Disclaimer: This should
be used for
reference only.
Always refer to the Ford Service
Manual,
before starting any procedure
as complex
as this.
Let's get started.
Step 1:Position
the crankshaft damper spoke at the
12 o'clock position and the
timing mark indentation
at the 1 o'clock position.
Note: You need to position the crank pulley before
removing the cam
followers. This orientates the cams, so that the 3
cam followers
on each side, have the least amount of spring pressure
on them.
I marked the crank pulley, so I can easily see the
damper spoke
and the timing mark locations. The line in the 1 o'clock
position
is the timing mark.
I used a large 18mm box end wrench on the crank pulley
bolt,
spark plugs were out and the transmission was in nuetral.
Step 2: Remove the cam covers:
Note: The Haynes manual has you
reverse the tightening
sequence, when loosening the
cam cover bolts. Here is the
tightening sequence.
RH side:
LH side:
Right Hand Side (passenger).
Left Hand side (Drivers).
Step 3: Loosen
and back off the RH and LH camshaft phaser
and sprocket bolts, one full
turn.
Note: I used a breaker bar with
a 15mm socket. I held a 18mm box end
wrench on the crank pulley bolt,
to keep the crankshaft from spinning.
Step 4: Disconnect
the RH and LH Camshaft Position Sensor
electrical connectors.
Step 5: Remove the bolts and the RH and LH Camshaft Position Sensors (CMP's).
Step 6: Is just a note.
NOTE: If the camshaft lobes
are not exactly positioned as shown, the crankshaft will require one full
additional rotation to 12
o'clock.
The No. 1 cylinder (passenger
side, front) camshaft exhaust lobe (the middle 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 No. 1 cylinder.
Step 7: RH
SIDE: Using the Valve Spring Compressor, remove
the 3 camshaft roller followers,
shown in the illustration.
CAUTION: Do not allow the valve
keepers to fall off the valve or the
valve may drop into the cylinder.
NOTE: The camshaft roller followers
must be installed in their
original locations. Record camshaft
roller follower locations.
NOTE: It may be necessary to
push the valve down while compressing
the spring.
Step 8: LH
SIDE: Using the Valve Spring Compressor, remove
the 3 camshaft roller followers,
shown in the illustration.
CAUTION: Do not allow the valve
keepers to fall off the valve or the
valve may drop into the cylinder.
NOTE: The camshaft roller followers
must be installed in their
original locations. Record camshaft
roller follower locations.
NOTE: It may be necessary to
push the valve down while compressing
the spring.
I removed the specified cam followers from the RH side,
then
the LH side. Be sure to keep them in order, so you
can
put them back in their original locations.
Step 9:
CAUTION: The crankshaft cannot
be moved past the
6 o'clock position once set.
Rotate the crankshaft clockwise,
as viewed from the front, positioning
the crankshaft damper spoke at
the 6 o'clock position and the timing
mark indentation at the 7 o'clock
position.
Step 10:
CAUTION: Engine is not freewheeling.
Camshaft procedure must be followed
exactly or damage to valves and
pistons will result.
CAUTION: The Timing Chain Wedge
tool must be installed square to the timing
chain and the engine block.
NOTE: Engine front cover removed for clarity.
Install the special tool in the
RH timing chain as shown.
Step 11:
CAUTION: Do not remove the Timing
Chain Wedge tool at any time during assembly. If the special tool is removed
or out
of placement, the engine front
cover must be removed and the engine must be retimed.
CAUTION: The timing chain must be
installed in its original position onto the camshaft phaser and sprocket
using the scribed
marks, or damage to valves and
pistons will result.
Scribe (index) a location mark on
the timing chain and the camshaft phaser and sprocket assembly.
Step 12:
CAUTION: Remove the front thrust
camshaft bearing cap straight upward from the bearing towers, or the bearing
cap may be damaged from sideloading.
NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
Remove the bolts in the sequence
shown and remove the front camshaft bearing cap and then the remaining
bearing caps.
Step 13: Clean
and inspect the RH camshaft bearing caps.
The camshaft front thrust bearing
cap contains an oil metering
groove.
Make sure the groove is free of foreign material.
Step 14:
CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
CAUTION: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket.
CAUTION: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed.
Remove the sprocket bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly, leaving the camshaft phaser and sprocket assembly in place.
Discard the bolt and washer.
Step 15: Inspect the camshaft phaser and sprocket for damage
INSTALLATION
Note: The 4.6l 3v engine has
different cam lengths, the passenger side
cam is a little shorter then
the drivers side. When you pull the first stock
cam out of your engine, just
match it up with the new
cam that is the same length.
Step 16: Lubricate the camshaft and camshaft journals with clean engine oil.
Note: I soaked my cams in fresh
engine oil before installing.....I had read
about people doing it, so I
figured it couldn't hurt.
Step 17:
CAUTION: Do not remove the Timing
Chain Wedge tool at any time during assembly. If the special tool is removed
or out of
placement, the engine front cover
must be removed and the engine must be retimed.
CAUTION: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
CAUTION: Do not allow the camshaft roller followers to move out of position when installing the camshaft.
Note: When you lay the cam down
onto the head, just make sure the lobes
are centered over the cam followers.
Install the camshaft into the camshaft
phaser and sprocket assembly and
onto the head. Install a new camshaft
phaser and sprocket bolt finger-tight.
Step 18:
CAUTION: Do not remove the Timing
Chain Wedge tool at any time during assembly. If the special tool is removed
or out of placement, the engine
front cover must be removed and
the engine must be retimed.
CAUTION: The timing chain must be
installed in its original position onto the camshaft phaser and sprocket
using the scribed marks, or damage to valves
and pistons will result.
Verify the camshaft phaser and sprocket
and timing chain scribe marks
are still in alignment
Note: Install the camshaft bearing caps in their original locations.
Lubricate the camshaft bearing caps
with clean engine oil.
Position the front camshaft bearing
cap.
Position the remaining camshaft
bearing caps.
Install the bolts loosely.
Step 19: Tighten the bolts in the sequence shown.
Tighten to 10 Nm (89 inch pounds).
Step 20: Remove the special tool.
NOTE: Engine front cover removed for clarity.
Now at this point you will move over and do the LH (drivers side) cam.
Step 21: Repeat steps 10-20
Note: For the LH side, step 10 will have you install the wedge like this:
Step 22: Rotate
the crankshaft a half turn counterclockwise and position the crankshaft
damper spoke at the 12 o'clock position and the timing mark indentation
at the 1 o'clock position.
Step 23:
Verify correct camshaft positions, by noting the position of the No. 1
& 5
cylinder intake and exhaust camshaft
lobes
Cylinder 1
Cylinder 5
Step 24:
Using the Valve Spring Compressor, install the 6
originally removed camshaft roller
followers. Make sure
you put them back, in their original
locations.
Note: For me, all of the cam
followers went in easily except for one, the
number 8 cylinder exhaust. I
had to rotate the crank pulley counter clock
wise, until enough room opened
up to slip the follower in.
Step 25:
Install the RH and LH CMP sensors and the bolts.
Torque these bolts to 89 inch pounds
Step 26:
Connect the CMP electrical connectors.
Step 27:
Tighten the RH and LH, camshaft
phaser and sprocket bolt in 2 stages:
Stage 1: Tighten to 40 Nm (30 lb-ft).
Stage 2: Tighten an additional
90 degrees.
Note: I drew lines on the phaser
and also on the
15mm socket I was using to turn
the bolt.
I held an 18mm box end wrench
on the crank pulley, in
order to keep the cam and crankshaft
from spinning.
Here are before and after pics:
Step 28: Install your cam covers.
Step 29:
Make sure all connectors that were removed during engine
prep, are reconnected.
Step 30: Reinstall battery tray and battery if it was removed for the RH cam cover removal.
Cam install complete.
Bonus Material: