Synchronizer

NOTE: Ford does not provide a TDC (Top Dead Center) mark or determination procedure for this engine in this vehicle.
ALLDATA users have reported success using aftermarket tools to determine TDC on this engine.

SYNCHRONIZER

Syncro Positioning Tool:

SPECIAL SERVICE TOOL(S)

REMOVAL
1. Rotate the crankshaft until the No.1 cylinder is at Top Dead Center (TDC) of the compression stroke.

CAUTION: Do not turn the crankshaft or camshaft during the removal and installation procedure or the fuel system timing will be out of time with the engine and could possibly cause engine damage.

2. Remove the Camshaft Position (CMP) Sensor. For additional information, refer to Camshaft Position (CMP) Sensor.







3. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum hose.







4. Remove the EGR valve tube upper fitting.







5. Remove the EGR valve and adapter.
1. Remove the nut and the bolts.
2. Remove the EGR valve and adapter assembly.







6. Remove the camshaft synchronizer retaining bolt.







7. Remove the camshaft synchronizer.


NOTE: The oil pump driveshaft may come out with the camshaft synchronizer. If so, retrieve the oil pump driveshaft before proceeding.

INSTALLATION







1. Install the Syncro Positioning Tool on the camshaft synchronizer by rotating the tool until it engages the notch in the camshaft synchronizer housing.

CAUTION:
- Do not turn the crankshaft or camshaft during the removal and installation procedure or the fuel system timing will be out of time with the engine and possibly causing engine damage.
- A Syncro Positioning Tool must be used during the Installation of the new synchronizer assembly. Failure to follow this procedure will result in the fuel system being out of time with the engine, possibly causing engine damage.







2. Install the camshaft synchronizer housing assembly so the arrow on the synchronizer alignment tool is 54 degrees from the centerline of the engine.

NOTE: During installation, the arrow on the Syncro Positioning Tool will rotate clockwise as the gears engage.







3. Install the camshaft synchronizer retaining bolt.







4. Install the EGR valve and adapter assembly.
1. Position the EGR valve adapter gasket.
2. Position the EGR valve.
3. Install the bolts and the nut

NOTE: Reuse the EGR valve adapter gasket.







5. Install the EGR valve tube upper fitting.







6. Connect the EGR valve vacuum hose.
7. Install the camshaft position (CMP) sensor. For additional information, refer to Camshaft Position (CMP) Sensor.