enlarged view
    Fig. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface-6.8L engine
  39. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
  40. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.

    Click image to see an enlarged view
    Fig. Front cover torque sequence-6.8L engine
  41. Tighten the engine front cover fasteners in sequence in 2 steps.

    Step 1: Tighten fasteners 1 through 15 to 25 Nm (18 ft. lbs.).
    Step 2: Tighten fasteners 6 and 7 to 48 Nm (35 ft. lbs.).

    Click image to see an enlarged view
    Fig. Oil pan-to-front cover bolt torque sequence-6.8L engine
  42. Loosely install the oil pan-to-front cover bolts, then tighten the bolts in 2 steps, in the sequence shown.

    Step 1: Tighten to 20 Nm (15 ft. lbs.).
    Step 2: Tighten an additional 60 degrees.
  43. Using a new O-ring seal, install the crankshaft position (CKP) sensor and the bolt.
  44. Lubricate the new O-ring seal with clean engine oil prior to installation. Tighten to 10 Nm (89 inch lbs.).
  45. Connect the CKP sensor electrical connector.
  46. Position the A/C compressor and install the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
  47. Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
  48. Position the starter electrical harness support bracket and install the bolt. Tighten to 10 Nm (89 inch lbs.).
    NOTE
    Lubricate the O-ring seal with clean engine oil prior to installation.
  49. Using a new O-ring seal, install the camshaft position (CMP) sensor and the bolt.
  50. Tighten to 10 Nm (89 inch lbs.).
  51. Connect the CMP sensor electrical connector.
  52. Install the left radio ignition interference capacitor and the nut. Tighten to 10 Nm (89 inch lbs.).
  53. Install the right radio ignition interference capacitor and the nut. Tighten to 10 Nm (89 inch lbs.).
  54. Connect the radio ignition interference capacitor electrical connectors.
  55. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
  56. Install the coolant pump pulley and the 4 bolts. Tighten to 25 Nm (18 ft. lbs.).
  57. Install the accessory drive idler pulley and the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
  58. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

    Click image to see an enlarged view
    Fig. Front cover seal installation-6.8L engine
  59. 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. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  60. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
  61. Use the special tool to install the crankshaft pulley.
  62. Tighten the new crankshaft pulley bolt in 4 steps.

    Step 1: Tighten to 90 Nm (66 ft. lbs.).
    Step 2: Loosen 360 degrees.
    Step 3: Tighten to 50 Nm (37 ft. lbs.).
    Step 4: Tighten an additional 90 degrees.
  63. Rotate the tensioner clockwise and install the accessory drive belt.
  64. Install the right valve cover.
  65. Install the left valve cover. Install the engine cooling fan.
  66. Fill the crankcase with clean engine oil.



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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