Thursday, March 15, 2012

Camshaft & Lifters Replacing for 2.3l engine and 3.0l engine on Ford, Lincoln and mercury vehicles?


The procedure is similar for both Ford, Lincoln and Mercury car models:----

The procedure is as follows:---

Camshaft & Lifters:---

Removal & Installation



2.3L Engine

WARNING
Do not loosen or remove the crankshaft pulley bolt without first installing the special tools as instructed in this 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 you loosen the pulley bolt. Before any repair requiring loosening or removal of the crankshaft pulley bolt, the crankshaft and camshafts must be locked in place by the special service tools, otherwise severe engine damage can occur.


WARNING
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

  1. Raise and safely support the vehicle.
  2. Release the fuel system pressure, as outlined in the Fuel Section.
  3. Check the valve clearance.
  4. Remove the degas bottle.
  5. Remove the catalytic converter.
  6. Remove the generator.
  7. Remove the fuel supply rail.
  8. Remove the intake manifold.
  9. On Vehicles with secondary air injection (AIR):
    1. Disconnect the secondary air injection (AIR) pump electrical connector.
    2. Remove the 3 bolts and position the AIR pump aside.
  10. Remove the bolt and the radio frequency interference capacitor from the engine mount bracket.
  11. Remove the engine mount bracket bolt.
  12. Install the special tool (303-050) and a suitable length of chain to the threaded hole in the LH side of the engine block.
  13. Install the special tools 313-F072 and 303-050, or equivalent, then using the special tool, lift the engine 25 mm (0.98 in).
  14. Remove the nut, 2 bolts and the engine mount.
  15. Lower the engine 25 mm (0.98 in).
  16. Remove the 2 nuts and the engine mount bracket.
  17. Remove the timing drive components.
  18. Remove the special tool.
  19. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
  20. Remove the bolt and the variable camshaft timing (VCT) solenoid.
    WARNING
    Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
  21. Remove the camshafts from the engine.
  22. Loosen the camshaft bearing cap bolts, in the sequence shown, one turn at a time until all tension is released from the camshaft bearing caps.
  23. Remove the bolts and the camshaft bearing caps.
  24. Remove the camshafts.
    WARNING
    If the camshafts and valve tappets are to be reused, mark the location of the valve tappets to make sure they are assembled in their original positions.


    NOTE
    The number on the valve tappets only reflects the digits that follow the decimal. For example, a tappet with the number 0.650 has the thickness of 3.650 mm.



    Click image to see an enlarged view
    Fig. Camshaft bearing bolt loosening sequence-2.3L engine
  25. Remove and inspect the valve tappets.
To install:

NOTE
Coat the valve tappets with clean engine oil prior to installation.

  1. Install the valve tappets.
    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 can cause severe damage to the valves and pistons.


    NOTE
    Lubricate the camshaft journals and bearing caps with clean engine oil.
  2. Install the camshafts and bearing caps. Tighten the camshaft bearing caps in the sequence shown in 3 stages:
    1. Steps 1: Tighten the camshaft bearing cap bolts until finger-tight.
    2. Steps 2: Tighten to 62 inch lbs. (7 Nm).
    3. Steps 3: Tighten to 12 ft. lbs. (16 Nm).

      Click image to see an enlarged view
      Fig. Camshaft bearing cap bolt tightening sequence-2.3L engine
  3. Install the special tool 303-465, or equivalent..
  4. Install the VCT solenoid and bolt. Tighten to 89 inch lbs. (10 Nm).
  5. Install the timing drive components.
  6. Install the engine mount bracket and the 2 nuts. Tighten to 76 ft. lbs. (103 Nm).
  7. Using the special too, lift the engine 25 mm (0.98 in).
  8. Install the engine mount, nut and 2 bolts. Tighten to 41 ft. lbs. (55 Nm).
  9. Lower the engine 25 mm (0.98 in).
  10. Install the engine mount bracket bolt. Tighten to 85 ft. lbs. (115 Nm).
  11. Install the radio frequency interference capacitor and bolt to the engine mount bracket. Tighten to 89 inch lbs. (10 Nm).
  12. On Vehicles with secondary air injection (AIR):
    1. Install the AIR pump and the 3 bolts.
    2. Tighten to 22 ft. lbs. (30 Nm).
    3. Connect the AIR pump electrical connector.
  13. Install the intake manifold.
  14. Install the fuel supply rail.
  15. Install the generator.
  16. Install the catalytic converter.
  17. Install the degas bottle.
  18. Fill and bleed the engine cooling system
3.0L Engine
Left Side
Specific to:
Ford Fusion 2008-2009
Mercury Milan 2008-2009
  1. Remove the timing drive components (timing chain and sprockets), as outlined in this section.
  2. Cut and discard the coolant pump belt.
  3. Using the special tools, remove the coolant pump drive pulley from the camshaft.
    NOTE
    To make sure of correct sealing, do not scratch the camshaft.



    Click image to see an enlarged view
    Fig. Using the special tools, remove the coolant pump drive pulley from the camshaft
  4. Using the special tools, remove and discard the camshaft oil seal.

    Click image to see an enlarged view
    Fig. Using the special tools, remove and discard the camshaft oil seal
  5. Remove the 2 bolts and the camshaft oil seal retainer.
  6. Discard the press-in-place gasket.
    WARNING
    The camshafts must be in the neutral position before removing the bearing caps.
  7. Verify the camshafts are in the neutral position.
    WARNING
    Do not allow the camshaft to rotate from the neutral position while removing the variable camshaft timing (VCT) actuator.


    NOTE
    Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the VCT actuator bolt.



    Click image to see an enlarged view
    Fig. Verify the camshafts are in the neutral position
  8. Remove the bolt and the variable camshaft timing (VCT) actuator.
    WARNING
    Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If the numbers cannot be seen, mark the camshaft bearing caps prior to removing them.


    WARNING
    After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (1L and 6L) first, or damage to the thrust caps may occur.
  9. Loosen the bolts evenly in the sequence shown:
    1. Remove the camshaft bearing thrust caps (1L and 6L).
    2. Remove the remaining camshaft bearing caps.
    3. Remove the camshafts from the cylinder head.

      Click image to see an enlarged view
      Fig. Left side camshaft bearing cap loosening sequence-3.0L engine
To install:
  1. Position the VCT actuator onto the intake camshaft. Install the bolt finger-tight.
    WARNING
    The camshafts must be installed in the neutral position.
  2. Lubricate the camshafts with clean engine oil and carefully position the camshafts into the cylinder head.
  3. Align the camshafts in the neutral position.
    WARNING
    The camshaft caps must be installed in their original positions or damage to the engine may occur.


    WARNING
    Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur.


    NOTE
    Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil.
  4. Install the camshaft bearing caps and loosely install the bolts.
    NOTE
    Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil.
  5. Install the camshaft bearing thrust caps. Loosely install the bolts.
  6. Tighten the camshaft bearing cap bolts in the sequence shown to 89 inch lbs. (10 Nm).
    WARNING
    Do not allow the camshaft to rotate from the neutral position while tightening the VCT actuator bolt.


    NOTE
    Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the VCT actuator bolt.



    Click image to see an enlarged view
    Fig. Tighten the left side camshaft bearing cap bolts in the sequence shown to 89 inch lbs. (10 Nm)-3.0L engine
  7. Tighten the VCT actuator bolt to 30 ft. lbs. (40 Nm) plus an additional 90 degrees.
    NOTE
    Clean the sealing surface with metal surface cleaner before installing a new press-in-place gasket.
  8. Install the camshaft oil seal retainer and the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
  9. Apply clean engine oil to the seal lip and seal bore before installing the seal.
  10. Using the special tools, install a new camshaft oil seal.
    WARNING
    The pulley is pressed on flush to the end of the camshaft.



    Click image to see an enlarged view
    Fig. Using the special tools, install a new camshaft oil seal
  11. Using the special tool, install the coolant pump drive pulley.

    Click image to see an enlarged view
    Fig. Using the special tool, install the coolant pump drive pulley.
  12. Install the timing drive components (timing chain), as outlined in this section.
  13. Install the coolant pump belt
Right Side
Specific to:
Ford Fusion 2008-2009
Mercury Milan 2008-2009
  1. Remove the timing drive components/timing chain, as outlined in this section.
    WARNING
    The camshafts must be in the neutral position before removing the bearing caps.
  2. Verify the camshafts are in the neutral position.
    WARNING
    Do not allow the camshaft to rotate from the neutral position while removing the variable camshaft timing (VCT) actuator.


    NOTE
    Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the VCT actuator bolt.



    Click image to see an enlarged view
    Fig. Verify the camshafts are in the neutral position-3.0L engine
  3. Remove the bolt and the VCT actuator.
    WARNING
    Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If the numbers cannot be seen, mark the camshaft bearing caps prior to removing them.


    WARNING
    After loosening all of the camshaft bearing cap bolts, remove the camshaft bearing thrust caps (5R and 1R) first, or damage to the thrust caps may occur.
  4. Loosen the bolts evenly in the sequence shown:
    1. Remove the camshaft bearing thrust caps (5R and 1R).
    2. Remove the remaining camshaft bearing caps.
    3. Remove the camshafts from the cylinder head.

      Click image to see an enlarged view
      Fig. Right side camshaft bearing cap loosening sequence-3.0L engine
To install:
  1. Position the VCT actuator onto the intake camshaft. Install the bolt finger-tight.
    WARNING
    The camshafts must be installed in the neutral position.
  2. Lubricate the camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
  3. Align the camshafts in the neutral position.
    WARNING
    The camshaft caps must be installed in their original positions or damage to the engine may occur.


    WARNING
    Do not install the camshaft bearing thrust caps until all of the camshaft bearing caps have been installed, or damage to the thrust caps may occur.


    NOTE
    Lubricate the bearing surfaces of the camshaft bearing caps with clean engine oil.
  4. Install the camshaft bearing caps. Loosely install the bolts.
    NOTE
    Lubricate the bearing surfaces of the camshaft bearing thrust caps with clean engine oil.
  5. Install the camshaft bearing thrust caps. Loosely install the bolts.
  6. Tighten the camshaft bearing cap bolts in the sequence shown to 89 inch lbs. (10 Nm).
    WARNING
    Do not allow the camshaft to rotate from the neutral position while tightening the VCT actuator bolt.


    NOTE
    Install a 3/8-in ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the VCT actuator bolt.



    Click image to see an enlarged view
    Fig. Tighten the right side camshaft bearing cap bolts in the sequence shown to 89 inch lbs. (10 Nm)-3.0L engine
  7. Tighten the VCT actuator bolt to 30 ft. lbs. (40 Nm) plus an additional 90 degrees.
  8. Install the timing drive components/timing chain.


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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