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Installation (4.2L)

CAUTION: Synchro Positioning Tool (T96T-12200-A) MUST be used during installation of synchronizer assembly. Failure to follow this procedure could cause fuel system control to be out of time. This could possibly cause engine damage.
  1. Install Synchro Positioning Tool (T96T-12200-A) on camshaft synchronizer by rotating tool until it engages notch in camshaft synchronizer housing. See Fig 1.
    Fig 1: Installing Synchro Positioning Tool On Synchronizer
    G00194444Courtesy of FORD MOTOR CO.
    2. NOTE: During installation, arrow on Synchro Positioning Tool (T96T-12200-A) will rotate clockwise as the gears engage.
    Fig 2: Positioning Camshaft Synchronizer Assembly For Installation
    G00194445Courtesy of FORD MOTOR CO.
  2. With No. 1 cylinder at TDC of compression stroke, install camshaft synchronizer housing assembly so the arrow on the Synchro Positioning Tool (T96T-12200-A) is 54 degrees from centerline of engine. See Fig 2.
  3. Install and tighten the synchronizer hold down bolt. See TORQUE SPECIFICATIONS.
  4. Install EGR valve and adapter gasket. Install bolts and nut and tighten to 89 INCH lbs. (10 N.m). Install EGR valve tube upper fitting. Tighten fitting to 25-35 ft. lbs. (34-47 N.m). Install EGR vacuum hose.
  5. Remove Synchro Positioning Tool (T96T-12200-A). Install CMP sensor. See REMOVAL & INSTALLATION (4.2L)  under CAMSHAFT POSITION (CMP) SENSOR.
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