Camshaft synchronizer assembly removal problem - need advice

[jayjp200]

Hi,
I need to change the camshaft positioner assembly on my 3.8 liter 98 Windstar. I have opened as suggested in Hayness manual.
I am not able to lift up the assembly out as the fuel injecter railing line is coming in the way.

Can someone please help...what shall I do? do I have to remove fuel injector railing or just disconnect it.


Thank and regards,
Jay

[lord Kelvin]

Had the same problem on my '98. This is from memory, but as I recall....I removed the cowl (easy), the upper intake plenum (easy), than unbolted & lifted the fuel-rail with the back 3 injectors still connected just enough to remove the assembly. (might want to shopvac top of engine before removing plenum to keep stuff from falling into lower-intake. Lots of stuff collected on my engine, and I stopped and got the vacuum)

Make sure you mark everything really good. Must mark both the outer housing and the rotating inner piece (relative to the housing). Once out, I had to transfer the oil-pump shaft to the new assembly, and also transfer the marks as precise as possible. Re-install, align, tighten, and put her back together. I lightly oiled the injector o-rings before installing. It might sound like alot, but it's less than 2 hrs work....and not complicated at all.

Just mark it real good!!!

The hex-shaft is held in the assembly with a cir-clip as I recall. I grabbed it with a vise-grip and tapped the vise-grip with a hammer to separate. Just presses into the new assembly. You can feel it bottom out.

Like I said, this is from memory, but that's pretty much what I recall.