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In-Vehicle Servicing: Camshafts: Installation

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.
    NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.
  1. Install the camshafts and bearing caps in their original location and orientation. Tighten the bearing caps in the sequence shown in 3 stages:
    • Stage 1: Tighten the camshaft bearing cap bolts one turn at a time, until finger tight.
    • Stage 2: Tighten to 7 Nm (62 lb-in).
    • Stage 3: Tighten to 16 Nm (12 lb-ft).
    2. Fig 1: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
    GF0008949Courtesy of FORD MOTOR CO.
  2. Install the special tool.
    3. Fig 2: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  3. Install the intake camshaft drive gear and hand-tighten the bolt.
    4. Fig 3: Locating Intake Camshaft Drive Gear Bolt
    GF0024090Courtesy of FORD MOTOR CO.
  4. Install the timing chain on the intake camshaft drive gear.
    5. Fig 4: Locating Timing Chain
    GF0024088Courtesy of FORD MOTOR CO.
    NOTE: The timing chain must be correctly engaged on the teeth of the crankshaft timing sprocket and the intake camshaft drive gear in order to install the exhaust camshaft drive gear onto the exhaust camshaft.
  5. Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft.
    • Hand-tighten the bolt.
    6. Fig 5: Locating Exhaust Camshaft Drive Gear Bolt
    GF0024091Courtesy of FORD MOTOR CO.
    NOTE: Releasing the tensioner arm will remove the slack from the timing chain release.
  6. Remove the M6 x 30 mm bolt from the upper front cover timing hole to release the tensioner arm.
    7. NOTE: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.
  7. Using the flats on the camshafts to prevent camshaft rotation, tighten the bolts.
    • Tighten to 72 Nm (53 lb-ft).
    8. Fig 6: Locating Camshaft Bolts
    GF0024092Courtesy of FORD MOTOR CO.
  8. Remove the special tool.
    9. Fig 7: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  9. Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.
    10. Fig 8: Aligning Crankshaft Pulley Bolt Holes
    G03897704Courtesy of FORD MOTOR CO.
  10. Remove the special tool.
    11. Fig 9: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  11. Install the upper front cover timing hole plug.
    • Tighten to 10 Nm (89 lb-in).
    12. Fig 10: Locating Upper Front Cover Timing Hole Plug
    GF0024084Courtesy of FORD MOTOR CO.
  12. Apply silicone gasket and sealant to the threads of the lower front cover timing hole plug.
    • Install the plug and tighten to 12 Nm (9 lb-ft).
    13. Fig 11: Locating Lower Front Cover Timing Hole Plug
    GF0024083Courtesy of FORD MOTOR CO.
  13. Install the engine plug bolt.
    • Tighten to 20 Nm (15 lb-ft).
    14. Fig 12: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
  14. Install the accessory drivebelt. For additional information, refer to ACCESSORY DRIVE - HYBRID article.
  15. Install the front RH wheel and tire. For additional information, refer to WHEELS AND TIRES article.
  16. Install the valve cover. For additional information, refer to Valve Cover .
  17. Install the direct current/direct current (DC/DC) converter. For additional information, refer to HIGH VOLTAGE CONVERTER/INVERTER article.
  18. Install the degas bottle. For additional information, refer to ENGINE COOLING - HYBRID article.
  19. Repower the vehicle high voltage traction battery electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY article.
  20. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
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