Camshaft Synchronizer (4.2L): Installation

WARNING: This page is about a different car, the 2003 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.

Install Synchronizer Alignment Gauge on camshaft synchronizer assembly (CMP sensor removed). See Fig 2. Turn camshaft synchronizer shaft clockwise until tool boss engages with notch in camshaft synchronizer assembly. Tool should fit squarely in top of camshaft synchronizer assembly.
Ensure piston No. 1 is in TDC position on compression stroke. Install oil pump drive shaft in camshaft synchronizer assembly. Lubricate camshaft synchronizer gear with engine oil.

NOTE: During installation, arrow on synchronizer positioner will rotate clockwise until oil pump intermediate shaft and camshaft gear engage.

Install camshaft synchronizer housing assembly so arrow on Synchronizer Alignment Gauge is 54 degrees from the centerline of the engine. See Fig 2.
Position water outlet tube and connect coolant hose(s). Install camshaft synchronizer retaining bolt. Tighten bolt to specification. See TORQUE SPECIFICATIONS .
Inspect EGR valve adapter gasket and replace if necessary, position EGR valve adapter gasket and EGR valve adapter assembly. See Fig 1. Install bolts and nut. Tighten bolts and nut to specification. See TORQUE SPECIFICATIONS .
Install EGR valve tube upper fitting. Tighten fitting to specification. See TORQUE SPECIFICATIONS . Connect EGR valve vacuum hose.
Install CMP sensor. See CAMSHAFT POSITION SENSOR . On vehicles with dual batteries, see DUAL BATTERIES under MISCELLANEOUS. Fill and bleed the engine cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM.

Fig 1: Removing & Installing Exhaust Gas Recirculation Valve & Adapter (4.2L)

Courtesy of FORD MOTOR CO.

Fig 2: Installing Camshaft Synchronizer (4.2L)

Courtesy of FORD MOTOR CO.