Camshaft removal and check for damage

The Toyota Hilux D4D 3.0 1KDFTV is an interference engine, so if the timing is wrong then the pistons will critically damage the valves. Removing the camshafts is easy, you just need to remove the set of bearing cap bolts that fasten them, in a predetermined order. When reinstalling the camshafts you just need to ensure the peripheral stamp marks on each of the camshaft sprockets align with each other. ie Align the indented dot with its adjacent indented dot or align the highlighted indented dot with its adjacent highlighted indented dot. The bearing cap bolts will need to be fastened with a torque wrench. Then connect the timing gear pulley onto the right camshaft using a key woodruff slotted into the right camshaft groove. Always double check the timing - that the peripheral stamp marks align. Don't under tension bolts, don't over tighten bolts either.

Did you take pictures while removing the originals? It's always a good habit. Below are the instructions you need to follow. Your own pics are very helpful when doing a big job like this.

1. Disconnect negative battery (1) cable.
2. Drain cooling system.
3. Remove upper intake manifold.
4. Remove cylinder head covers, crankshaft vibration damper, and timing chain cover.

CAUTION: When aligning timing marks, always rotate engine by turning the crankshaft. Failure to do so will result in valve and/or piston damage.

1. Align crankshaft sprocket timing mark to mark on oil pump housing (2). The mark on oil pump housing is 600 ATDC of #1 cylinder.

CAUTION: When the timing chain is removed and the cylinder heads are still installed, DO NOT rotate the camshafts or crankshaft without first locating the proper crankshaft position. Failure to do so will result in valve and/or piston damage.

1. Remove primary timing chain tensioner retainer cap (2) and tensioner (1) from right cylinder head.

1. Disconnect and remove camshaft position sensor (4) from left cylinder head.
2. Remove timing chain guide access plugs (3) from cylinder heads.

NOTE: When camshaft sprocket bolts are removed, the camshafts will rotate in a clockwise direction.

1. Starting with the right camshaft sprocket, remove the sprocket attaching bolts. Remove camshaft damper (1) (if equipped) and sprocket.
2. Remove left side camshaft sprocket attaching bolts and remove sprocket.
3. Remove lower chain guide (7) and tensioner arm (8).
4. Remove the primary timing chain (5).
5. Remove crankshaft sprocket (6).

INSTALLATION

1. Inspect all sprockets (4,9,11) and chain guides (2,5,10). Replace if worn.
2. For crankshaft sprocket installation procedures Refer to CRANKSHAFT SPROCKET.
3. If removed, install right and left side short chain guides (11). Tighten attaching bolts to 28 Nm (250 inch lbs.) .
4. Align crankshaft sprocket timing mark to the mark on oil pump housing (3).

NOTE: Lubricate timing chain and guides with engine oil before installation.

1. Place left side primary chain sprocket onto the chain so that the timing mark is located in-between the two (plated) timing links (1).

1. Lower the primary chain with left side sprocket through the left cylinder head opening.

NOTE: The camshaft sprockets can be allowed to float on the camshaft hub during installation.

1. Loosely position left side camshaft sprocket over camshaft hub.
2. Align timing (plated) link to the crankshaft sprocket timing mark (3).
3. Position primary chain onto water pump drive sprocket (10).
4. Align right camshaft sprocket timing mark to the timing (plated) link on the timing chain (8) and loosely position over camshaft hub.
5. Verify that all chain timing (plated) links are properly aligned to the timing marks on all sprockets.
6. Install left side lower chain guide (2) and tensioner arm (5). Tighten attaching bolts to 28 Nm (250 inch lbs.) .

NOTE: Inspect O-ring on chain guide access plugs before installing. Replace O-ring as necessary.

1. Install chain guide access plugs to cylinder heads. Tighten plugs to 20 Nm (15 ft. lbs.) .

NOTE: To reset the primary timing chain tensioner, engine oil will first need to be purged from the tensioner.

1. Purge oil from timing chain tensioner using the following procedure:

1. Place the check ball (2) end of tensioner into the shallow end of Special Tool 8186 (3).
2. Using hand pressure, slowly depress tensioner until oil is purged from tensioner.

1. Reset timing chain tensioner using the following procedure:

1. Position cylinder plunger (4) into the deeper end of Special Tool 8186 (3).
2. Apply a downward force until tensioner is reset.

NOTE: If oil was not first purged from the tensioner, use slight finger pressure to assist the center arm pin of Special Tool 8186 to unseat the tensioner's check ball.

CAUTION: Ensure the tensioner is properly reset. The tensioner body (4) must bottom against the top edge of Special Tool 8186 (3). Failure to properly perform the resetting procedure may cause tensioner jamming.

NOTE: Inspect the tensioner O-ring (2) for nicks or cuts and make sure the snap ring (1) is correctly installed, replace as necessary.

1. Install the reset chain tensioner (1) into the right cylinder head.
2. Position tensioner retaining plate (2) and tighten bolts (1) to 12 Nm (105 inch lbs.) .

1. Starting at the right cylinder bank, first position the camshaft damper (1) (if equipped) on camshaft hub, then insert a 3/8 square drive extension with a breaker bar into intake camshaft drive hub. Rotate camshaft until the camshaft hub aligns to the camshaft sprocket and damper attaching holes. Install the sprocket attaching bolts and tighten to 28 Nm (250 inch lbs.) .
2. Turn the left side camshaft by inserting a 3/8 square drive extension with a breaker bar into intake camshaft drive hub and rotate camshaft until the sprocket attaching bolts can be installed. Tighten sprocket bolts to 28 Nm (250 inch lbs.).
3. Rotate engine slightly clockwise to remove timing chain slack, if necessary.

1. Activate the timing chain tensioner by using a flat bladed pry tool to gently pry tensioner arm towards the tensioner slightly. Then release the tensioner arm. Verify the tensioner is activated (extends).

1. Install camshaft position sensor (2) and connect electrical connector.
2. Install the timing chain cover, crankshaft vibration damper, and cylinder head covers.
3. Install upper intake manifold.

NOTE: After installation of a reset tensioner, engine noise will occur after initial start-up. This noise will normally disappear within 5-10 seconds.

1. Fill cooling system.

Removal & Installation

3.5L Engine

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
2. Record the radio anti theft code data.
3. Remove or disconnect the following:
   
   Negative battery cable Engine cover Accessory drive belts Idler pulley Crankshaft pulley Power steering pump pulley Belt tensioner pulley Upper and lower timing belt covers
   
4. Support the engine with a floor jack and remove the engine mount.
5. Rotate the engine to align the camshaft sprocket timing marks with the cylinder head cover timing marks.
   
   

   Fig. Timing belt routing and timing marks-3.5L Engine
   

6. Remove or disconnect the following:
   
   Auto tensioner Timing belt
   
   

   Fig. Timing belt and related components-3.5L Engine
   
   

To install:

1. Ensure that the engine is set to Top Dead Center (TDC).
2. Prepare the auto tensioner for installation by compressing it in a vise and installing a retaining pin.
3. Install the timing belt in the following order:
   1. Crankshaft sprocket
   2. Idler pulley
   3. Left bank exhaust camshaft sprocket
   4. Left bank intake camshaft sprocket
   5. Water pump pulley
   6. Right bank intake camshaft sprocket
   7. Right bank exhaust camshaft sprocket
   8. Tensioner pulley
   
   
4. Install the auto tensioner. Do not remove the retaining pin at this time.
5. Check that the crankshaft and camshaft timing marks are aligned correctly.
6. Rotate the crankshaft 1 / 4 turn Counterclockwise .
7. Rotate the crankshaft 1 / 4 turn Clockwise to return the engine to TDC.
8. Loosen the tensioner pulley center bolt.
9. Apply 44 inch lbs. (5 Nm) torque to the tensioner pulley as shown and tighten the center bolt to 32-41 ft. lbs. (43-55 Nm).
   
   

   Fig. Adjusting the tensioner pulley-3.5L Engine
   

10. Remove the auto tensioner retaining pin.
11. Rotate the crankshaft 2 revolutions Clockwise , then wait 5 minutes for the auto tensioner to adjust.
12. Measure the auto tensioner rod as shown. If the measurement is not 3.8-4.5 mm, then repeat the belt tensioning procedure.
    
    

    Fig. Measuring the auto tensioner rod-3.5L Engine
    

13. When the auto tensioner measurement is correct, install or connect the following:
    
    Engine mount Upper and lower timing belt covers Belt tensioner pulley Power steering pump pulley Crankshaft pulley Idler pulley Accessory drive belts Engine cover Negative battery cable
    
14. Reprogram the radio anti theft codes.

    Kia_Sedona_2002-2006
    Timing Chain, Sprockets, Front Cover & Seal

    • REMOVAL & INSTALLATION

    Print
    

    
    Removal & Installation
    
    3.8L Engine
    

    1. Before servicing the vehicle, refer to the precautions at the beginning of this section.
    2. Record the radio anti theft code data.
    3. Remove the engine from the vehicle.
    4. Remove the drive belt. Remove the power steering pump. Remove the air conditioning compressor.
    5. Remove the alternator. Remove the drive belt idler. Remove the drive belt tensioner. Remove the water pump pulley. Remove the intake manifold.
    6. Remove the connector bracket from the left cylinder head cover. Disconnect the right ignition coil connector, condenser connector and remove the bracket.
    7. Remove the left cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    8. Remove the right cylinder head cover retaining bolts. Remove the cylinder head cover from the engine.
    9. Set the No. 1 cylinder to TDC on the compression stroke. Turn the crankshaft pulley and align its groove with the timing mark T of the lower timing chain cover.
    10. Check that the mark of the camshaft timing sprockets are in straight line positioning on the cylinder head surface. If not rotate the crankshaft 360 degrees. Do not rotate the engine counterclockwise.
    11. Remove the oil pan. Remove the crankshaft damper pulley. Remove the timing chain cover.
        NOTE Be careful not to damage the contact surfaces of the cylinder block, cylinder head and timing chain cover. Before removing the timing chain, mark the right and left timing chains with an identification mark based on the location of the sprocket because the identification mark on the chain for TDC can be erased.
        
    12. After compressing the timing chain tensioner, install a set pin. Remove the right cam to cam guide. Remove the right timing chain auto tensioner and timing chain tensioner arm.
    13. Remove the oil pump chain cover. Remove the oil pump chain tensioner assembly. Remove the oil pump chain guide. Remove the right timing chain.
    14. Remove the right timing chain guide. Remove the oil pump chain sprocket and oil pump chain. Remove the crankshaft sprocket, oil pump and camshaft drive gear.
    15. Remove the left cam to cam guide. Remove the left timing chain auto tensioner and timing chain tensioner arm. Remove the left timing chain.
    16. Remove the left timing chain guide. Remove the crankshaft sprocket and left camshaft drive. Remove the tensioner adapter assembly.
        
        

        Fig. Timing chain and related components-3.8L Engine
        

    
    To install:
    
    1. Check the camshaft and crankshaft sprockets for wear and damage, replace as required.
    2. Inspect the tensioner arm and chain guide for wear and damage, replace as required.
    3. Check that the tensioner pin moves smoothly when the ratchet pawl is released with a thin rod.
    4. The key of the crankshaft should be aligned with the timing mark of the timing chain cover. This indicates that the piston is at TDC on the compression stroke.
    5. Install the tensioner adapter assembly. Install the crankshaft sprocket and left camshaft drive.
    6. Install the left timing chain guide and torque the retaining bolts 14-18 ft. lbs.
    7. Install the left timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, timing chain guide, exhaust camshaft sprocket, intake camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
       
       

       Fig. Left timing chain markings and installation: (D) exhaust camshaft sprocket (C) intake camshaft sprocket-3.8L Engine
       

    8. Install the left timing chain tensioner arm and torque the retaining bolts 14-16 ft. lbs.
    9. Install the left timing chain tensioner and torque the retaining bolts 7-9 ft. lbs.
    10. Install the left cam to cam guide and torque the retaining bolts 7-9 ft. lbs.
    11. Install the crankshaft sprocket, oil pump and right camshaft drive.
    12. Install the oil pump chain and oil pump sprocket. Torque the retaining bolt to 14-16 ft. lbs.
    13. Install the right timing chain guide. Torque the retaining bolts to 14-18 ft. lbs.
    14. Install the right timing chain. Be sure to install the chain with no slack between the camshaft and the crankshaft (crankshaft sprocket, intake camshaft sprocket, exhaust camshaft sprocket). The timing mark of each sprocket should be matched with the timing mark (color ink) of the timing chain at installation of the timing chain.
        
        

        Fig. Right timing chain markings and installation: (C) exhaust camshaft sprocket (B) intake camshaft sprocket-3.8L Engine
        

    15. Install the right timing chain tensioner arm. Torque the retaining bolts to 14-17 ft. lbs.
    16. Install the right timing chain auto tensioner. Torque the retaining bolts to 7-9 ft. lbs.
    17. Install the right cam to cam guide and torque the retaining bolts to 7-9 ft. lbs.
    18. Install the oil pump chain guide. Torque the retaining bolts to 7-9 ft. lbs.
    19. Install the oil pump tensioner assembly. Torque the retaining bolts to 7-9 ft. lbs.
    20. Pull out the pins on both the left and right hydraulic tensioners. Install the oil pump chain cover.
    21. Rotate the crankshaft two revolutions in the clockwise direction. Confirm the timing mark. Be sure to rotate the crankshaft in the clockwise direction.
    22. Apply sealant on the chain cover and on the cylinder head, cylinder block, and lower oil pan. Be sure these parts are free of engine oil and dirt.
        NOTE Before assembling the timing chain cover, the liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
        
        
        

        Fig. Sealant application (1 inch bead width)-3.8L Engine
        

    23. Apply sealant on the chain cover.
        NOTE The liquid sealant TB1217H should be applied on the gap between the cylinder head and block. The part must be assembled with five minutes after the sealant is applied.
        
        
        

        Fig. Timing cover sealant application-3.8L Engine
        

    24. Install a new gasket to the timing case cover.
        NOTE It is important that the dowel pins on the cylinder block and holes on the timing chain cover should be used as a reference in order to assemble the timing chain cover in the correct position.
        
        
        

        Fig. Timing cover gasket installation (A) gaskets-3.8L Engine
        

    25. Install the timing chain cover. Torque the retaining bolts in the proper sequence and to specification. The engine should not be started for at least thirty minutes after timing chain cover assembly.
        
        

        Fig. Timing cover bolt torque sequence and specification-3.8L Engine
        

    26. Install the timing case cover oil seal.
    27. Continue the installation in the reverse order of the removal procedure.

For The 3.0 Motor. (3.3 Way down the line.)

Drain cooling system.
Remove timing belt. Refer to Engine for procedure.
Remove water pump mounting bolts.
Separate pump from water inlet pipe and remove water pump.

Timing Belt Removal
Raise vehicle and remove accessory drive belt splash shield (Fig. 66).
Remove accessory drive belts.
Remove crankshaft pulley and damper (Fig. 68).
Support engine and remove right side engine mount.
Remove engine support bracket (Fig. 67).
Remove timing belt covers (Fig. 67).
Mark belt running direction for installation (Fig. 69).
Loosen timing belt tensioner bolt (Fig. 71) and remove timing belt.
Remove crankshaft sprocket flange shield (Fig. 68). CAMSHAFT SPROCKETS To remove camshaft sprockets
Hold camshaft sprocket with Spanner Tool MB-990775. Loosen and remove bolt and washer (Fig. 70).
Remove camshaft sprocket from camshaft. To install camshaft sprockets:
Place camshaft sprocket on camshaft.
Install bolt and washer to camshaft. Using Spanner Tool MB-990775, hold camshaft sprocket and torque bolt to 95 Nm (70 ft. lbs.) (Fig. 70). TIMING BELT TENSIONER
Install timing belt tensioner and tensioner spring.
Hook spring upper end to water pump pin and lower end to tensioner bracket with hook out (Fig. 71).
Turn timing belt tensioner counterclockwise full travel in adjustment slot and tighten bolt to temporarily hold this position (Fig. 72).

INSTALLATION


Install timing belt on crankshaft sprocket and keep belt tight on tension side (Fig. 69). Install belt on the front (radiator side) camshaft sprocket. Install belt on the water pump pulley, rear camshaft sprocket and finally on the timing belt tensioner.
Rotate the front camshaft sprocket in opposite direction to take up belt slack. Check that all timing marks are aligned (Fig. 69).
Install crankshaft sprocket flange (Fig. 68).
Loosen tensioner bolt and allow spring to tension timing belt.
Turn crankshaft two full turns in clockwise direction. Turn smoothly and in clockwise direction ONLY.
Align the timing marks on the sprockets and tighten the timing belt tensioner locking bolt to 28 Nm (250 in. lbs.) torque.
Install timing belt covers.
Install engine support bracket.
Install right side engine mount.
Install crankshaft damper and pulleys (Fig. 68). Tighten damper center bolt to 135 Nm (100 ft. lbs.) .
Install accessory drive belts.
Install accessory drive belt splash shield (Fig. 66).

Be sure to also replace all the cam and crank seals why you are there. Might as well put a belt on too.

FOR THE 3.3 OR 3.8 MOTORS.

Drain Cooling System.
Remove accessory drive belt.
Remove right front lower fender shield.
Remove water pump pulley bolts and remove pulley.
Remove water pump mounting screws. Remove water pump.
Remove and discard O-ring seal.
Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to scratch or gouge sealing surface

Installation

Install new O-ring into groove.
Install water pump to chain case cover. Tighten screws to 12 Nm (105 inch lbs.) .
Rotate pump by hand to check for freedom of movement.
Position pulley on pump. Install screws and tighten to 30 Nm (250 inch lbs.) .
Install accessory drive belt.
Install right front lower fender shield.
Refill Cooling System.

FOR THE 2.4 MOTOR

Disconnect negative cable from battery.
Raise vehicle on a hoist. Remove right inner splash shield.
Remove accessory drive belts.
Drain cooling system.
Support engine from the bottom and remove right engine mount.
Remove right engine mount bracket.
Remove timing belt. Refer to Engine for procedure.
Remove timing belt idler pulley.
Hold camshaft sprocket with Special tool C-4687 and adaptor C-4687-1 while removing bolt. Remove both cam sprockets.
Remove rear timing belt cover.

Install new O-ring gasket in water pump body O-ring groove. CAUTION: Make sure O-ring is properly seated in water pump groove before tightening screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak.
Assemble pump body to block and tighten screws to 12 Nm (105 inch lbs.) . Pressurize cooling system to 15 psi with pressure tester and check water pump shaft seal and O-ring for leaks.
Rotate pump by hand to check for freedom of movement.
Install rear timing belt cover.
Install camshaft sprockets and torque bolts to 101 Nm (75 ft. lbs.) .
Install timing belt idler pulley and torque mounting bolt to 61 Nm (45 ft. lbs.) .
Install timing belt. Refer to Engine for procedure.
Install right engine mount bracket and engine mount. Refer to Engine for procedure.
Fill cooling system.
Install accessory drive belts.
Lower vehicle and connect battery cable.

please let me know if you have questions.
2.4L Engine
NOTE It is recommended that the entire procedure be reviewed before attempting to service the timing chain.

1. Before servicing the vehicle, refer to the precautions section.
2. Drain the cooling system.
3. Remove or disconnect the following: Negative battery cable, Coolant surge tank, Accessory drive belt, Alternator
4. Install an engine support.
5. Remove or disconnect the following: Upper cover fasteners, Front cover vent hose, Right engine mount and bracket, Right front wheel, Right lower splash shield, Crankshaft balancer, Lower cover fasteners, Front cover
6. Rotate the crankshaft clockwise, as viewed from front of engine (normal rotation) until the camshaft sprocket's timing dowel pin holes align with the timing chain housing holes. The crankshaft sprocket mark should align with the engine mark. The crankshaft sprocket keyway should point upward and align with the cylinder bores centerline. This is the normal timed position.
7. Remove the timing chain guides.
8. Remove the timing chain tensioner.
   NOTE Be sure all the slack in the timing chain is above the tensioner assembly when removing it. CAUTION The tensioner plunger is spring loaded and could fly out causing personal injury.
9. Remove or disconnect the following: Timing chain, Camshaft sprockets

To install:

1. Install or connect the following: Camshaft sprockets. Torque the bolts to 52 ft. lbs. (70 Nm),
   Camshaft sprocket alignment pin through the camshaft sprockets holes into the timing chain housing holes to position the camshafts for timing.
2. If the camshafts are out of position and must be rotated more than 1 / 8 turn in order to install the alignment dowel pins, perform the following:
   1. Rotated the crankshaft 90 degrees clockwise off Top Dead Center (TDC) in order to give the valves adequate clearance to open.
   2. Once the camshafts are positioned and the dowels installed, rotate the crankshaft counterclockwise back to TDC.
      WARNING Do not rotate the crankshaft clockwise to TDC or valve and piston damage may occur.
      
3. Install the timing chain over the exhaust camshaft sprocket, around the idler sprocket and around the crankshaft sprocket.
   

   Fig. Timing chain and sprocket alignment positions-2.4L DOHC engine
   

4. Remove the alignment dowel pin from the intake camshaft. Using a dowel pin remover tool, rotate the intake camshaft sprocket counterclockwise enough to slide the timing chain over the intake camshaft sprocket. Release the camshaft sprocket wrench. The length of chain between the 2 camshaft sprockets will tighten.
   NOTE If properly timed, the intake camshaft alignment dowel pin should slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated.
5. Leave the alignment dowel pins installed.
6. With slack removed from chain between intake camshaft sprocket and crankshaft sprocket, the timing marks on the crankshaft and the cylinder block should be aligned. If marks are not aligned, move the chain 1 tooth forward or rearward, remove slack and recheck the marks.
7. Tighten the chain housing to engine stud. The stud is installed under the timing chain. Torque it to 19 ft. lbs. (26 Nm).
8. Reload the timing chain tensioner as follows:
   1. Form a keeper from heavy gauge wire.
   2. Slightly, compress the shoe plunger and insert a small screwdriver into the access hole.
   3. Release the ratchet pawl and compress the plunger completely into the hole.
   4. Insert the keeper between the access hole and the blade.
9. Install or connect the following:
   Tensioner assembly to the chain housing. Torque the bolts to 89 inch lbs. (10 Nm). Tensioner shoe and retainer. Torque the bolts to 89 inch lbs. (10 Nm). NOTE Recheck plunger assembly installation. It is correctly installed when the long end is toward the crankshaft.
10. Remove the alignment dowel pins. Rotate crankshaft clockwise 2 full rotations. Align the crankshaft timing mark with mark on cylinder block and reinstall alignment dowel pins. Alignment dowel pins will slide in easily if engine is timed correctly.
    WARNING If the engine is not correctly timed, severe engine damage could occur.
11. Install or connect the following: Timing chain guides, New seal into the front cover by lubricating the seal lip and tapping it into place, Front cover and gaskets. Torque the nuts and bolts to 106 inch lbs. (12 Nm), Crankshaft balancer. Torque the bolt to 129 ft. lbs. (175 Nm), Right front lower splash shield, Front wheel. Torque the nuts to 100 ft. lbs. (140 Nm), Right engine mount bracket. Torque the bolts to 81 ft. lbs. (110 Nm) plus an additional 90 degree turn, Right engine mount. Torque the bolt to 49 ft. lbs. (60 Nm), Upper cover vent hose
12. Remove the engine support.
13. Install or connect the following: Alternator. Torque the bolts to 37 ft. lbs. (50 Nm), Accessory drive belt, Coolant surge tank, Negative battery cable.
    
14. Refill the cooling system.
15. Start the engine and check for leaks.

Removal & Installation 3.1L Engine To Remove:
CMP sensor

1. Disconnect the battery ground cable.
2. Remove the power steering pump and set aside with the lines connected.
3. Disconnect the camshaft position (CMP) sensor electrical connector.
4. Remove the CMP mounting bolt.
5. Remove the CMP sensor.
6. Check the O-ring for damage and replace if necessary.

To Install:
NOTE: Lubricate the O-ring with clean engine oil.

1. Install the camshaft position sensor.
   • Tighten the mounting bolt to 89 in lb (10 Nm).
2. Connect the CMP sensor electrical connector.
3. Install the power steering pump.

3.4L Engine To Remove:

1. Disconnect the negative battery cable.
2. Detach the electrical connector from the camshaft position sensor.
3. Remove the sensor retainer bolt and carefully pull the sensor from the camshaft carrier. An O-ring seal may hold the sensor in place. Use care not to lose the O-ring.

Camshaft Position (CMP) sensor removal (3.4L (VIN X) engine)

To Install:

1. Installation is the reverse of the removal procedure.
2. Before installing a replacement camshaft sensor, lubricate the new O-ring with clean engine oil.
   • Tighten the bolt to 88 inch lbs. (10 Nm). Do not over-tighten.
3. Connect the negative battery cable.

3.8L Engine To Remove:

1. Disconnect the negative battery cable.
2. Detach the electrical connector from the camshaft position sensor. Camshaft Position Sensor removal (3.8L engines)
   
   
3. Remove the retaining screw and separate the sensor from the front cover.

To Install:

1. Installation the sensor in the front cover.
2. Tighten the bolt to just 44 inch lbs. (5 Nm). Do not over-tighten. Verify the electrical connector is secure.
3. Connect the negative battery cable.

hi,
it is under the upper timing belt cover between the camshaft gears. According to the manual touching anything related to timing belt requires removing million parts including right front wheel. I suspect this might be an overkill just to remove upper timing belt cover.

So my advice would be to get it done by some mechanic as u will not be able to do it and may damage other parts also.

Thanks!
Sandy

2.0L 2.4L Removal The camshaft position sensor is mounted to the rear of the cylinder head.

Remove the negative battery cable. Disconnect the PCV hose and reposition Disconnect electrical connectors from the camshaft position sensor. Remove camshaft position sensor mounting screws. Remove sensor.Loosen screw attaching target magnet to rear of camshaft and remove magnet.
Instalation The target magnet has locating dowels that fit into machined locating holes in the end of the camshaft.
- Install target magnet in end of camshaft. Tighten mounting screw to 3 Nm (30 in. lbs.) torque. Over torqueing could cause cracks in magnet. If magnet cracks replace it.
- Install camshaft position sensor. Tighten sensor mounting screws to 12.9 Nm (115 in. lbs.) torque.
- Carefully attach electrical connector to camshaft position sensor. Installation at an angle may damage the sensor pins. - Connect the PCV Valve hose. - Connect the negative battery cable.
2.7L V6 Removal
The camshaft position sensor is mounted in the front of the head.

Disconnect electrical connector from sensor. Remove camshaft position sensor screw.
CAM Sensor Location 2.7L
Without pulling on the connector, pull the sensor out of the chain case cover.

Installation - Install sensor in the chain case cover and push sensor in until contact is made with the boss on the head. While holding the sensor in this position,install and tighten the retaining bolt to 12 Nm (105 in. lbs.) torque.
- Attach electrical connector to sensor.

Good luck and hope this helps

The camshaft position sensor sends a signal to the PCM, powertrain control module. The PCM then determines spark plug firing. Could be the camshaft position sensor.

1996 is all I have
Camshaft Position (CMP) Sensor 3.0L (2V) Engine
The camshaft position sensor (CMP sensor) (12126):

• is a single Hall-effect magnetic switch activated by a single vane which is driven by the camshaft (6250).
• provides camshaft position information which is used by the ignition coil (12029) and the powertrain control module (PCM) (12A650) for fuel synchronization.

3.0L (4V) Engine
The camshaft position sensor (CMP sensor) (6B288) is:

• a variable reluctance sensor.
• triggered by the high-point mark on the LH exhaust camshaft sprocket (6256).

-----------------
3.0L (2V) Engine
SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Syncro Positioning Tool T95T-12200-A
CAUTION: Prior to removal of the camshaft position sensor (CMP sensor) (12126), set cylinder No.1 to zero degrees top dead center (TDC) of compression stroke. Then note the position of the camshaft position sensor electrical connector. The installation procedure requires that the connector be located in the same position.
Removal

1. Disconnect battery ground cable. Refer to Section 14-01 .
   

1. Disconnect engine control sensor wiring connector from camshaft position sensor.
   

1. Remove camshaft position sensor retaining screws and camshaft position sensor from camshaft position sensor housing.
   

1. If removing camshaft position sensor housing from the cylinder block (6010), proceed with Removal Step 5. If not removing camshaft position sensor housing, proceed to installation Step 6.
   

1. Remove hold-down clamp (bolt and washer assembly).
   

1. Remove camshaft position sensor housing from cylinder block.
   

Installation

1. CAUTION: A special service tool such as Syncro Positioning Tool T95T-12200-A must be obtained prior to installation of the replacement camshaft position sensor. Failure to follow this procedure will result in improper camshaft position sensor alignment. This will result in the fuel system being out of time with the engine, possibly causing engine damage.
   Attach Syncro Positioning Tool T95T-12200-A as follows:
   
   1. Engage camshaft position sensor housing vane into the radial slot of the tool.
   1. Rotate tool on camshaft position sensor housing until tool boss engages notch in camshaft position sensor housing.

1. Pre-lubricate synchronizer gear with engine oil meeting Ford specification ESE-M2C123-A prior to assembly.
   

1. Install camshaft position sensor housing so that drive gear engagement occurs when arrow on locator tool is pointed approximately 75 degrees counterclockwise from the rear face of the cylinder block. This step will locate camshaft position sensor electrical connector in the pre-removal position.
   

1. Roatate Syncro Positioning Tool T95T-12200-A clockwise slightly. This will engage oil pump intermediate shaft. Push downward while adjusting Syncro Positioning Tool T95T-12200-A until the Syncro Gear engages the camshaft gear.
   

1. When synchronizer flange is fully seated against block, the installation tool should be facing counterclockwise of engine centerline approximately 33 to 45 degrees.
   

1. Install hold-down clamp (washer and bolt) and tighten bolt to 19-30 Nm (14-22 lb-ft).
   

1. Remove Syncro Positioning Tool T95T-12200-A.
   

1. CAUTION: If camshaft position sensor electrical connector is not positioned properly, DO NOT reposition the connector by rotating the camshaft position sensor housing. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the camshaft position sensor housing and repeat installation procedure, beginning with Step 1.
   Install camshaft position sensor and retaining screws. Tighten screws to 1.5-4.0 Nm (13-35 lb-in).
   

1. Connect engine control sensor wiring connector to camshaft position sensor.
   

1. Connect battery ground cable.
   

Item Part Number Description 1 T95T-12200-A Syncro Positioning Tool 2 — Water Outlet (Part of Intake Assy) 3 9424 Intake Manifold 4 N602704-S Screw and Washer 5 12126 Camshaft Position Sensor 6 12A362 Synchronizer Assembly 7 12270 Hold-Down Clamp A — Tighten to 1.5-4 Nm (13-35 Lb-In) B — Tighten to 19-30 Nm (14-22 Lb-Ft)

do you have 3.L 2v or 4 valve?

3.0L (2V) Engine
SPECIAL SERVICE TOOL(S) REQUIRED Description Tool Number Syncro Positioning Tool T95T-12200-A
CAUTION: Prior to removal of the camshaft position sensor (CMP sensor) (12126), set cylinder No.1 to zero degrees top dead center (TDC) of compression stroke. Note the position of the camshaft position sensor electrical connector. The installation procedure requires that the connector be located in the same position.
Removal

1. Disconnect battery ground cable. Refer to Section 14-01 .
   

1. Disconnect engine control sensor wiring connector from camshaft position sensor.
   

1. Remove camshaft position sensor retaining screws and camshaft position sensor from camshaft position sensor housing.
   

1. If removing camshaft position sensor housing from the cylinder blocks (6010), proceed with Removal Step 5. If not removing camshaft position sensor housing, proceed to installation Step 6.
   

1. Remove hold-down clamp (12270) (bolt and washer assembly).
   

1. Remove camshaft position sensor housing from cylinder blocks.
   

Installation

1. CAUTION: A special service tool such as Syncro Positioning Tool T95T-12200-A must be used to position the synchronizer assembly prior to installation of the camshaft position sensor. Failure to follow this procedure will result in improper camshaft position sensor alignment. This will result in the fuel system being out of time with the engine, possibly causing engine damage.
   Attach Syncro Positioning Tool T95T-12200-A as follows:
   
   1. Engage camshaft position sensor housing vane into the radial slot of the tool.
   1. Rotate tool on camshaft position sensor housing until tool boss engages notch in camshaft position sensor housing.

1. Pre-lubricate synchronizer gear with engine oil meeting Ford specification ESE-M2C123-A prior to assembly.
   

1. Install camshaft position sensor housing so that drive gear engagement occurs. Locate camshaft position sensor electrical connector in the pre-removal position.
   

1. Install hold-down clamp (washer and bolt) and tighten bolt to 19-30 Nm (14-22 lb-ft).
   

1. Remove Syncro Positioning Tool T95T-12200-A.
   

1. CAUTION: If camshaft position sensor electrical connector is not positioned properly, DO NOT reposition the connector by rotating the camshaft position sensor housing. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the camshaft position sensor housing and repeat installation procedure, beginning with Step 1.
   Install camshaft position sensor and retaining screws. Tighten screws to 1.5-4.0 Nm (14-35 lb-in).
   

1. Connect engine control sensor wiring connector to camshaft position sensor.
   

1. Connect battery ground cable.