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Home >> Ford >> 2005 >> Freestar Base >> Repair and Diagnosis >> Engine Performance >> Remove, Overhaul & Install >> Electronic Engine Control System >> Removal And Installation >> Camshaft Synchronizer >> Installation
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Camshaft Synchronizer: Installation

    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 on the No. 1 cylinder.
    CAUTION: A special tool must be used when installing a synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage.
    Fig 1: Installing Special Tool On Camshaft Synchronizer By Rotating Tool
    G04004498Courtesy of FORD MOTOR CO.
  1. Install the special tool on the camshaft synchronizer by rotating the tool until it engages both the notch in the camshaft synchronizer housing and the notch in the armature.
    2. CAUTION: It is very important to coat the gear on the camshaft synchronizer with clean engine oil prior to installation. Failure to do so could result in gear failure.
    NOTE: During installation, the arrow on the special tool will rotate clockwise until the oil pump intermediate shaft and camshaft gear engages.
    Fig 2: Installing Camshaft Synchronizer Housing Assembly
    G04004255Courtesy of FORD MOTOR CO.
  2. Install the camshaft synchronizer housing assembly so the arrow on the special tool is 54 degrees from the centerline of the engine.
  3. Install the camshaft synchronizer-to-engine front cover bolt.
    • Tighten to 25 Nm (18 lb-ft).
  4. Position the power steering pump and install the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  5. Install the accessory drive belt.
    • Position the accessory drive belt onto the engine.
    • Rotate the accessory drive belt tensioner counterclockwise until spring clip releases.
    Fig 3: Locating Accessory Drive Belt Tensioner
    G04004448Courtesy of FORD MOTOR CO.
  6. Position the coolant pump outlet tube and install the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
  7. Connect the coolant bypass hose to the coolant pump outlet tube.
  8. Install the CMP sensor and install the bolts.
    • Tighten to 3 Nm (27 lb-in).
  9. Connect the CMP electrical connector.
  10. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  11. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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