Ford Freestar, Monterey 2004-2006

Camshaft, Bearings & Lifters

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Removal & Installation



  1. Rotate the crankshaft until the No. 1 piston is at the TDC on its compression stroke and the timing marks are aligned.
  2.  
  3. Remove or disconnect the following:

    Engine from the vehicle
     
    Valve covers
     
    Intake manifolds
     
    Pushrods
     
    Tappet guide plate and retainer
     
    Tappets
     
    Crankshaft pulley and damper
     
    Engine front cover assembly
     

  4.  
  5. Check the camshaft end-play as follows:
    1. Push the camshaft toward the rear of the engine and install a dial indicator, so the indicator point is on the camshaft sprocket attaching screw.
    2.  
    3. Zero the dial indicator. Position a small prybar between the camshaft sprocket or gear and block.
    4.  
    5. Pull the camshaft forward and release it. Camshaft end-play should be 0.001-0.006 in. (0.025-0.15mm).
    6.  
    7. If the camshaft end-play is not within specification, replace the thrust plate upon reassembly.
    8.  

  6.  
  7. Remove or disconnect the following:

    Timing chain and sprockets
     
    Balance shaft drive gear
     
    Camshaft keyway
     
    Balance shaft driven gear, thrust plate and balance shaft as an assembly
     
    Camshaft thrust plate and spacer
     

  8.  
  9. Carefully remove the camshaft by pulling it toward the front of the engine. Remove it slowly to avoid damaging the bearings, journals and lobes.
  10.  

To install:

  1. Clean and inspect all parts before installation.
  2.  
  3. Lubricate the camshaft lobes and journals with Molylube® or heavy engine oil.
  4.  
  5. Carefully install the camshaft, spacer and camshaft key.
    NOTE
    If a new camshaft is being installed, recheck camshaft end-play.

  6.  
  7. Lubricate the engine thrust plate with engine assembly lubricant, then install the thrust plate. Tighten the retaining bolts to 71 inch lbs. (8 Nm).
  8.  
  9. Install the timing chain and sprockets.
  10.  
  11. Install the balance shaft assembly. Tighten the bolts to 71 inch lbs. (8 Nm).
  12.  
  13. Install the balance shaft drive gear, ensuring that the timing marks are correctly located as shown.
    NOTE
    Check the camshaft sprocket bolt for blockage of the drilled oil passages prior to installation, and clean if necessary.



    Click image to see an enlarged view

    Fig. Aligning balance shaft drive gear and driven gear-3.9L and 4.2L engines

  14.  
  15. Install or connect the following:

    Engine front cover
     
    Crankshaft damper and pulley
     
    Hydraulic tappets into their original bores
     
    Align the valve tappet flats and install the tappet guide plate with the word UP facing you
     
    Install the intake manifold assembly
     
    Lubricate and install the pushrods and rocker arms
     
    Install the valve covers
     
    Install the engine assembly into the vehicle
     

  16.  

 
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