Caution
If you have never installed
cams, I highly
recommend you read the "Tips
on using the
valve spring compressor tool"
page, before
starting. The link for it
is located at the bottom
of this page.
I just want you to understand
and be
aware of what's happening,
during the
cam follower removal/installation
portions of the procedure.
Disclaimer: This guide
should be used for
reference only. I do believe
however, that
it is 100% accurate and if you
follow
it step by step, you will be
fine.
Always refer to the Ford Service
Manual,
before starting any procedure
as complex
as this.
Alrighty then, now that all the
cautions
and disclaimers are satisfied...
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: I followed Taco Bill's write up on cam cover removal.
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: 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.
CAUTION: The crankshaft cannot be
moved past the
6 o'clock position once set.
Step 10: Install the special tool in the RH timing chain as shown.
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.
Step 11: Scribe
(index) a location mark on the timing chain and
the camshaft phaser and sprocket
assembly.
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.
Step 12: Remove
the bolts in the sequence shown and remove the
front camshaft bearing cap and
then the remaining bearing caps.
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.
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: 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.
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.
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: Install
the camshaft into the camshaft phaser and
sprocket assembly and onto the
head. Install a new camshaft
phaser and sprocket bolt finger-tight.
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.
Step 18: Verify
the camshaft phaser and sprocket and timing
chain scribe marks are still in
alignment.
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.
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.
Note: Install the camshaft bearing
caps in their original locations.
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.
Note: I followed Taco Bill's write up on cam cover installation.
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: