Wednesday, June 8, 2011

How to remove Camshaft, Bearings and Lifters on ford Taurus?

REMOVAL & INSTALLATION




CAUTION
The fuel injection system remains under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

3.0L OHV Engine

See Figures 1 through 6

  1. Remove the engine from the vehicle and position on a suitable holding fixture.
  2. Rotate the crankshaft to Top Dead Center (TDC) for No. 1 cylinder on its compression stroke.
  3. Remove the upper intake manifold.
  4. Disconnect the engine wiring harness connectors from the cylinder head cover stud bolts. Tag and carefully unplug the fuel injector harness connectors from each fuel injector and position engine wiring harness aside.
  5. Label and disconnect the ignition wires from the spark plugs. Remove the ignition wire separators from the cylinder head cover stud bolts.
  6. Remove the Camshaft Position (CMP) sensor housing retainer bolt and washer and remove the CMP sensor housing.
  7. Remove the ignition coil from the rear of the left cylinder head.
  8. Remove the valve head covers.
  9. Loosen the No. 3 intake valve rocker arm seat retaining bolt and rotate the rocker arm off the pushrod. Remove the pushrod.
  10. Remove the accessory drive belt.
  11. Remove the drive belt tensioner, alternator and alternator brackets.
  12. Remove the lower intake manifold leaving the fuel supply manifold (fuel rail) and fuel injectors in place.
  13. Loosen the remaining rocker arm fulcrum nuts enough to allow the rocker arms to be lifted off the pushrods. Remove the remaining pushrods, identifying each pushrod for installation as the pushrods must be installed in their original positions.
  14. Remove the valve lifter guide plate retainer bolts and the valve lifter guide plate.
  15. Using a suitable magnet or lifter removal tool, remove the hydraulic valve lifters and keep them in order so they can be installed in their original positions. If the valve lifters are stuck in the bores by excessive varnish, use a hydraulic lifter puller to remove the lifters.
  16. Remove the crankshaft pulley retaining bolts and the crankshaft pulley.
  17. Remove the crankshaft damper retaining bolt and washer. Remove the crankshaft damper using remover T58P- 6316-D or equivalent puller and adapter T82L-6316-B or equivalent.
  18. Remove the engine oil pan.
  19. Unfasten the engine front cover retaining bolts leaving the water pump attached. Remove the engine front cover.
  20. Align the timing marks on the camshaft and crankshaft sprockets. Check the camshaft end-play as follows:
    1. Push the camshaft toward the rear of the engine and install a dial indicator tool, so the indicator point is on the camshaft sprocket attaching screw.
    2. Zero the dial indicator. Position a small prybar or equivalent, between the camshaft sprocket and block.
    3. Pull the camshaft forward and release it. Compare the dial indicator reading with the specification given in the engine rebuilding chart. If the camshaft end-play is over the amount specified, replace the thrust plate.

  21. Remove the camshaft sprocket retaining bolt and washer.
  22. Inspect the timing chain for excessive deflection.
  23. Grasp the camshaft sprocket and the crankshaft sprocket and slide the timing chain and sprocket assembly off the engine.
  24. Remove the two camshaft thrust plate retaining bolts and the camshaft thrust plate. Discard the thrust plate if it was found to be worn beyond specifications made during the camshaft end-play check.
  25. Carefully remove the camshaft by pulling it toward the front of the engine. Remove it slowly to avoid damaging the bearings, journals and lobes.

If replacing the camshaft, the valve lifters must also be replaced.

  1. Inspect the camshaft journals, lobes and bearings for wear and/or damage.
  2. Remove the camshaft bearings using camshaft bearing set T65L-6250-A or its equivalent as follows:
    1. If necessary, remove the camshaft rear bearing cover using a suitable puller/removal tool.
    2. Select the proper size expanding collet and back-up nut, then assemble them on the expanding mandrel.
    3. With expanding collet collapsed, install the collet assembly in the camshaft bearing and tighten the back-up nut on the expanding mandrel until the collet fits the bearing.
    4. If necessary, assemble the puller screw and extension and install on the expanding mandrel. Wrap a cloth around the threads of the puller screw to protect the camshaft bearing or journal.. Tighten the puller nut against the thrust bearing and pulling plate to remove the bearing. Hold the end of the puller screw to prevent it from turning. Repeat this step to remove all the bearings except the front bearing.
    5. Install the puller from the rear of the cylinder block to remove the front bearing.




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Fig. Fig. 1: Exploded view of camshaft bearing removal/installation using a suitable camshaft bearing set-3.0L OHV engines



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Fig. Fig. 2: The guide plate is held by two retaining bolts, remove the bolts and...



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Fig. Fig. 3: ... remove the guide plate



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Fig. Fig. 4: The lifters are held by a retainer



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Fig. Fig. 5: Remove the retainer and...



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Fig. Fig. 6: ... remove the lifters from the engine

To install:

CAUTION
Failure to use the correct expanding collet may cause damage to the camshaft bearings.

The camshaft bearings are available pre-finished to size and require no reaming for standard and 0.015 (0.38mm) undersize journal diameters.

  1. Insatll the camshaft bearings as follows:
  2. Place the bearings at the bearing bores, align the oil holes in the camshaft bearings with the oil holes in the cylinder block before pressing the bearing into place.
  3. Using camshaft bearing set T65L-6250-A or its equivalent, press the bearings into place. Make sure the pulling plate and puller screw are centered to prevent damage to the bearing.Make sure the front camshaft bearing is installed 0.020-0.035 in. (0.51-0.89mm) below the front face of the cylinder block
  4. If removed, install the camshaft rear bearing cover using a suitable driver/installer tool.
  5. Clean all gasket mating surfaces.
  6. Lubricate the camshaft lobes, journals, drive gear and bearing surfaces with engine assembly lubricant or equivalent. Carefully insert the camshaft through the bearings into the cylinder block.
  7. Lubricate the camshaft thrust plate on both sides with engine assembly lubricant. Install the thrust plate and the two retaining bolts. Tighten the retaining bolts to 88 inch lbs. (10 Nm).If installing a new camshaft, check the camshaft end-play.
  8. Lubricate the timing chain and sprockets with engine assembly lubricant or equivalent and align the timing marks on the sprockets before installation.
  9. Install the timing chain and sprocket assembly. Install the camshaft sprocket bolt. Tighten the camshaft sprocket bolt to 37-51 ft. lbs. (50-70 Nm).


CAUTION
The camshaft bolt has a drilled oil passage in it for timing chain lubrication. Be sure the passage is clean prior to bolt installation. If the bolt is damaged, do not replace the camshaft bolt with a standard bolt or engine damage will result.

  1. Lubricate the valve lifters and lifter bores with engine assembly lubricant or equivalent. Install the valve lifters into their original bores.
  2. Align the flat surfaces on the valve lifters and install the valve lifter guide plate. The plate must be installed with the word UP and/or a dimple on the plate visible. Install the two retaining bolts and tighten to 8-10 ft. lbs. (10-14 Nm).
  3. Install the lower intake manifold.
  4. Install the CMP sensor.
  5. Lubricate the pushrods and rocker arms with engine assembly lubricant or equivalent. Install the pushrods into their original positions. Position each rocker arm onto its related pushrod.
  6. Before installation, coat the valve tips, rocker arm and fulcrum contact areas with Lubriplate® or equivalent.
  7. Rotate the crankshaft one full turn (360 degrees) until the lifter is on the base circle of the cam as shown in the accompanying illustration (camshaft position A).
  8. Install the rocker arm assemblies and tighten the rocker arm fulcrum bolts to 6-11 ft. lbs. (7-17 Nm) to position the rocker arm seats.
  9. Rotate the crankshaft clockwise 120 degrees to camshaft position B as shown in the accompanying illustration. Tighten the rocker arm fulcrum bolts to 6-11 ft. lbs. (7-17 Nm) to position the rocker arm seats.The fulcrums must be fully seated in the cylinder head and the pushrods must be seated in the rocker arm sockets prior to the final tightening.
  10. Final tighten the rocker arm fulcrum bolts to 20-28 ft. lbs. (26-38 Nm).If the same valve train components are used a valve train check is not required. If new components were installed, measure the clearance with the valve tappet fully collapsed on the base circle of the camshaft lobe. The measurement should be 0.085-0.185 inch (2.15-4.69mm). Refer to the accompanying illustration if necessary for the valve clearance measurement.
  11. Install the engine front cover and the engine oil pan.
  12. Install the crankshaft damper and pulley.
  13. Install the alternator and brackets.
  14. Install the drive belt tensioner and the accessory drive belt.
  15. Install the valve covers.
  16. Attach the fuel injector harness to each fuel injector. Secure the harness to the cylinder head cover stud bolts.
  17. Install the ignition coil to the left cylinder head.
  18. Install the upper intake manifold.
  19. Install the ignition wiring harness retainers to the cylinder head cover stud bolts and connect the ignition wires to the spark plugs and ignition coil.
  20. Install the engine assembly into the vehicle.
  21. Fill the engine cooling system.
  22. Fill the crankcase with the correct amount and type of engine oil.
  23. Connect the negative battery cable.
  24. Start the engine and check for leaks and proper engine operation.

3.0L DOHC Engine
  1. Remove the engine from the vehicle and place it on a suitable work stand.
  2. Remove the upper intake manifold.
  3. Remove the valve covers.
  4. Remove the engine front cover.
  5. Remove the timing chains
  6. Rotate the crankshaft clockwise to position the crankshaft key-way to the 11 o'clock position and the engine to Top Dead Center (TDC) for the No. 1 cylinder prior to the removal and installation of camshafts and rocker arms or you may damage the camshafts.
  7. Verify that the alignment flags (arrows) on the camshafts (marked RFF) are aligned. If not, rotate the crankshaft one complete revolution and recheck.
  8. Rotate the crankshaft clockwise so the crankshaft key-way is at the 3 o'clock position. This positions the right cylinder head camshafts to the neutral position (base circle).

Cylinder head camshaft journal caps and the cylinder heads should be given an identification mark to make sure they are assembled in their original position. When removed, keep the camshaft journal caps from each cylinder head with the head they were removed from. Do not mix the caps with those from another cylinder head.

Remove the cylinder head camshaft journal thrust cap first to make sure that damage to the camshaft journal thrust cap does not occur.

  1. Remove the right cylinder head camshaft journal thrust cap retaining bolts and thrust caps.
  2. Loosen the remaining camshaft journal cap bolts in the sequence illustrated, releasing the bolts several revolutions at a time by making several passes to allow the camshaft to be raised from the cylinder head evenly. Do not remove the retaining bolts completely.

If the lash adjusters (tappets) and roller rocker arms are to be reused, mark the positions of the lash adjusters and rocker arms so they are reassembled into their original positions.

  1. Remove the camshaft journal caps with the retaining bolts installed.
  2. Remove the camshafts from the cylinder head, then repeat the procedure for both cylinder heads.
  3. Pull the valve lifters out of their bores. Mark them so they can be installed in their original locations.
  4. Inspect the camshafts and cylinder heads for wear or damage.

To install:

WARNING
The crankshaft key-way must be at the 11 o'clock position before reassembly. Failure to do so may lead to engine damage.

  1. Rotate the crankshaft so the key-way is at the 11 o'clock position for installation of the camshafts.
  2. Lubricate the camshaft lobes and journals with engine assembly lubricant.
  3. Install the valve lifters in their original positions.
  4. Install the camshafts into their correct positions into each cylinder head with the timing marks on the camshaft sprockets aligned.
  5. Loosely install the camshaft journal caps and retaining bolts into their correct positions.

Do not install the camshaft journal thrust caps until the rocker arms and timing chains have been installed and the camshaft journal caps are tightened into position.

  1. Install the timing chains.
  2. Tighten the camshaft journal cap bolts, in sequences illustrated, to 71-106 inch lbs. (8-12 Nm). Install the thrust caps and tighten the retaining bolts to 71-106 inch lbs. (8-12 Nm).
  3. Install the engine front cover.
  4. Install both cylinder head covers.
  5. Install the upper intake manifold.
  6. Install the engine assembly into the vehicle.
  7. Fill the engine cooling system.
  8. Fill the crankcase with the correct amount and type of engine oil.
  9. Connect the negative battery cable.
  10. Start the engine and check for leaks and proper engine operation.

3.4L DOHC Engine

See Figures 7 and 8

  1. Remove the engine from the vehicle and place it on a suitable work stand.
  2. Remove the valve covers as outlined earlier in this section.
  3. Remove the timing chain, sprockets and front cover, as outlined earlier in this section.
  4. Remove the timing chain sprocket tensioners from the cylinder heads.
  5. Remove the camshaft timing chain sprocket tensioners from the cylinder heads.

The camshaft journal caps and the cylinder heads are numbered to make sure they are assembled in their original positions. Make sure to keep the journal caps from each cylinder head together. Do not mix the caps from each head.

Make sure to remove camshaft journal thrust caps first to ensure that damage to thrust caps does not occur.

  1. Loosen the camshaft journal thrust caps in the sequence illustrated 7-8 revolutions in several passes to allow the camshafts to be raised from the head. Do not remove the retaining bolts completely.
  2. Inspect the camshafts for wear and/or damage and replace, as necessary.
  3. Pull the valve lifters out of their bores. Mark them so they can be installed in their original locations.

To install:
  1. Apply a thin coat of clean engine oil to the valve lifters and install the valve lifters in their original positions.
  2. Apply a thin coat of clean engine oil to the camshaft bearing surfaces on the cylinder head and camshaft journal caps.



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Fig. Fig. 7: Camshaft journal thrust cap retaining bolt removal sequence-3.4L DOHC engine

  1. Rotate the crankshaft to position the No. 1 piston at top-dead-center TDC by aligning the crankshaft key-way groove with the oil pump mark.
  2. Install the timing chain on the intake and exhaust camshafts. Match the sprocket and chain timing marks and install the camshafts into the cylinder heads with the timing marks pointing up.
  3. Apply a 0.08-0.11 inch (2-3mm) bead of silicone gasket and sealant to the left side cylinder head camshaft journal cap.

Be sure the camshaft journal caps are installed in their original positions.

  1. Loosely install the cylinder head camshaft journal caps and retaining bolts.
  2. Tighten the cylinder head camshaft journal caps retaining bolts in sequence illustrated using two steps:
    1. First step: Tighten in sequence to 62-106 inch lbs. (7-12 Nm).
    2. Second step: Tighten in sequence to 12-15 ft. lbs. (16-21 Nm).

  3. Install a new camshaft seal with a Cam Seal expander T89P-6256-B, or equivalent and Cam Seal Replacer T89-6256-A or equivalent.
  4. Install a Cam Position Tool T96P-6256-AH, or equivalent on the left side intake cam and the right side exhaust cam using the existing cam chain tensioner bolts.
  5. Install the timing chain, sprockets and front cover, as outlined earlier in this section.
  6. Install the valve covers.
  7. Install the engine in the vehicle.
  8. Fill the engine cooling system.
  9. Fill the crankcase with the correct amount and type of engine oil.
  10. Connect the negative battery cable.
  11. Start the engine and check for leaks and proper engine operation.



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Fig. Fig. 8: Tighten the camshaft journal caps in the sequence shown to avoid damaging the camshafts-3.4L DOHC engine

INSPECTION



Camshaft

See Figures 9 through 13

Degrease the camshaft using safe solvent, clean all oil grooves. Visually inspect the cam lobes and bearing journals for excessive wear. If a lobe is questionable, check all lobes and journals with a micrometer.

Measure the lobes from nose to base and again at 90°. The lift is determined by subtracting the second measurement from the first. If all exhaust lobes and all intake lobes are not identical, the camshaft must be reground or replaced. Measure the bearing journals and compare to the specifications. If a journal is worn there is a good chance that the cam bearings are worn too, requiring replacement.

If the lobes and journals appear intact, place the front and rear camshaft journals in V-blocks and rest a dial indicator on the center journal. Rotate the camshaft to check for run-out, if deviation exceeds specification, replace the camshaft.

Measure the camshaft journal diameter at the points shown in the accompanying illustration. If the If the diameters do not conform to specifications, replace the camshaft.



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Fig. Fig. 9: Checking the camshaft lobe lift



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Fig. Fig. 10: Checking the camshaft run-out



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Fig. Fig. 11: Checking the camshaft journal diameter



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Fig. Fig. 12: Inspect the lobes of the camshaft and...



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Fig. Fig. 13: ... the lifter bores for scoring or other damage

Bearings and Journals

Check the camshaft bores for size, taper, roundness, alignment and finish. If any of these exceed the specifications given in the engine rebuilding chart at the end of this section, install new bearings or cylinder heads.

Lifters

See Figure 14



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Fig. Fig. 14: Inspect the rollers on the lifters for wear

  1. Throughly clean the lifter and its bore, then check for pitting, scoring or excessive wear.
  2. On flat lifters, the bottom should be flat and not concave.
  3. If equipped with a roller, the roller should rotate freely without excessive play.


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