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Camshaft REMOVAL & INSTALLATION For Ford Taurus and Mercury Sable?

The details are similar for both Ford Taurus and Mercury Sable car models.

Its for 2008 and 2009 year models.


Camshaft
REMOVAL & INSTALLATION  and VALVE CLEARANCE CHECK
The instructions are as follows :----


Removal & Installation



Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009
  1. Remove engine. Refer to Engine.
  2. Remove upper intake manifold. Refer to Intake Manifold.
  3. Remove the valve covers. Refer to Valve Cover.
  4. Remove the engine front cover and timing chains. Refer to Timing Chain.
  5. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
    NOTE
    The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
  6. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt.
  7. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
    NOTE
    When the special tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
  8. Remove the special tool from the LH camshafts.
    NOTE
    The camshafts must remain in the neutral position during removal or engine damage may occur.
  9. Verify the LH camshafts are in the neutral position. 
    NOTE
    Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.


    image
    Fig. LH camshafts in neutral position
  10. Remove the bolts and the LH camshaft bearing caps.
  11. Remove the LH camshafts.
To install:

WARNING
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.


NOTE
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, may cause engine failure.


NOTE
The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

  1. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
    NOTE
    The camshafts must remain in the neutral position during removal or engine damage may occur.


    NOTE
    Coat the camshafts with clean engine oil prior to installation.



    Click image to see an enlarged view
    Fig. Crankshaft in 9 o-clock position
  2. Position the camshafts onto the LH cylinder head in the neutral position as shown.
    NOTE
    Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.



    Click image to see an enlarged view
    Fig. LH camshafts in neutral position
  3. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).
    NOTE
    If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.


    NOTE
    Use a camshaft sprocket bolt to turn the camshafts.



    Click image to see an enlarged view
    Fig. LH camshaft cap tightening sequence
  4. Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to Valve Clearance Check.
  5. Install the engine front cover and timing chains. Refer to Timing Chain.
  6. Install the valve covers. Refer to Valve Cover.
  7. Install upper intake manifold. Refer to Intake Manifold.
  8. Install engine. Refer to Engine.
RH Camshafts
  1. Remove engine. Refer to Engine.
  2. Remove upper intake manifold. Refer to Intake Manifold.
  3. Remove the valve covers. Refer to Valve Cover.
  4. Remove the engine front cover and timing chains. Refer to Timing Chain.
  5. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
    NOTE
    The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
  6. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt.
  7. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
  8. Remove the special tool from the RH camshafts.
    NOTE
    The camshafts must remain in the neutral position during removal or engine damage may occur.
  9. Rotate the RH camshafts counterclockwise to the neutral position.
    NOTE
    Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.



    Click image to see an enlarged view
    Fig. RH camshafts in neutral position
  10. Remove the bolts and the RH camshaft bearing caps.
  11. Remove the RH camshafts.
To install:

WARNING
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.


NOTE
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, may cause engine failure.


NOTE
The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

  1. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
    NOTE
    The camshafts must remain in the neutral position during removal or engine damage may occur.


    NOTE
    Coat the camshafts with clean engine oil prior to installation.



    Click image to see an enlarged view
    Fig. Crankshaft in 9 o-clock position
  2. Position the camshafts onto the RH cylinder head in the neutral position as shown.
    NOTE
    Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.



    Click image to see an enlarged view
    Fig. RH camshafts in neutral position
  3. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).
    NOTE
    If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.


    NOTE
    Use a camshaft sprocket bolt to turn the camshafts.



    Click image to see an enlarged view
    Fig. RH camshaft cap tightening sequence
  4. Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to Valve Clearance Check.
  5. Install the engine front cover and timing chains. Refer to Timing Chain.
  6. Install the valve covers. Refer to Valve Cover.
  7. Install upper intake manifold. Refer to Intake Manifold.
  8. Install engine. Refer to Engine.

Valve Clearance Check



Specific to:
Ford Taurus 2008-2009
Mercury Sable 2008-2009
  1. Remove the valve covers. Refer to Valve Cover.
    NOTE
    The valve clearance must be measured with the camshaft at base circle. The engine will have to be rotated with the crankshaft pulley bolt to bring each valve to base circle.
  2. Use a feeler gauge to measure the clearance of each valve and record its location. A midrange clearance is the most desirable:
Intake: 0.15-0.25 mm (0.006-0.01 in)
Exhaust: 0.300-0.400 mm (0.0118-0.0157 in)
Click image to see an enlarged view
Fig. Checking valve clearance

NOTE
The number on the valve tappet reflects the thickness of the valve tappet. For example, a tappet with the number 3.310 has the thickness of 3.31 mm (0.13 in).

  1. If any of the valve clearances are out of specification, select new tappets using this formula: tappet thickness = measured clearance + the base tappet thickness - most desirable thickness.
  2. Select the tappets and mark the installation location.
  3. If required, install the new selected valve tappets in the marked locations.


The details will help.
Thanks.






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