More than one camshaft alignment tool specified for ZETEC engines?

[Overheadcam427]

FYI: I own a 98 Mystique with a build date of 4-97. I believe this is the original engine but I'm the 2nd owner so I'm not 100% sure.

I recently had to redo a timing belt installation that was done incorrectly at a shop. When I tried to align the cams I substituted a 3/16" thick, mending bar (~12" x 1-1/8") from ACE hardware to lock the cams in place of the Ford specified tool. I set the crank @ at TDC using the marks on the pulley/oil pan and also used a rod inserted into cylinder #1 to verify.

When I attempted to lock the cams, I couldn't get the mending bar to slide into the cam slots. It seemed like the centerline of the slots were below the deck height of the head. I didn't loosen the cams from the pulleys and ended up "eyeballing" the alignment as best as I could. I finishing the job with no problems and the engine runs fine.

I would like to open things up again in a few weeks and set up the cams correctly. I ended up buying a cam locking tool & crankshaft TDC pin from OTC (http://www.amazon.com/gp/product/B00...ls_o00_s00_i00), but the cam tool looks very similar to the bar I already tried to use.

My question is this:
1. Did I make a mistake in my procedure?
2. If I didn't, are there different kinds of camshaft locking tools available for the ZETEC? It seems like my cams need a locking tool that extends below the head deck.

Any help would be appreciated!

[BrApple]

as far as I am aware there is only one cam tool. If the slots where below the deck of the head then I would hazard a guess that the cams needed to be rotated 180 degrees so that the cam alignment tool would fit.

[striker2]

correct, only 1 style tool is used. I have used mine on pre98 Zetecs, 98+ VCT Zetecs, and Focus Zetecs without any issues. as BrApple said, if the slots were below the deck than the cams were off 180 degrees.

[Overheadcam427]

I wish I would have documented things better (photos) but I do realize that meant the cams would be 180° out. I ignored the cam slots and timed the engine as follows.

-I set TDC using the markings on the crankshaft pully/oil pan and also measured the movement of the piston in cylinder #1.

-I checked to make sure the int & exh cam lobes on #1 were pointed inwards (towards each other). In this configuration the intake cam lobe would be just begining to lift the int valve off its seat and the exh valve is fully seated.

-Just looking at the cam lobes (and knowing the cam direction of rotation) you could see the firing order was #1-#3-#4-#2. The engine fired up immediately and runs great.

If I would have rotated the cams another 180° (360° at the crank), then I would be in the middle of the firing order and setting up #4 to fire. Perhaps this is how Ford wanted it or my cam slots were ground wrong? I do recall seeing photos somewhere (not sure if it was on this site) of a guy who made his own cam locking tool but had to weld some additional tabs under the bar in order to insert it into the cam slots.

[ContourGuy9817]

if you dont have a p0340 cam correlation or anything else then repair is complete. the second tool, the crank pin, requires removal of the catylitic converter or manifold to gain access to the block plug. i line the crank dampener dots up to the oil pan mark and use a flat piece of steel on the cams. technically you could just install the belt anywhere and set your tension. then rotate engine over until cranks lines up and then loosen cam sprocket bolt and move cams into position...vct engines have 1 cam that refuses to rotate though so more time must be invested.

Steve-O
Fairlane Ford Heavy Tech

[striker2]

No need to remove.the cat to install the crank pin. I have done it many times without issues.

[Overheadcam427]

I was just thinking...it doesn't really matter if my cam slots are cut for cyl #1 or #4. When I was doing the timing belt job I just assumed that I should be setting the engine up at the begining of the firing order (#1), but that isn't important because the crank is in the same orientation when cyl #1 & #4 fire anyway. Your thoughts?

You guys have been great, thanks for your input. When I recheck the cams I will post some pictures.

[andreslobo]

The Coils fire 1 and 4 at the same time as well as 2 and 3, so it really doesn't matter. There is a reluctor on the end of one of the cams that helps the puter to know which way is up.