Friday, March 16, 2012

How To Replace Camshaft & Valve Lifters On Ford Ranger?

The Details For Ford Ranger Camshaft & Valve Lifters Are as follows:---


In this Camshaft & Valve Lifters section it provides details for the Following Points:----


  • CAMSHAFT TIMING
  • INSPECTION
  • REMOVAL & INSTALLATION


Camshaft Timing



4.0L Engine
  1. Turn the crankshaft clockwise to position the No. 1 cylinder at Top Dead Center (TDC).
  2. If equipped, remove the nut and position the A/C hose aside.
    WARNING
    Do not rotate the engine counterclockwise. Rotating the engine counterclockwise will result in damage to the damper crankshaft sensor speed wheel and incorrect timing of the engine.


    NOTE
    The crankshaft TDC timing tool must be installed on the damper and should contact the engine block, this positions the engine at TDC.
  3. Install the crankshaft TDC timing tool. 
    image

    Fig. Install the crankshaft TDC timing tool-303-573
  4. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 to the RH cylinder head and, if necessary, tighten the 2 top clamp bolts to 89 inch lbs. (10 Nm). 

    image
    Fig. Install the camshaft sprocket holding tool and the adapter for 303-564
  5. If necessary, using the torque wrench extension and the camshaft sprocket nut socket, loosen the RH camshaft sprocket bolt.
    NOTE
    The camshaft timing slots are off center.
  6. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the camshaft holding tool and the adapter for 303-577 and install the camshaft holding tool and the adapter for 303-577 on the front of the RH cylinder head. 

    image
    Fig. Install the camshaft holding tool 303-577 and the adapter 303-576
  7. Remove the 6 pushpins and the RH lower splash shield.
  8. Remove the RH hydraulic timing chain tensioner. Discard the washer.
  9. Install the timing chain tensioner.
    NOTE
    The RH camshaft sprocket is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt.
  10. Using the torque wrench extension and the camshaft sprocket nut socket, loosen the camshaft sprocket bolt. 
image 
Fig. Install the camshaft sprocket nut socket 303-575 and loosen the camshaft sprocket bolt
  1. Tighten the camshaft sprocket holding tool top 2 clamp bolts to 89 inch lbs. (10 Nm).
  2. Using the torque wrench extension and the camshaft sprocket nut socket, tighten the camshaft bolt to 63 ft. lbs. (85 Nm).
  3. Remove the timing chain tensioner.
  4. Install a new washer on the tensioner.
  5. Install the RH hydraulic timing chain tensioner and tighten to 32 ft. lbs. (44 Nm).
  6. Install the RH lower splash shield and the 5 pushpins.
  7. Remove the camshaft sprocket holding tool, the adapter for 303-564, the camshaft holding tool and the adapter for 303-577 from the RH cylinder head.
  8. Install the Camshaft Sprocket Holding Tool and the Adapter for 303-564 on the front of the LH cylinder head and, if necessary, tighten the top 2 clamp bolts to 89 inch lbs. (10 Nm).
  9. If necessary, loosen the LH camshaft sprocket bolt.
  10. If necessary, loosen the top 2 clamp bolts on the camshaft sprocket holding tool to allow the camshaft sprocket to rotate freely.
    NOTE
    The camshaft timing slots are off center.
  11. Position the camshaft timing slots below the centerline of the camshaft to correctly fit the camshaft holding tool and the adapter for 303-577 and install the camshaft holding tool and the adapter for 303-577 on the rear of the LH cylinder head.
  12. Remove the LH hydraulic timing chain tensioner. Discard the washer.
  13. Install the timing chain tensioner.
  14. Tighten the Camshaft Sprocket Holding Tool top 2 clamp bolts to 89 inch lbs. (10 Nm).
  15. Tighten the LH camshaft bolt to 63 ft. lbs. (85 Nm).
  16. Remove the timing chain tensioner.
  17. Install a new washer on the tensioner.
  18. Install the LH hydraulic timing chain tensioner and tighten to 32 ft. lbs. (44 Nm).
  19. Remove the camshaft sprocket holding tool, the adapter for 303-564, the camshaft holding tool and the adapter for 303-577 from the LH cylinder head.
  20. Remove the Crankshaft TDC timing tool.
  21. If equipped, position the A/C hose and install the nut. Tighten the nut to 177 inch lbs. (20 Nm).
  22. Install the camshaft roller followers.
  23. Start the engine check for leaks and repair if necessary.

Inspection



Camshaft Lobe Lift
Camshaft lobe lift is the amount (measured in inches or millimeters) that the camshaft is capable of LIFTING the valve train components in order to open the valves. The lobe lift is a measure of how much taller the -egg shaped'' portion of the camshaft lobe is above the base or circular portion of the shaft lobe. Lift is directly proportional to how far the valves can open and a worn camshaft (with poor lobe lift) cannot fully open the valves. The lobe lift therefore can be directly responsible for proper or poor engine performance.
Lobe lift can be measured in 2 ways, depending on what tools are available and whether or not the camshaft has been removed from the engine. A dial gauge can be used to measure the lift with the camshaft installed, while a micrometer is normally only used once the shaft has been removed from the engine.
Dial Gauge Method
Specific to:
Ford Ranger 2008-2009
Lobe lift may be checked with the camshaft installed. In all cases, a dial gauge is positioned somewhere on the valve train (pushrod, lifter, or camshaft itself) and the camshaft is then turned to measure the lift.
Check the lift of each lobe in consecutive order and make a note of the reading.
  1. Remove the valve cover for access to the camshaft.
  2. Install a dial indicator so that the actuating point of the indicator is directly placed on the camshaft.
    NOTE
    A remote starter can be used to turn the engine over during the next steps. If a remote starter is not available, remove the spark plugs in order to relieve engine compression, and turn the engine over using a large wrench or socket on the crankshaft damper bolt. BE SURE to only turn the engine in the normal direction of rotation.
  3. Turn the crankshaft over until the tappet is on the base circle of the camshaft lobe.
  4. Zero the dial indicator. Continue to rotate the crankshaft slowly until the pushrod (or camshaft lobe) is in the fully raised position.
  5. Compare the total lift recorded on the dial indicator with the elevation specification.
To check the accuracy of the original indicator reading, continue to rotate the crankshaft until the indicator reads zero. If the lift on any lobe is below specified wear limits listed, the camshaft and the valve tappets must be replaced.
  1. Install the valve cover(s).
Micrometer
Specific to:
Ford Ranger 2008-2009
A micrometer may used to measure camshaft lobe lift, but this is usually only after it has been removed from the engine. Once the valve cover is removed from the, access may be possible (though a little awkward) to measure the camshaft lobes using a micrometer.
In any case, two measurements are necessary for each lobe. Measurement Y or the total LOBE HEIGHT and measurement X or the total LOBE WIDTH. To find the lobe lift, you simply subtract X from Y (subtract the width from the height).
Click image to see an enlarged view
Fig. Camshaft lobe lift is measured in two places
Note each measurement, then make your calculation to determine the lift. Note the final results and repeat the process on the remaining camshaft lobes. Finally, you should compare your results to the specifications and decide if a new camshaft is in your future.

Removal & Installation



2.3L Engine
Specific to:
Ford Ranger 2008-2009

WARNING
Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in the crankshaft pulley procedure. The crankshaft pulley and the crankshaft timing sprocket are not keyed to the crankshaft. The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if the pulley bolt is loosened. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special tools, otherwise severe engine damage may occur.

  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Relieve the fuel system pressure.
  3. Drain the cooling system.
  4. Remove the front timing cover. Refer to Timing Chain, Cover and Sprockets Removal & Installation in this section.
  5. Remove the timing chain and sprockets. Refer to Timing Chain, Cover and Sprockets Removal & Installation in this section.
  6. Remove the camshaft alignment plate.
    WARNING
    Failure to follow the camshaft loosening procedure may result in damage to the camshafts.



    Click image to see an enlarged view
    Fig. Camshaft alignment plate-303-465
  7. Mark the location and orientation of each camshaft bearing cap.
  8. Note the position of the lobes on the No. 1 cylinder before removing the camshafts for assembly reference
  9. Remove the camshafts from the engine as follows:

    Loosen the 20 camshaft bearing cap bolts, in sequence, one turn at a time.
    Repeat the first step until all tension is released from the camshaft bearing caps.
    Remove the 10 camshaft bearing caps.
    Remove the 2 camshafts.

    Click image to see an enlarged view
    Fig. Camshaft bearing cap removal sequence
To install:

WARNING
Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position, may cause severe damage to the valves and pistons.

  1. Lubricate the camshaft journals and bearing caps with clean engine oil prior to installation.
  2. Position the camshafts and bearing caps in their original location and orientation. Loosely install the 20 bolts and tighten the bearing caps in the sequence shown in 3 stages:

    Stage 1: Tighten the camshaft bearing cap bolts one turn at a time until snug.
    Stage 2: Tighten the bolts to 62 inch lbs. (7 Nm).
    Stage 3: Tighten the bolts to 142 lbs.(16 Nm).

    Click image to see an enlarged view
    Fig. Camshaft bearing cap tightening sequence
  3. Install the timing chain and sprockets.
  4. Install the timing front cover.
3.0L Engine
Specific to:
Ford Ranger 2008
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Properly relieve the fuel system pressure.
  3. Disconnect the negative battery cable.
  4. Drain the cooling system.
  5. Drain the engine oil.
  6. Remove the radiator assembly.
  7. Remove the upper intake manifold.
  8. Remove the valve covers.
  9. Loosen the rocker arm bolts.
    NOTE
    Identify the location of each push rod. Each push rod is to be installed in the original location to prevent premature wear.
  10. Remove all the push rods.
  11. Remove the bolts from the lower intake manifold.
  12. Remove the 2 bolts and the hydraulic lash adjuster guide plate retainer.
  13. Remove the hydraulic lash adjuster guide plates.
  14. Remove the hydraulic lash adjusters.
  15. Remove the engine front cover.
  16. Remove the timing chain.
    NOTE
    Prior to the removal of the CMP sensor, note the position of the CMP sensor electrical connector. The installation procedure requires that the electrical connector be located in the same position.
  17. Remove the camshaft synchronizer assembly as follows:

    Disconnect the Camshaft Position (CMP) sensor electrical connector.
    Remove the 2 bolts and the CMP sensor.
    Remove the camshaft synchronizer bolt.
    Remove the camshaft synchronizer. Inspect the O-ring seal and install a new O-ring seal if damaged
  18. Remove the bolts and the camshaft thrust plate.
    WARNING
    Damage to the camshaft or the camshaft bearings may occur if the camshaft is allowed to drop on the bearing surface or cylinder block.
  19. Remove the camshaft.

    Click image to see an enlarged view
    Fig. Camshaft-3.0L engine
To install:
  1. Lubricate the camshaft, the camshaft bearings and the camshaft position sensor drive gear with clean engine oil prior to installation.
  2. Carefully install the camshaft.
  3. Lubricate the camshaft thrust plate with clean engine oil prior to installation.
  4. Install the camshaft thrust plate and the bolts. Tighten the bolts to 89 inch lbs. (10 Nm).
  5. Measure the camshaft end play. Camshaft end-play specification: 0.003-0.007
  6. Install the timing chain and front cover.
    WARNING
    If a new camshaft is installed, always add the rest of the clean engine oil to the engine oil by pouring it through the distributor hole onto the camshaft drive gear. Run engine at idle for 5 minutes before driving vehicle. Failure to follow these instructions may cause engine damage.
  7. Completely coat camshaft synchronizer gear teeth with clean engine oil.
    WARNING
    After installation, do not loosen the synchronizer bolt and rotate the synchronizer assembly. The synchronizer assembly is not adjustable. Do not loosen the synchronizer bolt after the alignment tool has been removed in order to align the camshaft position (CMP) sensor electrical connector for any reason. If the electrical connector is not in the correct position, the synchronizer assembly must be removed. The alignment tool and the assembly must be reinstalled if the engine has not been rotated from top dead center (TDC) of the compression stroke on the No. 1 cylinder. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage.


    NOTE
    Do not turn the crankshaft or camshaft during the removal and installation procedure or the fuel system timing will be out of time with the engine, possibly causing engine damage.


    NOTE
    A special tool must be used during the installation of the new synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage.
  8. Install the special tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing and the armature. During installation, the arrow on the special tool will rotate clockwise until the oil pump intermediate shaft and the camshaft gear engages.

    Click image to see an enlarged view
    Fig. Special tool 303-589 shown on the camshaft synchronizer
  9. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 38 degrees from the centerline of the engine.

    Click image to see an enlarged view
    Fig. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 38 degrees from the centerline of the engine
  10. Install the camshaft synchronizer housing bolt. Tighten to 22 ft. lbs. (30 Nm).
  11. Position the CMP sensor and install the 2 bolts. Tighten to 27 inch lbs. (3 Nm).
  12. Connect the CMP sensor electrical connector.
    NOTE
    Lubricate the hydraulic lash adjusters and the hydraulic lash adjuster bores with clean engine oil prior to installation.
  13. Install the hydraulic lash adjusters.
  14. Install the hydraulic lash adjuster guide plates.
  15. Install the hydraulic lash adjuster guide plate retainer and the 2 bolts. Tighten to 106 inch lbs. (12 Nm).
  16. Install the lower intake manifold.
  17. Tighten the rocker arm bolts and tighten to 24 ft. lbs. (32 Nm).
  18. Install the valve covers.
  19. Install the upper intake manifold.
  20. Install the radiator assembly.
  21. Fill the engine with clean engine oil.
  22. Fill and bleed the cooling system.
  23. Connect the negative battery cable.
  24. Start the engine check for leaks and repair if necessary.
4.0L Engine
Specific to:
Ford Ranger 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Properly relieve the fuel system pressure.
  4. Disconnect the negative battery cable.
  5. Remove the LH and RH valve covers.
  6. Remove the fuel rail.
  7. Remove the cooling fan.
  8. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle.
    NOTE
    Mark each camshaft roller follower to make sure it is returned to its original position.



    Click image to see an enlarged view
    Fig. Rotate the crankshaft until the camshaft for the cylinder being serviced is at base circle
  9. Using the valve spring compressor, remove the camshaft roller followers.

    Click image to see an enlarged view
    Fig. Valve spring compressor-303-581
  10. Remove the RH hydraulic chain tensioner.

    Click image to see an enlarged view
    Fig. Remove the RH hydraulic chain tensioner
  11. Install the camshaft sprocket holding tool and the adapter for 303-564 on the rear of the RH cylinder head and tighten the top 2 clamp bolts to 89 inch lbs. (10 Nm).
    NOTE
    The RH camshaft sprocket is a LH-threaded bolt. Turning the bolt in the wrong direction can damage the bolt.



    Click image to see an enlarged view
    Fig. Install the camshaft sprocket holding tool and the adapter for 303-564
  12. Using the torque wrench extension and the camshaft sprocket nut socket, loosen the camshaft sprocket bolt.

    Click image to see an enlarged view
    Fig. Install the camshaft sprocket nut socket 303-575 and loosen the camshaft sprocket bolt
  13. Remove the bolt and position the camshaft sprocket aside.
  14. Remove the LH hydraulic chain tensioner
  15. Install the camshaft sprocket holding tool and the adapter for 303-564 on the rear of the RH cylinder head and tighten the top 2 clamp bolts to 89 inch lbs. (10 Nm).
  16. Loosen the LH camshaft sprocket bolt.
  17. Remove the bolt and position the camshaft sprocket aside.
  18. Mark the position of the camshaft bearing caps so they can be installed in their original positions.
  19. Remove the 8 bolts in the sequence shown for the RH and LH side and remove the camshaft bearing caps.

    Click image to see an enlarged view
    Fig. Camshaft bearing cap removal sequence
  20. Remove the camshafts.
To install:
  1. Install the camshafts.
  2. Install the camshaft bearing caps and the 8 bolts on each side.
  3. Tighten the 8 bolts in the sequence shown on each side in 2 stages:
    NOTE
    After installing the bolts, check the camshaft for free rotation.



    Stage 1: Tighten to 53 inch lbs. (6 Nm).
    Stage 2: Tighten to 142 inch lbs. (16 Nm).
  4. Install the RH camshaft sprocket and loosely install the bolt.
  5. Install the LH camshaft sprocket and loosely install the bolt.
    WARNING
    The camshafts must be retimed or engine damage may occur.
  6. Retime the camshafts. Refer to Camshaft Timing in this section.
  7. Using the valve spring compressor, install the camshaft roller followers.
  8. Install the cooling fan.
  9. Install the fuel rail.
  10. Install the LH and RH valve covers.
  11. Start the engine check for leaks and repair if necessary.

These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

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


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