Camshaft: Service and Repair

NOTE: Ford does not provide a TDC (Top Dead Center) mark or determination procedure for this engine in this vehicle.
ALLDATA users have reported success using aftermarket tools to determine TDC on this engine.

Special Tools:

Removal
1. Remove engine from the vehicle and place on a workstand.
2. Rotate crankshaft to zero degrees at Top Dead Center (TDC) on the compression stroke.
3. Remove upper intake manifold.
4. Disconnect engine control sensor wiring retainers from valve cover stud bolts. Carefully disconnect engine control sensor wiring from each fuel injector and position the engine control sensor wiring out of the way.
5. Remove ignition wires from spark plugs. Remove ignition wire separators from valve cover stud bolts.
6. Remove camshaft position sensor housing retaining bolt and washer. Remove camshaft position sensor housing.
7. Remove ignition coil from rear of LH cylinder head.
8. Remove valve covers.
9. Loosen cylinder No. 3 intake valve rocker arm seat retaining bolt and rotate rocker arm off of push rod and away from top of valve stem. Remove push rod.
10. Remove Generator (GEN), brackets, drive belt tensioner and drive belt.

11. NOTE: Lower intake manifold maybe removed with fuel injection supply manifold and fuel injector in place as an assembly

Remove intake manifold retaining bolts using a Torx head socket. Before attempting to remove lower intake manifold, break the seal between the lower intake manifold and cylinder block. Wedge a large pry bar or similar tool between lower intake manifold and cylinder block. Pry upward on tool using lug on top of engine front cover as a leverage point.
12. Loosen rocker arm seat retaining bolts enough to allow the rocker arms to be lifted off the push rods and rotated to one side.
13. Remove push rods. Identify each push rod location. The push rods should be installed in their original location and position during assembly.
14. Remove tappet guide plate and retainer bolts. Remove tappet guide plate and retainer from valve tappet valley.
15. Remove valve tappet guide plate from valve tappets by lifting straight up.

16. NOTE: If the valve tappets are stuck in the bores due to excessive varnish or gum deposits, it may be necessary to use a claw type tool to aid removal. Rotate the valve tappet back and forth to loosen it from the deposits. Remove valve tappets by grasping each valve tappet and pulling in line with bore.

17. Remove crankshaft pulley retaining bolts and remove crankshaft pulley.
18. Remove crankshaft damper retaining bolt and washer. Remove damper using Crankshaft Damper Remover 303-009 (T58P-6316-D) and Vibration Damper Remover Adapter 303-176 (T82L-6316-B).
19. Remove oil pan. Discard oil pan gasket.

20. NOTE: Water pump may be removed with engine front cover as an assembly. Do not remove bolts No. 11 through 15 to remove as an assembly.

Remove engine front cover retaining bolts.

21. CAUTION: Use care to not damage machined surfaces when removing engine front cover. Only drive pry bar enough to break gasket seal.

Remove engine front cover and discard old engine front cover gasket. Place a dull, thin-bladed pry bar or similar device between engine front cover and cylinder block and tap to break seal. Walk engine front cover off alignment dowels using a soft rocking motion. Use crankshaft seal protector if available.
22. Align marks on camshaft sprocket and crankshaft as shown.

Fig. 8 Timing Chain Alignment:

23. Check camshaft end play. If clearance is excessive, replace camshaft thrust plate.
24. Check timing chain deflection.
25. Remove camshaft sprocket retaining bolt and washer.
26. Using one hand on the camshaft sprocket and the other on the crankshaft sprocket, pull assembly forward and off of crankshaft and camshaft. Remove timing chain and camshaft sprocket and crankshaft sprocket.
27. Remove two camshaft thrust plate retaining bolts and camshaft thrust plate.
28. Carefully remove camshaft by pulling slowly toward front of engine keeping camshaft perfectly in line with camshaft bores. Damage to camshaft bearings and/or camshaft can occur if camshaft is allowed to drop on bearing surface or cylinder block.

Installation

1. CAUTION: Aluminum components gouge easily which cause gasket leaks. Always use care when scraping aluminum gasket surfaces.

NOTE: Lightly oil all bolt and stud bolt threads with Motorcraft Super Premium 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G before installation except those specified for special sealant.

Clean mating gasket surfaces of lower intake manifold and cylinder head. Lay a clean cloth or shop cloth in the valve tappet valley to catch any gasket material. After scraping, carefully lift cloth from valve tappet valley to prevent any particles from entering oil drain holes or cylinder head. Use a suitable solvent to remove old rubber sealant. Clean gasket mating surfaces of engine front cover to cylinder block and oil pan to cylinder block.
2. Inspect camshaft bearings for wear.
3. Clean and inspect all components before installation.

4. CAUTION: If a new camshaft and/or a camshaft position sensor housing is installed, ALWAYS add the rest of the Engine Assembly Lubricant D9AZ-19579-D or equivalent (pint) meeting Ford specification ESR-M99C80-A to the engine oil by pouring it through the distributor hole onto the camshaft drive gear. Run engine at idle for five minutes prior to driving vehicle.

Lubricate camshaft lobes, distributor drive gear and bearing surfaces liberally with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Coat entire camshaft drive gear with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Carefully slide camshaft through camshaft bearings into cylinder block. Keep camshaft in line with front camshaft bearing.
5. Lubricate camshaft thrust plate with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install with two retaining bolts. Tighten bolts to 10 Nm (88 inch lbs.).





6. If installing a new camshaft, check endplay. If clearance is excessive, replace camshaft thrust plate.

7. CAUTION: Do not replace camshaft sprocket bolt with a standard bolt or severe engine damage will occur. This bolt is an oil carrying, precision component.

Lubricate timing chain, crankshaft sprocket and camshaft sprocket with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Align marks as illustrated. Inspect camshaft sprocket bolt for blockage of drilled oil passages and clean as required. Install bolt and washer and tighten to 50-70 Nm (37-51 ft. lbs.).





8. Lubricate valve tappets and bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
9. Install valve tappets into original bores.

10. NOTE: Install plate with the word "UP" and or button visible.

Aligning valve tappet flats, install valve tappet guide plate.
11. Install tappet guide plate and retainer over valve tappet guide plate. Hand.-start two retaining bolts. Tighten bolts to 10-14 Nm (89-123 inch lbs.).

12. NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5131392-A, to remove all residues that may interfere with the sealer's ability to adhere.

Apply a 6 mm (1/4 inch) drop of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSK-M2G343-A4 to intersection of cylinder block and cylinder head at four corners as shown.
13. Position intake manifold gaskets onto cylinder heads. Align intake manifold gasket locking tabs to the provisions on the head gaskets as shown.
14. Install front and rear intake manifold end seals as shown. Secure with retaining features.

15. NOTE: Use care to prevent disturbing the silicone sealer which can cause sealing voids.

Carefully lower intake manifold into position aligning intake manifold bolt holes to those in the cylinder head.
- Install bolts No. 1, 2, 3 and 4 and hand-tighten.
- Install remaining bolts and tighten in sequence in two steps:
- Tighten in numerical sequence to 20-30 Nm (15-22 ft. lbs.).
- Then tighten again to 26-32 Nm (20-23 ft. lbs.).
16. Coat camshaft position sensor housing drive gear teeth with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Install Camshaft Position Sensor (CMP sensor).
17. Apply Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A to removed push rods and rocker arms. Install rocker arms. Move rocker arms into position with push rod and valve stem.
18. Rotate crankshaft to align camshaft and crankshaft timing marks as shown to camshaft position A. Tighten rocker arm seat retaining bolts of specified rocker arms to 7-15 Nm (6-11 ft. lbs.) to seat rocker arm seats into cylinder head. Rotate crankshaft to camshaft position B.
- Tighten rocker arm seat retaining bolts of remaining rocker arms to 7-15 Nm (6-11 ft. lbs.).
- Final-tighten rocker arm seat retaining bolts to 26-38 Nm (20-28 ft. lbs.) in any position. If new valve tappets are being installed check collapsed tappet gaps.

Rocker Arm & Valve Locations:

19. NOTE: Rocker arm seat must be fully seated into cylinder head and push rod must be fully seated in rocker arm and valve tappet sockets prior to final tightening.

Inspect crankshaft front seal for damage and replace if required. Install new engine front cover gasket on alignment dowels on cylinder block. Install engine front cover and tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.). Install water pump and new water pump housing gasket if removed.
20. Install new oil pan gasket to cylinder block and secure with Gasket and Trim Adhesive F3AZ-1913608-AA or equivalent meeting Ford specification ESE-M2G52-A. Make sure the oil pan gasket retaining tab features are properly installed on cylinder block, rear crankshaft main bearing cap and engine front cover. Install oil pan and all retaining bolts.
- Tighten four corner bolts to 10-14 Nm (89-123 inch lbs.).
- Then tighten the remaining bolts to the same value.
- Back off all 16 retaining bolts and retighten to 10-14 Nm (89-123 inch lbs.).
21. Install crankshaft damper and crankshaft pulley.
22. Install generator, brackets, drive belt tensioner and drive belt.
23. Install valve covers.
24. Install engine control sensor wiring to each fuel injector. Secure retainers to valve cover stud bolts.
25. Install ignition coil to rear of LH cylinder head. Tighten retaining bolts to 40-55 Nm (30-40 ft. lbs.).
26. Install upper intake manifold and new intake manifold upper gasket.
27. Install ignition wire harness retainers to valve cover stud bolts and connect ignition wires to spark plugs and ignition coil.
28. Install engine in vehicle.
29. Fill and bleed engine cooling system.
30. Fill crankcase to proper level with Motorcraft Super Premium 5W30 Motor Oil X0-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
31. Start engine and check for coolant, oil, exhaust, vacuum and fuel leaks. Check and, if necessary, adjust base ignition timing.