Friday, March 16, 2012

Ford Camshaft, Bearings & Lifters Replacing procedure for 4.2L,4.6L,5.8L & 6.0L?


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

In this section  Camshaft, Bearings & Lifters Replacing procedure is shown for Ford F series Truck and Lincoln Mark vehicle.
Engine Models 4.2L,4.6L,5.8L & 6.0L:----

Removal & Installation



4.2L Engine

NOTE
It may be easier to remove the engine from the vehicle.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove or disconnect the following:

    Negative battery cable
    Lower intake manifold
    Rocker arm cover
    Rocker arm hold-down bolt, then remove the rocker arm from the cylinder head.
    Pushrods
    Valve lifters by pulling them up out of their bores
    Timing chain and sprockets; see procedure in this section
    Camshaft key from the end of the camshaft, then slide the engine dynamic balance shaft drive gear off the camshaft.
    The 2 camshaft thrust plate retaining bolts (1), then remove the thrust plate (2).
  3. Remove the camshaft spacer (3), then slide the camshaft (4) out of the front of the engine block. Be cautious not to gouge or scratch the camshaft bearing journals. 

    image
    Fig. Exploded view of the camshaft retaining hardware-4.2L engine
To install:
  1. Lubricate the camshaft with engine oil prior to installation.
  2. Carefully slide the camshaft into the camshaft bore. Do not scratch the bearing surfaces.
  3. Install the camshaft thrust plate with the spacer. Tighten the thrust plate mounting bolts to 72-120 inch lbs. (8-14 Nm).
  4. Slide the engine dynamic balance shaft drive gear onto the camshaft. Install the camshaft key to the camshaft groove.
  5. Install the timing chain and sprockets.
  6. Install the valve lifters, pushrods, intake manifolds and rocker arm covers.
4.6L Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Remove the timing drive components. See -Timing Chain and Sprockets- in this section.
  3. Install the special tool between the valve spring coils to protect the valve stem seal from damage.
    NOTE
    The camshaft roller followers must be installed in their original locations. Record the camshaft roller follower locations.


    NOTE
    The 3 rearmost camshaft roller followers on the RH side must use special tool 303-567 in the same manner as is shown in the illustration.



    Click image to see an enlarged view
    Fig. The 3 rearmost camshaft roller followers on the RH side must use special tool 303-567 in the same manner as is shown
  4. Using the special tool, compress the valve spring and remove the camshaft roller follower.
  5. Remove all of the camshaft roller followers from the camshaft being serviced.
  6. Remove the bolt, camshaft sprocket and camshaft sprocket spacer from the camshaft being serviced.
  7. Remove the special tools from the camshaft being serviced.
  8. Remove the bolts, camshaft bearing caps and the camshaft.
  9. Clean and inspect the camshaft bearing caps.
  10. One of the bearing caps contains an oil flow restriction groove. Make sure the groove is free of foreign material.

    Click image to see an enlarged view
    Fig. One of the bearing caps contains an oil flow restriction groove-4.6L engine
  11. Clean and inspect the camshaft bearing caps. One of the bearing caps contains an oil flow restriction groove. Make sure the groove is free of foreign material.
To install:
  1. Install the camshaft and the camshaft bearing caps in their original locations, performing the following:
    1. Lubricate the camshaft with clean engine oil.
    2. Position the camshaft.
    3. Lubricate the camshaft bearing caps with clean engine oil.
    4. Position the camshaft bearing caps.
    5. Install the bolts loosely.

      Click image to see an enlarged view
      Fig. Camshaft bearing cap torque sequence-4.6L engine
  2. Tighten the bolts in the sequence shown to 89 inch lbs. (10 Nm).
  3. Install the camshaft sprocket. Install and tighten the bolt.

    Tighten in two stages.
    Stage 1: Tighten to 40 Nm (30 ft. lbs.).
    Stage 2: Tighten an additional 90 degrees.
  4. Install the timing chains.
  5. Install the camshaft roller followers.
5.4L Engine
Left Side
  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    The camshaft procedure must be followed exactly or damage to the valves and pistons will result.
  2. Remove the cooling fan shroud.

    Click image to see an enlarged view
    Fig. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position-5.4L engine
  3. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
  4. Remove the left valve cover.
    WARNING
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
  5. Loosen and back off the left camshaft phaser bolt 1 full turn.
  6. Disconnect the left camshaft position (CMP) sensor electrical connector.
  7. Remove the left CMP sensor and the bolt.
    WARNING
    If servicing both camshafts, do not rotate the crankshaft. Camshaft position has been established earlier.


    NOTE
    If the camshaft lobes are not exactly positioned as shown, the crankshaft keyway will require 1 full additional rotation to 12 o'clock.



    Click image to see an enlarged view
    Fig. The number 5 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 5 cylinder-5.4L engine
  8. The number 5 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 5 cylinder.
  9. Remove only the 3 roller followers shown in the illustration.
    WARNING
    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.



    Click image to see an enlarged view
    Fig. Remove only these 3 roller followers at this time-5.4L engine
  10. Using special tool 303-1039, remove only the 3 designated roller followers from the previous step.
    WARNING
    The crankshaft cannot be moved past the 6 o'clock position once set.



    Click image to see an enlarged view
    Fig. Using special tool 303-1039-5.4L engine
  11. 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.
    WARNING
    Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result.


    WARNING
    The Timing Chain Wedge tool must be installed square to the timing chain and the engine block.


    NOTE
    Front cover removed for clarity.



    Click image to see an enlarged view
    Fig. 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-5.4L engine
  12. Install the special tools in the left timing chain as shown.
    WARNING
    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.


    WARNING
    The timing chain must be installed in its original position onto the camshaft phaser sprocket using the scribed marks, or damage to valves and pistons will result.



    Click image to see an enlarged view
    Fig. The Timing Chain Wedge tool must be installed square to the timing chain and the engine block-5.4L engine
  13. Scribe a location mark on the timing chain and the camshaft phaser sprocket assembly.
    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.
  14. Remove the bolts in the sequence shown and remove the front camshaft bearing cap and then the remaining bearing caps.
  15. 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.
    WARNING
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.


    WARNING
    Only use hand tools to remove the camshaft phaser sprocket bolt or damage may occur to the camshaft or camshaft phaser unit.


    WARNING
    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.
  16. Remove the bolt and withdraw the camshaft from the phaser sprocket assembly leaving the sprocket assembly in place. Discard the bolt and washer.
To install:
  1. Lubricate the camshaft and camshaft journals with clean engine oil.
    WARNING
    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.


    WARNING
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.


    WARNING
    Do not allow the roller followers to move out of position when installing the camshaft.
  2. Install the camshaft into the camshaft phaser sprocket assembly and onto the head.
  3. Install a new camshaft phaser bolt finger tight.
    WARNING
    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.


    WARNING
    The timing chain must be installed in its original position onto the camshaft phaser sprocket using the scribed marks, or damage to valves and pistons will result. Verify the camshaft phaser sprocket and timing chain scribe marks are still in alignment.


    WARNING
    Do not allow the roller followers to move out of position when installing the camshaft.
  4. Lubricate the camshaft bearing caps with clean engine oil.
  5. Position the front camshaft bearing cap.
  6. Position the remaining camshaft bearing caps.
  7. Install the bolts loosely.
  8. Tighten the bolts in the sequence shown. Tighten to 10 Nm (89 inch lbs.).
  9. Remove the special tools.
  10. 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.
  11. Verify correct cam position by noting the position of the number 5 cylinder intake and exhaust camshaft lobes.
  12. Using the special tool, install the 3 originally removed roller followers.
  13. Install the CMP sensor and the bolt.
  14. Connect the CMP electrical connector.
    WARNING
    Only use hand tools to install the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.


    WARNING
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
  15. Tighten the camshaft phaser bolt in 2 stages:

    Stage 1: Tighten to 40 Nm (30 ft. lbs.).
    Stage 2: Tighten an additional 90 degrees.
  16. Install the left valve cover.
  17. Install the cooling fan shroud.
Right Side
  1. Before servicing the vehicle, refer to the Precautions Section.
    WARNING
    The camshaft procedure must be followed exactly or damage to the valves and pistons will result.
  2. Remove the cooling fan shroud.
  3. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
  4. Remove the right valve cover.
    WARNING
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
  5. Loosen and back off the right camshaft phaser bolt 1 full turn.
  6. Disconnect the right camshaft position (CMP) sensor electrical connector.
  7. Remove the bolt and the right CMP sensor.
    NOTE
    If the camshaft lobes are not exactly positioned as shown, the crankshaft will require 1 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-5.4L engine
  8. 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.
  9. Remove only the 3 roller followers shown in the illustration.
    WARNING
    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.



    Click image to see an enlarged view
    Fig. Remove only these 3 roller followers at this time-5.4L engine
  10. Using special tool 303-1039, remove only the 3 designated roller followers from the previous step.
    WARNING
    The crankshaft cannot be moved past the 6 o'clock position once set.



    Click image to see an enlarged view
    Fig. Using special tool 303-1039-5.4L engine
  11. 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.
    WARNING
    Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result.


    WARNING
    The Timing Chain Wedge tool must be installed square to the timing chain and the engine block.


    NOTE
    Front cover removed for clarity.
  12. Install the special tools in the right timing chain as shown.
    WARNING
    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.


    WARNING
    The timing chain must be installed in its original position onto the camshaft phaser sprocket using the scribed marks, or damage to valves and pistons will result.



    Click image to see an enlarged view
    Fig. Timing chain wedge tool installed-5.4L engine
  13. Scribe a location mark on the timing chain and the camshaft phaser sprocket assembly.
    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. Scribe a location mark on the timing chain and the camshaft phaser sprocket assembly-5.4L engine


    Click image to see an enlarged view
    Fig. Camshaft bearing cap removal/installation sequence-5.4L engine
  14. Remove the bolts in the sequence shown and remove the front camshaft bearing cap and then the remaining bearing caps.
  15. 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.
    WARNING
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.


    WARNING
    Only use hand tools to remove the camshaft phaser sprocket bolt or damage may occur to the camshaft or camshaft phaser unit.


    WARNING
    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.



    Click image to see an enlarged view
    Fig. The camshaft front thrust bearing cap contains an oil metering groove-5.4L engine
  16. Remove the bolt and withdraw the camshaft from the phaser sprocket assembly leaving the sprocket assembly in place. Discard the bolt and washer.
To install:
  1. Lubricate the camshaft and camshaft journals with clean engine oil.
    WARNING
    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.


    WARNING
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.


    WARNING
    Do not allow the roller followers to move out of position when installing the camshaft.
  2. Install the camshaft into the camshaft phaser sprocket assembly and onto the head.
  3. Install a new camshaft phaser bolt finger tight.
    WARNING
    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.


    WARNING
    The timing chain must be installed in its original position onto the camshaft phaser sprocket using the scribed marks, or damage to valves and pistons will result.
  4. Verify the camshaft phaser sprocket and timing chain scribe marks are still in alignment.
    WARNING
    Do not allow the roller followers to move out of position when installing the camshaft.
  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 bolts in the sequence shown. Tighten to 10 Nm (89 inch lbs.).
  10. Remove the special tools.
  11. 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.
  12. Verify correct cam position by noting the position of the number 1 cylinder intake and exhaust camshaft lobes.
  13. Using the special tool, install the 3 originally removed roller followers.
  14. Install the CMP sensor and the bolt.
  15. Connect the CMP electrical connector.
    WARNING
    Only use hand tools to install the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.


    WARNING
    Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
  16. Tighten the camshaft phaser bolt in 2 stages:

    Stage 1: Tighten to 40 Nm (30 ft. lbs.).
    Stage 2: Tighten an additional 90 degrees.
  17. Install the right valve cover.
6.0L Diesel Engine
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Mount the engine on an engine stand.
  3. Remove the serpentine belt idler.
  4. Remove the serpentine belt tensioner.
  5. Remove and discard the O-rings from the oil filter base.
  6. Remove the exhaust gas recirculation (EGR) cooler coolant supply port cover. Clean and inspect the gaskets. Install new gaskets if necessary. Clean and inspect the sealing surfaces.
    WARNING
    In the event of a catastrophic engine failure, always install a new oil cooler cover assembly (with oil cooler). Foreign material cannot be removed from the oil cooler.


    NOTE
    The oil cooler is replaced as an assembly.
  7. Remove the oil cooler assembly. Clean and inspect the gaskets. Install a new gasket if necessary. Clean and inspect the sealing surfaces.
  8. Remove the oil pump inlet strainer. Clean and inspect for tears and other damage.
  9. Remove bolts and the turbocharger heat shield.
  10. Remove the high-pressure oil pump cover. Use a thin gasket scraper to separate the cover from the crankcase. Clean and inspect the gaskets. Install a new gasket if necessary. Clean and inspect the sealing surfaces.
  11. Remove the bolts from the high-pressure oil pump discharge pipe.
  12. Disconnect and remove the high-pressure oil pump discharge pipe.
  13. Remove and discard the D-ring seal.
  14. Remove and discard the high-pressure pump O-ring seal.
  15. Remove the bolts and the high-pressure oil pump.
  16. Remove and discard the lower O-ring seal.
  17. Remove the glow plug buss bar.
  18. Remove the eight glow plugs.
    NOTE
    Mark the location of the stud bolts.
  19. Remove the valve covers. Clean and inspect the gaskets. Install a new gasket if necessary. Clean and inspect the sealing surfaces.
  20. Remove the bolts and the coolant pump pulley.
  21. Remove the coolant pump.
  22. If equipped, remove the bolts and the dual alternator pulley.
  23. Prior to removing the crankshaft damper, check the crankshaft vibration damper runout.
    NOTE
    Pry the crankshaft forward at the same point to eliminate possible error caused by crankshaft end play.
  24. Rotate the crankshaft 90 degrees. Pry the crankshaft forward. Record the measurement. Repeat every 90 degrees. If the runout exceeds 0.002 inch, install a new crankshaft vibration damper.
    WARNING
    To prevent engine damage, you must always replace all four bolts when installing the vibration damper.


    CAUTION
    To avoid personal injury, support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft very easily.
  25. Remove the bolts and the crankcase vibration damper. Discard the bolts.
  26. Punch two holes in the seal. Remove the crankshaft seal with a slidehammer.
    NOTE
    Production engine will not have a wear sleeve. If equipped, remove the crankshaft damper wear sleeve.
  27. Remove the oil pump body. Remove and discard the O-ring seal.
    NOTE
    Mark the front of each drive rotor for correct reassembly orientation.
  28. Remove the inner and outer oil pump drive rotors.
  29. Remove the engine front cover. Clean and inspect the gaskets. Install new gaskets if necessary. Clean and inspect the sealing surfaces.
  30. Using a quick-disconnect tool, disconnect the high-pressure oil rail supply line at the high-pressure oil rail.
  31. Remove the bolts and the high pressure oil rail. Disconnect and remove the high-pressure oil supply line.
    WARNING
    Do not attempt to put battery voltage to the fuel injector or damage to the fuel injector will occur.
  32. Using a 19 mm socket, push the fuel injector electrical connector out of the rocker arm carrier.
    WARNING
    To prevent engine damage, do not use air tools to remove the fuel injectors. The clip that extracts the injector can dislodge and fall into the oil drain hole.


    NOTE
    If engine oil is found in the engine coolant or engine coolant is found in the combustion chambers, new injector sleeve may need to be installed.
  33. Remove the bolt, the fuel injector hold down and the fuel injector.
  34. Remove and discard the crankcase-to-head tube assembly.
  35. Remove the inner head bolts from both cylinder heads.
  36. Remove the 16 bolts and the rocker arm assemblies.
  37. Remove the rocker arm carrier from the cylinder head. Clean and inspect the gaskets. Install new gaskets if necessary. Clean and inspect the sealing surfaces.
    NOTE
    Mark the location of the valve bridges before removing.
  38. Remove the 16 valve bridges.
    WARNING
    To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
  39. Mark the location and remove the 16 push rods.
  40. Remove the 10 outer head bolts.
  41. Remove the cylinder heads.
  42. Remove and discard the cylinder head gasket.
  43. Remove and discard the four cylinder head dowel sleeves.
  44. Remove the bolts from the rear engine tube assembly.
  45. Remove the bolt and the rear engine tube assembly.
    WARNING
    To prevent engine damage, keep the cam followers in the order in which they were removed. Install all cam followers back in their original positions.
  46. Remove the bolts and the roller follower guides. Remove the hydraulic cam followers.
  47. Install the special tool and measure the camshaft gear backlash. Install a new camshaft gear if backlash is not within specification.
  48. Install a dial indicator and measure the camshaft end play. Install a new camshaft thrust plate if end play is not within 0.002-0.008 inch.
  49. Remove the bolt and the camshaft position (CMP) sensor.
    WARNING
    Do not knick or scratch the camshaft bearings with the camshaft lobes or engine damage will occur.
  50. Remove the thrust plate mounting bolts and remove the camshaft and gear.
To install:

NOTE
Check alignment of the oil holes after installing the bearings.

  1. If removed, install the camshaft bearings.
    WARNING
    Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage can occur.


    NOTE
    Apply clean engine oil to the camshaft prior to installing.



    Click image to see an enlarged view
    Fig. Using camshaft alignment tool 303-772, install the camshaft and gear assembly
  2. Using camshaft alignment tool 303-772, install the camshaft and gear assembly. Aligning it with the crankshaft. Install the thrust plate mounting bolts. Torque to 23 ft. lbs. (31 Nm).
  3. The remainder of installation is the reverse of removal.

These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



1 comment:

  1. A great article, many thanks for taking the trouble to put it together. babbit bearings

    ReplyDelete