Wednesday, March 14, 2012

How to Replace Camshaft & Valve Lash Adjuster on Ford Escape and Mercury Mariner?


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

The procedure to replace Camshaft & Valve Lash Adjuster is as follows:---

Removal & Installation



2.3L Engine
Specific to:
Ford Escape 2008
Mercury Mariner 2008

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.


WARNING
Do not rotate the camshafts unless instructed to in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves and pistons.


image
Fig. Special tools required
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. With the vehicle in NEUTRAL, position it on a hoist.
  4. Remove the valve cover. Refer to Valve Cover Removal & Installation in this section.
  5. Check the valve clearance. Refer to Valve Lash Adjustment in this section.
    NOTE
    Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time.
  6. Remove the front RH wheel and tire.
  7. Remove the accessory drive belt.
    WARNING
    Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  8. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.

    Click image to see an enlarged view
    Fig. Hole in the crankshaft pulley should be in the 6 o'clock position
  9. Install the alignment plate 303-465 special tool in the slots on the rear of both camshafts.
  10. Remove the engine plug bolt.

    Click image to see an enlarged view
    Fig. Remove the engine plug bolt
  11. Install the timing peg 303-507special tool.
    NOTE
    The timing peg special tool will contact the crankshaft and prevent it from turning past top dead center (TDC). However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the camshaft removal and installation.



    Click image to see an enlarged view
    Fig. Timing peg 303-507special tool installed
  12. Install a standard 0.23 inch (6 mm) x 0.7 inch (18 mm) bolt through the crankshaft pulley and thread it into the front cover.
  13. Remove the lower front cover timing hole plug from the engine front cover.

    Click image to see an enlarged view
    Fig. Lower front cover timing hole plug
  14. Remove the upper front cover timing hole plug from the engine front cover.

    Click image to see an enlarged view
    Fig. Upper front cover timing hole plug
  15. Reposition the alignment plate 303-465 special tool to the slot on the rear of the intake camshaft only.
    NOTE
    Releasing the ratcheting mechanism in the timing chain tensioner allows the plunger to collapse and create slack in the timing chain. Installing an 1.18 inch (M6 x 30 mm) bolt into the upper front cover timing hole will hold the tensioner arm in a retracted position and allow enough slack in the timing chain for removal of the exhaust camshaft gear.



    Click image to see an enlarged view
    Fig. Reposition the alignment plate 303-465 special tool to the slot on the rear of the intake camshaft
  16. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole.

    Click image to see an enlarged view
    Fig. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole
  17. Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise to collapse the timing chain tensioner plunger.
  18. Insert an 1.18 inch (M6 x 30 mm) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
  19. Remove the alignment plate 303-465 special tool.
  20. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.
  21. Remove the timing chain from the intake camshaft drive gear.
  22. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and intake camshaft drive gear.
  23. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
  24. Mark the location and orientation of each camshaft bearing cap.
  25. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps.
  26. Remove the bolts and the camshaft bearing caps.
  27. Remove the camshafts.
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 can cause severe damage to the valves and pistons.

  1. Lubricate the camshaft journals and bearing caps with clean engine oil.
  2. Install the camshafts and bearing caps in their original location and orientation. 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 finger tight.
    Stage 2: Tighten to 62 inch lbs. (7 Nm).
    Stage 3: Tighten to 12 ft. lbs. (16 Nm).

    Click image to see an enlarged view
    Fig. Camshaft bearing cap tightening sequence
  3. Install the alignment plate 303-465 special tool.
  4. Install the intake camshaft drive gear and hand-tighten the bolt.
  5. Install the timing chain on the intake camshaft drive gear.
    NOTE
    The timing chain must be correctly engaged on the teeth of the crankshaft timing sprocket and the intake camshaft drive gear in order to install the exhaust camshaft drive gear onto the exhaust camshaft.
  6. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft.
  7. Hand-tighten the bolt.
    NOTE
    Releasing the tensioner arm will remove the slack from the timing chain release.
  8. Remove the M6 x 30 mm bolt from the upper front cover timing hole to release the tensioner arm.
    NOTE
    The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  9. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts to 53 ft. lbs. (72 Nm).
  10. Remove the alignment plate 303-465 special tool.
  11. Remove the 0.23 inch (6 mm) x 0.7 inch (18 mm) bolt.
  12. Remove the timing peg special tool.
  13. Install the upper front cover timing hole plug and tighten to 89 inch lbs. (10 Nm).
  14. Apply silicone gasket and sealant to the threads of the lower front cover timing hole plug.
  15. Install the plug and tighten to 12 Nm (9 lb-ft).
  16. Install the engine plug bolt and tighten to 15 ft. lbs. (20 Nm).
  17. Install the accessory drive belt.
  18. Install the front RH wheel and tire.
  19. Install the valve cover.
  20. Connect the negative battery cable.
2.5L Engine
Specific to:
Ford Escape 2009
Mercury Mariner 2009

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.


WARNING
Do not rotate the camshafts unless instructed to in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves and pistons.



Click image to see an enlarged view
Fig. Special tools required
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. With the vehicle in NEUTRAL, position it on a hoist.
  4. Remove the valve cover. Refer to Valve Cover Removal & Installation in this section.
  5. Check the valve clearance. Refer to Valve Lash Adjustment in this section.
    NOTE
    Before removing the camshafts, measure the clearance of each valve at base circle, with the lobe pointed away from the tappet. Failure to measure all clearances prior to removing the camshafts will necessitate repeated removal and installation and wasted labor time.
  6. Remove the front RH wheel and tire.
  7. Remove the accessory drive belt.
    WARNING
    Failure to position the No. 1 piston at Top Dead Center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.
  8. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC). The hole in the crankshaft pulley should be in the 6 o'clock position.

    Click image to see an enlarged view
    Fig. Hole in the crankshaft pulley should be in the 6 o'clock position
  9. Install the alignment plate 303-465 special tool in the slots on the rear of both camshafts.
  10. Remove the engine plug bolt.

    Click image to see an enlarged view
    Fig. Remove the engine plug bolt
  11. Install the timing peg 303-507special tool.
    NOTE
    The timing peg special tool will contact the crankshaft and prevent it from turning past top dead center (TDC). However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the camshaft removal and installation.



    Click image to see an enlarged view
    Fig. Timing peg 303-507special tool installed
  12. Install a standard 0.23 inch (6 mm) x 0.7 inch (18 mm) bolt through the crankshaft pulley and thread it into the front cover.
  13. Remove the lower front cover timing hole plug from the engine front cover.

    Click image to see an enlarged view
    Fig. Lower front cover timing hole plug
  14. Remove the upper front cover timing hole plug from the engine front cover.

    Click image to see an enlarged view
    Fig. Upper front cover timing hole plug
  15. Reposition the alignment plate 303-465 special tool to the slot on the rear of the intake camshaft only.
    NOTE
    Releasing the ratcheting mechanism in the timing chain tensioner allows the plunger to collapse and create slack in the timing chain. Installing an 1.18 inch (M6 x 30 mm) bolt into the upper front cover timing hole will hold the tensioner arm in a retracted position and allow enough slack in the timing chain for removal of the exhaust camshaft gear.



    Click image to see an enlarged view
    Fig. Reposition the alignment plate 303-465 special tool to the slot on the rear of the intake camshaft
  16. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole.

    Click image to see an enlarged view
    Fig. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole
  17. Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise to collapse the timing chain tensioner plunger.
  18. Insert an 1.18 inch (M6 x 30 mm) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
  19. Remove the alignment plate 303-465 special tool.
  20. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.
  21. Remove the timing chain from the intake camshaft drive gear.
  22. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and intake camshaft drive gear.
  23. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
  24. Mark the location and orientation of each camshaft bearing cap.
  25. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time until all tension is released from the camshaft bearing caps.
  26. Remove the bolts and the camshaft bearing caps.
  27. Remove the camshafts.

    Click image to see an enlarged view
    Fig. Camshaft bearing cap loosening sequence
  28. If removal of the camshaft phaser and sprocket is necessary, mark the sprocket and camshaft for reference during installation. If necessary, place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.

    Click image to see an enlarged view
    Fig. Mark the sprocket and camshaft for reference during installation
To install:

NOTE
If new parts are installed, transfer the reference marks made during disassembly to the new parts.

  1. If necessary, position the camshaft in a soft-jawed vise and install the camshaft phaser and sprocket and the bolt.
  2. Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt to 53 ft. lbs. (72 Nm).
    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.
  3. Lubricate the camshaft journals and bearing caps with clean engine oil.
  4. Install the camshafts and bearing caps in their original location and orientation. 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 finger tight.
    Stage 2: Tighten to 62 inch lbs. (7 Nm).
    Stage 3: Tighten to 12 ft. lbs. (16 Nm).

    Click image to see an enlarged view
    Fig. Camshaft bearing cap tightening sequence
  5. Install the alignment plate 303-465 special tool.
  6. Install the intake camshaft drive gear and hand-tighten the bolt.
  7. Install the timing chain on the intake camshaft drive gear.
    NOTE
    The timing chain must be correctly engaged on the teeth of the crankshaft timing sprocket and the intake camshaft drive gear in order to install the exhaust camshaft drive gear onto the exhaust camshaft.
  8. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft.
  9. Hand-tighten the bolt.
    NOTE
    Releasing the tensioner arm will remove the slack from the timing chain release.
  10. Remove the M6 x 30 mm bolt from the upper front cover timing hole to release the tensioner arm.
    NOTE
    The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  11. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts to 53 ft. lbs. (72 Nm).
  12. Remove the alignment plate 303-465 special tool.
  13. Remove the 0.23 inch (6 mm) x 0.7 inch (18 mm) bolt.
  14. Remove the timing peg special tool.
  15. Install the upper front cover timing hole plug and tighten to 89 inch lbs. (10 Nm).
  16. Apply silicone gasket and sealant to the threads of the lower front cover timing hole plug.
  17. Install the plug and tighten to 12 Nm (9 lb-ft).
  18. Install the engine plug bolt and tighten to 15 ft. lbs. (20 Nm).
  19. Install the accessory drive belt.
  20. Install the front RH wheel and tire.
  21. Install the valve cover.
  22. Connect the negative battery cable.
3.0L Engine
Specific to:
Ford Escape 2008-2009
Mercury Mariner 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Remove the timing drive components.
  4. Using the water pump pulley plate, water pump shaft protector and the crankshaft vibration damper remover, remove the coolant pump pulley.
    NOTE
    Do not scratch the camshaft sealing surface while removing the camshaft oil seal. If scratched, camshaft oil seal leakage may occur.



    Click image to see an enlarged view
    Fig. Water pump drive pulley removal
  5. Using the oil seal remover, remove and discard the camshaft oil seal.
  6. Remove the 2 bolts and the camshaft oil seal retainer. Discard the press-in-place gasket.
    NOTE
    The camshafts must be in the neutral position before removing the bearing caps or damage to the engine may occur.
  7. Verify the LH camshafts are in the neutral position.
    NOTE
    Do not allow the camshaft to rotate from the neutral position while removing the camshaft phaser and sprocket or damage to the engine may occur.



    Click image to see an enlarged view
    Fig. LH camshafts in the neutral position
  8. Install a 3 / 8 inch ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for removal of the camshaft phaser and sprocket bolts. 

    Click image to see an enlarged view
    Fig. Holding camshaft in place for removal of the camshaft phaser and sprocket bolts
  9. Remove the 3 bolts and the LH camshaft phaser and sprocket.
    NOTE
    Cylinder head camshaft bearing caps must be assembled in their original positions. Some engines have factory markings on the camshaft bearing caps (as shown in illustration). Engines that do not have the factory markings must be marked for correct position and orientation prior to removal. Failure to install the camshaft bearing caps in their original positions may result in severe engine damage.
  10. If necessary, mark the camshaft bearing cap position and orientation as shown in the illustration.
    NOTE
    After loosening all of the camshaft bearing cap bolts, remove the front camshaft bearing thrust caps (1L and 5L) first, or damage to the thrust caps may occur. 2008 model front caps may be marked (1L and 6L).


    NOTE
    Make sure the camshaft bearing caps are marked as instructed in the previous step.



    Click image to see an enlarged view
    Fig. Camshaft bearing cap position
  11. Loosen the bolts evenly in the sequence shown as follows:

    Remove the camshaft bearing front thrust caps (1L and 5L). Or (1L and 6L) for 2008 models.
    Remove the remaining camshaft bearing caps.
    Remove the camshafts from the cylinder head.

    Click image to see an enlarged view
    Fig. Camshaft bearing cap removal sequence
To install:
  1. Position the camshaft phaser and sprocket onto the intake camshaft. Install the 3 bolts finger-tight.
  2. Lubricate the LH camshafts with clean engine oil and carefully position the camshafts onto the cylinder head.
  3. Align the LH camshafts as shown.
    NOTE
    Cylinder head camshaft journal caps and cylinder heads are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur


    NOTE
    Do not install the camshaft journal thrust caps until all of the camshaft bearing caps have been installed or damage to the thrust caps can occur.
  4. Lubricate the bearing surfaces of the LH camshaft bearing caps with clean engine oil and install the bearing caps. Loosely install the bolts.
  5. Lubricate the bearing surfaces of the LH camshaft bearing thrust caps with clean engine oil and install the bearing thrust caps. Loosely install the bolts.
  6. Loosely install the bolts.
  7. Tighten the LH camshaft bearing cap bolts in the sequence shown in 2 stages as flows:
    NOTE
    Do not allow the camshaft to rotate from the neutral position while tightening the camshaft phaser and sprocket bolts or damage to the engine may occur.



    Stage 1: Tighten to 89 inch lbs. (10 Nm).
    Stage 2: Individually loosen and then tighten each camshaft bearing cap to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Camshaft bearing cap tightening sequence
  8. Install a 3 / 8 inch ratchet and extension into the D-slot on the rear of the intake camshaft to hold the camshaft in place for tightening of the camshaft phaser and sprocket bolts.
  9. Tighten the 3 LH camshaft phaser and sprocket bolts to 159 inch lbs. (18 Nm).
  10. Clean the sealing surfaces with metal surface prep before installing a new press-in-place gasket.
  11. Install the camshaft oil seal retainer and the 2 bolts.
  12. Lubricate the camshaft oil seal with clean engine oil.
  13. Using the camshaft oil seal installer, camshaft oil seal protector and the power steering pump pulley installer, install the camshaft oil seal.

    Click image to see an enlarged view
    Fig. Camshaft oil seal installation
  14. Install the camshaft pulley installer in the camshaft as shown in the illustration.
  15. Adjust the collar on the camshaft pulley Installer screw to get the best thread engagement in the rear of the camshaft.
  16. Position the coolant pump pulley over the previously installed camshaft pulley installer and on the end of the camshaft. Install the camshaft pulley installer, power steering pump pulley installer and the water pump pulley spacer as shown in the illustration.
  17. Using the camshaft pulley installer, power steering pump pulley installer and the water pump pulley spacer, install a new service coolant pump pulley flush with the end of the camshaft.

    Click image to see an enlarged view
    Fig. Pulley installation
  18. Install the timing drive components.
  19. Install the coolant pump belt.
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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