ford windstar 3 8 camshaft synchronizer removal


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1996 Ford Aerostar/Ranger/Explorer Camshaft Position (CMP) Sensor REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 30-03-2011

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CAUTION: Syncro Positioning Tool T95T-12200-A (3.0L, 4.0L) or T96T-12200-A (5.0L) must be obtained prior to installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine (6007), possibly causing engine damage. CAUTION: Prior to the removal of the camshaft position sensor (CMP sensor) (12A112), set No. 1 cylinder to 0 degrees top dead center (TDC) of compression stroke. Then note the position of the camshaft position sensor electrical connector. The installation procedure requires that the electrical connector be located in the same position. Removal 1. Disconnect battery ground cable (14301). 2. Disconnect fuel charging wiring electrical connector from camshaft position sensor. 3. Remove the CMP sensor screws and camshaft position sensor from camshaft synchronizer. CAUTION: Do not move crankshaft (6303) until entire installation procedure is complete. Doing so will result in the fuel system being out of time with the engine resulting in possible emissions fault. NOTE: If camshaft synchronizer is to be removed from the cylinder block (6010), proceed with Step 4. If the camshaft synchronizer is not being removed, proceed to installation Step 8. 4. Remove hold-down clamp (12270). 5. Remove camshaft synchronizer from cylinder block. Installation 1. Attach Syncro Positioning Tool T95T-12200-A (3.0L, 4.0L) or T96T-12200-A (5.0L). Camshaft Synchronizer — 3.0L, 4.0L Camshaft Synchronizer — 5.0L 2. Align the synchronizer vane with the radial slot of the Syncro Positioning Tool T95T-12200-A (3.0L) or T96T-12200A (5.0L). 3. Rotate the tool on the synchronizer base until the tool’s boss engages the base notch. 4. Dip gear end into ESE-M2C123-A oil or equivalent to coat gear, thrust washer and lower bearing. Syncro Positioning Tool — 3.0L, 4.0L 5. CAUTION: Do not rotate crankshaft when syncro positioning tool is on the camshaft synchronizer. Armature tab will be damaged and synchronizer timing may be shifted. On 3.0L engines, install camshaft synchronizer so that drive gear engagement occurs when arrow on Syncro Positioning Tool T95T-12200-A is pointed approximately 75 degrees (3.0L), 60 degrees (4.0L) counterclockwise off the centerline of the engine. This step will locate camshaft position sensor electrical connector to the original position. Syncro Positioning Tool — 5.0L On 5.0L engines, install camshaft synchronizer into cylinder block making sure that arrow on Syncro Positioning Tool T96T-12200-A is pointing forward parallel to center line of crankshaft. This step will locate camshaft position sensor electrical connector to the pre-removal position. 6. CAUTION: If camshaft position sensor electrical connector is not positioned properly, DO NOT reposition the connector by rotating the synchronizer assembly. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the synchronizer assembly and repeat Step 5. Install hold-down clamp and tighten to 19-30 Nm (14-22 lb-ft) on 3.0L, 4.0L and 23-34 Nm (17-25 lb-ft) on 5.0L. 7. Remove Syncro Positioning Tool. 8. Install CMP sensor and CMP sensor screws. Tighten to 2.5-3.5 Nm (23-30 lb-in). 9. Connect fuel charging wiring electrical connector to camshaft position sensor (CMP sensor). 10. NOTE: When battery voltage is removed from the powertrain control module (PCM) (12A650), all learned values will be cleared and reset to predetermined values. When battery voltage is restored to the PCM, the vehicle may exhibit certain driveability concerns. It will be necessary to drive the vehicle to allow the PCM to relearn values for optimum driveability and performance. Connect battery ground cable. Camshaft Position (CMP) Sensor — 3.0L Shown, 4.0L, 5.0L Similar

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1998 Ford F-150/250 Synchronizer Camshaft 4.2L REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 20-02-2011

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Removal 1. Disconnect the battery ground cable. 2. Remove the camshaft position sensor (CMP sensor) (6B288); refer to Camshaft Position (CMP) Sensor—4.2L in this section. 3. Remove the exhaust gas recirculation (EGR) valve vacuum hose. 4. Remove the EGR tube upper fitting. 5. Remove the EGR valve (EGR valve) (9D475) and adapter. 1. Remove the bolts. 2. Remove the nut. 3. Remove the EGR valve and adapter assembly. 6. Remove the camshaft synchronizer adjustment bolt. 7. Remove the camshaft synchronizer (12A362). The oil pump drive shaft may come out with the camshaft synchronizer. Installation CAUTION: The Syncro Positioning Tool must be obtained prior to installation of the replacement camshaft synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. 1. Install the Syncro Positioning Tool on the camshaft synchronizer. Rotate the Syncro Positioning Tool until it engages the notch in the camshaft synchronizer housing. 2. NOTE: Rotate crankshaft to #1 cylinder TDC on compression stroke. Install the camshaft synchronizer housing assembly as shown. 3. NOTE: During installation, the arrow on the synchronizer alignment tool will rotate clockwise as the gears engage. Install the camshaft synchronizer housing assembly so the arrow on the Syncro Positioning Tool is 54 degrees from the centerline of the engine.

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1995 Ford Mustang Camshaft Position (CMP) Sensor Removal Installation

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Filed Under (Ford) by admin on 08-02-2011

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1. Disconnect battery ground cable (14301) . 2. Disconnect fuel charging wiring (9D930) from distributor stator (12A112) (camshaft position sensor). 3. Remove stator camshaft position sensor retaining screws and distributor stator (camshaft position sensor) from camshaft position sensor housing. 4. If removing camshaft position sensor housing from the engine front cover (6019) , proceed with Removal Step 5. If camshaft position sensor housing is not being removed, proceed to Installation Step 6. 5. CAUTION: Before proceeding with this procedure, set cylinder No. 1 to 26 degrees After Top Dead Center (ATDC) of the compression stroke. Then note the position of the stator (camshaft position sensor) electrical connector. The installation procedure requires that the connector be located in the same position. Remove retaining bolt and hold-down clamp (12270) . 6. NOTE: The oil pump intermediate shaft (6A618) should be removed with the camshaft position sensor housing. Remove camshaft position sensor housing from engine front cover . Installation 1. CAUTION: If the replacement distributor stator (camshaft position sensor) does not contain a plastic locator cover tool, a special service tool such as Syncro Positioning Tool T89P-12200-A must be obtained prior to installation of the replacement distributor stator (camshaft position sensor). Failure to follow this procedure will result in improper stator (camshaft position sensor) alignment. This will result in the fuel system being out of time with the engine, possibly causing engine damage. If the plastic locator cover tool is not attached to the replacement distributor stator (camshaft position sensor), attach Syncro Positioning Tool T89P-12200-A as follows: a. Engage camshaft position sensor housing vane into the radial slot of the tool. b. Rotate tool on camshaft position sensor housing until tool boss engages notch in camshaft position sensor housing. The cover tool should be square and in contact with entire top surface of camshaft position sensor housing. 2. Transfer oil pump intermediate shaft from old camshaft position sensor housing to replacement camshaft position sensor housing. 3. CAUTION: If stator (camshaft position sensor) electrical connector is not positioned properly (for example, contacting the A/C compressor bracket), DO NOT reposition the connector by rotating the camshaft position sensor housing. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the camshaft position sensor housing and repeat installation procedure, beginning with Step 1. Install camshaft position sensor housing so that drive gear engagement occurs when arrow on locator tool is pointed approximately 30 degrees counterclockwise from the front face of the cylinder block (6010) . This step will locate stator (camshaft position sensor) electrical connector in the pre-removal position. 4. Install hold-down clamp and retaining bolt and tighten bolt to 20-30 Nm (15-22 lb-ft). 5. Remove Syncro Positioning Tool T89P-12200-A. 6. CAUTION: If stator (camshaft position sensor) electrical connector is not positioned properly (for example, contacting the A/C compressor bracket), DO NOT reposition the connector by rotating the camshaft position sensor housing. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the camshaft position sensor housing and repeat installation procedure, beginning with Step 1. Install distributor stator (camshaft position sensor) and retaining screws. Tighten screws to 2.5-3.5 Nm (22-31 lb-in). 7. Connect fuel charging wiring connector to distributor stator (camshaft position sensor). 8. Connect battery ground cable .

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1998 Ford Windstar Camshaft Position (CMP) Sensor REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 17-02-2011

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CAUTION: Prior to removal of the camshaft position sensor (CMP sensor) (12126) , set cylinder No.1 to zero degrees top dead center (TDC) of compression stroke. Then note the position of the camshaft position sensor electrical connector. The installation procedure requires the connector be located in the same position. Removal 1. Disconnect battery ground cable (14301). Refer to Section 14-01. 2. Disconnect fuel charging wiring connector from camshaft position sensor. 3. Remove camshaft position sensor retaining screws and camshaft position sensor from camshaft position sensor housing. 4. If removing camshaft position sensor housing from the cylinder block (6010), proceed with Removal Step 5. If not removing camshaft position sensor housing, proceed to Step 6 of the installation procedures. 5. Remove hold-down clamp (12270) (bolt and washer assembly). 6. NOTE: Remove the oil pump intermediate shaft (6A618) with the camshaft position sensor housing. Remove camshaft position sensor housing from cylinder block. Installation 1. CAUTION: If the replacement camshaft position sensor housing does not contain a plastic locator cover tool, a special service tool must be obtained prior to installation of the replacement camshaft position sensor. Failure to follow this procedure will result in improper camshaft position sensor alignment. This will result in the ignition fuel system being out of time with the engine, possibly causing engine damage. NOTE: For 3.0L engines, use Syncro Positioning Tool 303-589. For 3.8L engines, use Syncro Positioning Tool 303-562 (T96T-12200-A). If the plastic locator cover tool is not attached to the replacement camshaft position sensor housing, attach syncro positioning tool as follows: a. Engage camshaft position sensor housing vane into the radial slot of the tool. b. Rotate tool on camshaft position sensor housing until tool boss engages notch in camshaft position sensor housing. 2. Transfer oil pump intermediate shaft from old camshaft position sensor housing to replacement camshaft position sensor housing. 3. Install camshaft position sensor housing so drive gear engagement occurs when arrow on syncro positioning tool is pointed approximately as shown in the illustrations. This step will locate camshaft position sensor electrical connector in the pre-removal position. 4. Install hold-down clamp (washer and bolt assembly) and tighten bolt to 20-30 Nm (15-22 lb-ft). 5. Remove syncro positioning tool. 6. CAUTION: If camshaft position sensor electrical connector is not positioned properly, DO NOT reposition the connector by rotating the camshaft position sensor housing. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the camshaft position sensor housing and repeat installation procedure, beginning with Step 1. Install camshaft position sensor and retaining screws. On 3.0L engine, tighten screws to 2.5-3.5 Nm (23-30 lb-in). On 3.8L engine, tighten screws to 4.5-7 Nm (40-61 lb-in). 7. Connect fuel charging wiring connector to camshaft position sensor. 8. Connect battery ground cable. Refer to Section 14-01. Camshaft Position Sensor—3.0L Engine

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2002 Ford Taurus Camshaft Synchronizer REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 31-03-2011

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Removal 1. CAUTION: The No. 1 cylinder must be set on top dead center (TDC) of the compression stroke or the synchronizer assembly will not be installed correctly. CAUTION: Do not turn the crankshaft or the camshaft during the removal and installation procedure or the fuel system timing will be out of time with the engine and possibly cause engine damage. Rotate the crankshaft until the No. 1 cylinder is at TDC of the compression stroke and the TDC mark lines up with the timing mark. 2. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 3. Remove the camshaft position (CMP) sensor. For additional information, refer to Camshaft Position (CMP) Sensor — 3.0L (2V) in this section. 4. Remove the camshaft synchronizer bolt. 5. NOTE: The oil pump driveshaft might not come out with the camshaft synchronizer. If so, retrieve the oil pump drive shaft before proceeding. Remove the camshaft synchronizer. Installation 1. CAUTION: 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 CMP 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 reinstalled, if the engine has not been rotated from top dead center (TDC) of the compression stroke on the No. 1 cylinder. CAUTION: Do not turn the crankshaft or the camshaft during the removal and installation procedure or the fuel system timing will be out of time with the engine and possibly cause engine damage. A special tool must be used during the installation of the replacement synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage. 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.