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Camshaft Synchronizer: Installation

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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.
  1. Install Synchro Positioner (303-589) on camshaft synchronizer assembly (CMP sensor removed). See Fig 1. 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.
    2. NOTE: Coat camshaft synchronizer gear with engine oil prior to installation. Failure to do so, may result in gear failure.
  2. 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. Arrow on synchro positioner will rotate clockwise until camshaft synchronizer is fully seated. Insert camshaft synchronizer assembly into engine.
  3. When installed, synchro positioner should point 38 degrees from centerline of engine. See Fig 2. Install and tighten camshaft synchronizer hold-down clamp bolt. If synchro positioner is not pointing in correct direction, remove camshaft synchronizer assembly and return to step  1. If camshaft synchronizer is installed correctly, remove synchro positioner.
  4. Install CMP sensor and tighten bolts to specification. See TORQUE SPECIFICATIONS . Connect CMP sensor harness connector and negative battery cable.
Fig 1: Installing Synchro Positioner On Synchronizer Assembly (Typical)
G95I35855Courtesy of FORD MOTOR CO.
Fig 2: Installing Camshaft Synchronizer (Except 3.0L VIN S)
G00194447Courtesy of FORD MOTOR CO.


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.
  1. Install Synchro Positioning Tool (303-630) on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing and the armature. See Fig 1.
  2. Install camshaft synchronizer housing assembly so the arrow on the Install Synchro Positioning Tool (303-630) is 54 degrees from centerline of the engine. See Fig 2.
  3. Install and tighten synchronizer hold down bolt. See TORQUE SPECIFICATIONS .
  4. Remove Synchro Positioning Tool (303-630). Install CMP sensor to camshaft synchronizer. See REMOVAL & INSTALLATION (3.8L)  under CAMSHAFT POSITION SENSOR. Install the EGR valve to exhaust manifold tube. Connect the battery ground cable.
Fig 1: Installing Synchro Positioning Tool On Camshaft Synchronizer Assembly
G00194449Courtesy of FORD MOTOR CO.
Fig 2: Aligning Camshaft Synchronizer Assembly
G00194450Courtesy of FORD MOTOR CO.
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