OTC 6489 Operating Instructions Manual

Ford cam and valve train tool kit

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Cam and Valve Train Tool Kit

511532 (6009)

511535 (6468)

511539 (6472)

511543 & 511544 (6476)

511548 (6480)

511552 (6484)

Parts List & Operating Instructions for

No. 6489

Ford

511555 (6020)

511536 (6469)

511540 (6473)

511545 (6477)

511549 (6481)

511553 & 511554 (6485)

511533 (6466)

511537 (6470)

511541 (6474)

511546 (6478)

511550 (6482)

511534 (6467)

511538 (6471)

511542 (6475)

511547 (6479)

511551 (6483)

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Summary of Contents for OTC 6489

Page 1 Parts List & Operating Instructions for No. 6489 Ford Cam and Valve Train Tool Kit 511532 (6009) 511555 (6020) 511533 (6466) 511534 (6467) 511535 (6468) 511536 (6469) 511537 (6470) 511538 (6471) 511539 (6472) 511540 (6473) 511541 (6474) 511542 (6475) 511543 & 511544 (6476)
Page 2 Ford Tool Application Chart Ford Ford Year Model Engine Tool Description Part No. American Global Part Part No. 1995-1997 Aerostar 3.0L V6 Cam Sensor Synch Tool 6472 (511539) T95T-12200-A 303-529 1996-1998 Aerostar 4.0L V6 Cam Sensor Synch Tool 6472 (511539) T95T-12200-A 303-529 1994-2002...
Page 3 Parts List & Operating Instructions Ford Tool Application Chart Ford Ford Year Model Engine Tool Description Part No. American Global Part Part No. 1997-2011 Explorer 4.0L SOHC V6 VIN E Cam Gear Holding Tool 6478 (511546) T97T-6256-B 303-564 Crankshaft Holding Tool 6479 (511547) T97T-6303-A 303-573...
Page 4: T95T-12200-A
Parts List & Operating Instructions Form No. 107267 Ford Tool Application Chart Ford Ford Year Model Engine Tool Description Part No. American Global Part Part No. 2010-2012 Milan Hybrid 2.5L VIN 3 Cam Alignment Tool 6474 (511541) T94P-6256-CH 303-465 2014 2.0L Cam Alignment Tool 6474 (511541)
Page 5: T97P-6000-A
Parts List & Operating Instructions Ford Tool Application Chart Ford Ford Year Model Engine Tool Description Part No. American Global Part Part No. 1998-2008 Ranger 3.0L V6 Cam Sensor Synch Tool 6473 (511540) 303-589 1996-1998 Ranger 4.0L V6 Cam Sensor Synch Tool 6472 (511539) T95T-12200-A 303-529...
Page 6 511532 (6009) Ford Camshaft Positioning Tool Application: 1991 – 2008 4.6L 2V Crown Victoria (V8), Grand Marquis 1997 – 1998 4.6L & 5.4L V8, 6.8L V10 Econoline 1997 – 2002 5.4L Expedition 1997 – 2002 4.6L Expedition, Explorer, Crown Victoria, Grand Marquis, Town Car (VIN W) 1997 –...
Page 7: T92P-6256-A
Parts List & Operating Instructions 511555 (6020) Ford Camshaft Positioning Tool Application: 1992 – 2008 4.6L 2V Crown Victoria (V8), Grand Marquis 1997 – 2002 4.6L Crown Victoria, Expedition, Explorer Grand Marquis, Town Car (VIN W) 1997 – 1998 4.6L & 5.4L V8, 6.8L V10 Econoline 1997 –...
Page 8 511533 (6466) Ford Crankshaft Sensor Positioner Application: 1989 – 1997 Ford Ranger w/ 2.3L, 4 cyl., dual plug engine Note: Same as Ford No. 303-354 (T89P-6316-A). 1. Install Crankshaft Sensor Positioner No. 6466 (511533) on sensor as shown. 2. Rotate crankshaft so outer vane on crankshaft pulley hub assembly engages both sides of tool.
Page 9 Parts List & Operating Instructions 511535 (6468) Ford Camshaft Pulley Holding Tool Application: 1993 – 1997 Ford Probe w/ 2.0L, 4 cyl., engine Note: Same as Ford No. 303-398 (T92C-6256-AH). 1. Rotate engine to align camshaft 2. Insert No. 6468 (511535) 3.
Page 10 511537 (6470) Ford Camshaft Sensor Synchronizer Tool Application: 1999 – 2002 5.0L V8 Explorer, Mountaineer 2004 – 2007 3.9L Freestar (VIN 6) 2004 3.9L Monterey (VIN 6) 1999 – 2004 3.8L V6 Mustang 1999 – 2003 3.8L V6 Windstar No. 511537 Note: Same as Ford No.
Page 11 Parts List & Operating Instructions 511539 (6472) Ford Camshaft Positioning Tool Set Application: 1995 – 1997 3.0L V6 Aerostar, Ranger, Windstar 1996 – 1998 4.0L V6 Aerostar, Explorer, Ranger 1996 – 1997 3.0L V6 2V Sable, Taurus CAUTION: Before removing the camshaft sensor housing No.
Page 12: T94P-6256-Ch
511541 (6474) Ford Camshaft Alignment Tool Application: 1994 – 2002 2.0L 4 cyl. Contour, Mystique (VIN 3) 1999 – 2002 2.0L Cougar (VIN 3) 2012 – 2014 2.0L Edge, Explorer (VIN 9) 2001 – 2004 2.0L Escape (VIN B) 2013 – 2014 2.0L Escape (VIN 9), Fusion, MKZ, Taurus 2005 –...
Page 13 Parts List & Operating Instructions 511542 (6475) Ford Crankshaft TDC Timing Pin Application: 1997 – 2002 2.0L 4 cyl. Contour, Mystique (VIN 3) 1999 – 2002 2.0L Cougar (VIN 3) 2012 – 2014 2.0L Edge, Explorer (VIN 9) 2001 – 2004 2.0L Escape (VIN B) 2013 –...
Page 14: T96T-6256-B
511543 / 511544 (6476) Ford Camshaft Positioning Tool Set Application: 1997 – 2002 4.6L Econoline, F-Series Truck (VIN W) 1997 – 2002 5.4L Econoline, Expedition, F-Series Truck 1997 – 2002 6.8L V10 Econoline 1998 – 2002 5.4L Navigator 2-Hole Note: Camshaft No.
Page 15: T97T-6303-A
Parts List & Operating Instructions 511546 (6478) Ford Camshaft Gear Holding Tool Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E) 1997 – 2008 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X) 2005 – 2010 4.0L SOHC Mustang (VIN N) No.
Page 16: T97T-6256-D
511548 (6480) Ford Camshaft Holding Tool Adapter Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E) 1997 – 2008 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X) 2005 – 2010 4.0L SOHC Mustang (VIN N) Note: No. 511549 •...
Page 17: T97T-6256-A
Parts List & Operating Instructions 511550 (6482) Ford Camshaft Holding Tool Adapter Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E) 1997 – 2008 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X) 2005 – 2010 4.0L SOHC Mustang (VIN N) Note: •...
Page 18: T97T-6K254-A
511552 (6484) Ford Timing Chain Tensioner Tool Application: 1997 – 2011 4.0L SOHC Explorer (V6), Mountaineer (V6), Ranger (VIN E) 1997 – 2008 4.0L SOHC Explorer, Mountaineer, Ranger (VIN X) 2005 – 2010 4.0L SOHC Mustang (VIN N) Note: Same as Ford No. 303-571 (T97T-6K254-A). 1.