Removal
1. Loosen the timing belt tension (p. 1-14 paragraph 10).
2. Remove the belt completely (paragraph 10 clauses 15 and 16) or pull it off the camshaft sprockets without creating large kinks, using only your fingers. Cover the belt and secure it away from the work area. Do not turn the crankshaft until the belt is installed.
3. Unscrew the pulley bolts (see paragraph 10. items 18 and 21) and remove the pulleys. Since the pulleys are identical, it makes sense to mark them to avoid confusion during installation (see Fig. 13.3).
4. Loosen the camshaft bearing cap bolts in a sequential, crisscross pattern (by loosening the bolt half a turn at a time) (see Fig. 13.4, a, b). This is necessary to gradually and evenly relieve the force on the caps, which are pressed by the valve springs.
5. Remove the covers, taking into account their markings and paying attention to the installation pins. Then remove the camshafts and pull out their cuffs. The intake camshaft has a cam for the camshaft position sensor. This is how it differs from the exhaust camshaft, and therefore it is not necessary to mark the shafts (see Fig. 13.5, a, b).
6. You will need 16 small containers numbered 1 through 16. Use a suction cup to remove the hydraulic compensators. On models produced since 05.1998, store the adjusting washers together with the corresponding compensators. On early models, to prevent oil leakage, turn them upside down and lower them into the corresponding containers, which should be filled with engine oil. Do not mix up the hydraulic compensators with each other, as this can lead to significant wear. Do not allow oil to leak out of them, otherwise they will take a long time to fill when the engine is started, which will cause a violation of the valve clearances (see Fig. 13.6, a, b).
Inspection
7. After removing the camshafts and hydraulic lifters, inspect them for wear (scratches, wear spots, etc.) and ovality. Replace faulty parts if necessary.
8. Measure the outside diameter of each hydraulic lifter (see Fig. 13.8). Measure the diameter at the top and bottom of the hydraulic lifter, and then repeat the measurements in a perpendicular direction. If any of the obtained dimensions differ significantly from the others, then the lifter is taper or out of roundness and must be replaced. If you have the necessary equipment, measure the inside diameter of the corresponding hole in the cylinder head. Compare the obtained dimensions with the technical requirements. If the hydraulic lifters or the holes for them are excessively worn, then you will need new hydraulic lifters and / or a new cylinder head.
9. If the valve mechanism is knocking, especially when starting a cold engine, then the cause is probably a faulty hydraulic compensator. Only an experienced auto mechanic who knows such engines can determine by ear whether such noise is normal or whether one or more hydraulic compensators need to be replaced. 8 In the case of searching for faulty hydraulic compensators, when you do not know what kind of maintenance the engine has undergone before, it makes sense to try changing the engine oil and filter (see chapter 1) before purchasing new hydraulic lifters. See also information paragraph 1 this chapter and use only high-quality motor oil of the specified viscosity and specification.
10. Inspect the camshaft lobes for scoring, pitting, areas of wear or metal galling, and areas of overheating (tempering color). Inspect each cam lobe for chipping of the hardened surface layer (see Fig. 13.10). If such signs are found, the faulty components must be replaced.
11. Inspect the camshaft bearing journals and cylinder head bearing surfaces for wear, particularly pitting. If any such signs are found, replace the faulty components.
12. Using a micrometer, measure the journal diameters in several places (see Fig. 13.12). If the diameter of one of the journals is less than that specified in Technical data, replace the camshaft.
13. To check the bearing clearance, remove the compensators and thoroughly wash the bearing surfaces with a suitable solvent using a clean, lint-free cloth. Then install the camshafts and bearing caps, placing a piece of "plastic feeler gauge" thread along the shaft axis on each journal (see Fig. 13.13, a). Tighten the bearing cap bolts to the required torque (without turning the camshafts). Then remove the caps and determine the clearances by comparing the width of the deformed thread with the template (see Fig. 13.13, b). Remove the used plastic thread with a fingernail or plastic scraper. Do not scratch the bearing journals or caps.
14. If the running clearance in one of the bearings is outside the limits specified in the Technical Data, install a new camshaft and repeat the check. If you find excessive clearances, the cylinder head must be replaced.
15. To check the axial play of the camshaft, remove the hydraulic compensators, thoroughly clean the bearing surfaces and install the camshafts and bearing caps. Tighten the bearing cap bolts to the required torque. Then measure the axial play with a dial indicator. To do this, install it on the cylinder head so that the tip of the indicator rests against the right end of the camshaft.
16. Press the camshaft against the indicator, reset the indicator, then press the camshaft away from the indicator and read the reading. If the reading is equal to or greater than the maximum clearance (see Technical Data), install a new camshaft and repeat the check. If the clearance is still excessive, the cylinder head must be replaced.
Installation
17. When assembling, generously lubricate the hydraulic compensators and the holes for them in the cylinder head with oil (see Fig. 13.17). If new hydraulic compensators are installed, they must first be filled with oil. Carefully install the hydraulic compensators in the cylinder head - in their places, with the appropriate side. Insert the hydraulic compensators into the holes without distortions.
18. Generously lubricate the bearing journals and camshaft cams with oil. Install the camshafts in their places so that the slot on the left end of each shaft is parallel and slightly above the surface of the joint between the cylinder head and the cover (see Fig. 13.18, a, b).
19. Make sure all dowel pins are firmly seated and all mating surfaces are clean and free of grease. Apply a thin coat of suitable sealant (Ford recommends Loctite 518) to the mating surfaces of the right-most bearing cap of each camshaft (see Fig. 13.19). New camshaft seals can now be installed (see item 6 paragraph 12).
20. Each bearing cap is etched with a number for identification (see Fig. 13.20). The exhaust camshaft bearing caps are numbered 0 (far right cap) to 4 (far left cap), and the intake camshaft caps are numbered 5 (far right cap) to 9 (far left cap) (see Fig. 13.21b). The cap should be installed with the numbered surface facing outward, either forward (for the exhaust camshaft) or rearward (for the intake camshaft).
21. When tightening the cover bolts, make sure that it is not skewed relative to the cylinder head. Tighten the covers in a crisscross pattern, one turn at a time for each bolt, until all the covers touch the cylinder head (see Fig. Fig. 13.21, a, b). Then tighten the bolts in the same sequence to the required torque at the first stage, and then at the second stage. This is necessary to gradually and evenly load the covers with the force of the valve springs. Install the device for aligning the camshafts. It should occupy the position described in p. 10 paragraph 10 (see Fig. 13.21, c).
22. Wipe off any remaining sealant to prevent it from getting into the oil channels. Follow the sealant's instructions for use. Usually, after applying the sealant, you need to wait a while (at least an hour) before starting the engine.
23. If you are following the procedures as recommended by Ford, install new seals on the camshafts as specified in p. 5 paragraph 12.
24. Using the marks made during removal, install the camshaft toothed pulleys in their places, slightly tightening their bolts (see Fig. 13.24). Pull the belt onto the pulleys (p. 21 paragraph 10) and tighten the bolts securely using a scissors-type tool (p. 18 paragraph 10).
25. Perform the remaining installation operations, including adjusting the position of the camshafts (gas distribution mechanism) and restoring the toothed belt tension, as specified in paragraph. 17-27 paragraph 10. On models produced from 05.1998, check and adjust the valve clearances (see paragraph 14).