In-Vehicle Repair: Camshafts: Removal

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan can cause engine failure.

CAUTION: Do not rotate the camshafts or crankshaft unless instructed to do so in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves or pistons.

All vehicles

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.3L .
If equipped, remove the 7 screws and the underbody cover.

Fig 1: Locating Underbody Cover Screws
Courtesy of FORD MOTOR CO.
Remove the variable camshaft timing (VCT) solenoid. For additional information, refer to ELECTRONIC ENGINE CONTROLS - 2.3L .
Check the valve clearance. For additional information, refer to VALVE CLEARANCE CHECK .

CAUTION: Failure to position the No. 1 piston at top dead center (TDC) can result in damage to the engine. Turn the engine in the normal direction of rotation only.

Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC.
- The hole in the crankshaft pulley should be in the 6 o'clock position.
  
  Fig 2: Identifying Crankshaft Pulley Bolt Turning Crankshaft Clockwise
  Courtesy of FORD MOTOR CO.

CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

NOTE: The camshaft timing slots are offset. If the special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

Fig 3: Identifying Special Camshaft Tool (303-465)

Courtesy of FORD MOTOR CO.

Install the special tool in the slots on the rear of both camshafts.

Automatic transaxle vehicles

Remove the 2 halfshaft carrier bracket bolts and slide the RH halfshaft 12 mm (0.47 in) out of the transaxle.

Fig 4: Removing Halfshaft Carrier Bracket Bolts And Sliding Halfshaft Out Of Transaxle
Courtesy of FORD MOTOR CO.

All vehicles

Remove the engine plug bolt.

Fig 5: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.

NOTE: The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the camshaft removal and installation.

Fig 6: Identifying Special Tool (303-507)

Courtesy of FORD MOTOR CO.

Install the special tool.

CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.

Fig 7: Aligning Crankshaft Pulley Bolt Holes

Courtesy of FORD MOTOR CO.

Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.
Remove the lower timing hole plug from the engine front cover.

Fig 8: Locating Lower Timing Hole Plug
Courtesy of FORD MOTOR CO.
Remove the upper timing hole plug from the engine front cover.

Fig 9: Locating Upper Timing Hole Plug
Courtesy of FORD MOTOR CO.
Reposition the special tool to the slot on the rear of the intake camshaft only.

Fig 10: Identifying Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Releasing the ratcheting mechanism in the timing chain tensioner allows the plunger to collapse and create slack in the timing chain. Installing the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole will lock the tensioner arm in a retracted position and allow enough slack in the timing chain for removal of the exhaust camshaft gear.

Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover timing hole.
- Have an assistant rotate (using the flats of the camshaft) the exhaust camshaft clockwise to collapse the timing chain tensioner plunger.
- Insert the M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
  
  Fig 11: Identifying Small Pick Tool And Timing Chain Tensioner Ratchet
  Courtesy of FORD MOTOR CO.
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft drive gear.

Fig 12: Locating Bolt And Exhaust Camshaft Drive Gear
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 13: Locating Special Tool
Courtesy of FORD MOTOR CO.
Remove the timing chain from the intake camshaft drive gear.

Fig 14: Locating Timing Chain
Courtesy of FORD MOTOR CO.
Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.

Fig 15: Locating Camshaft Lobe
Courtesy of FORD MOTOR CO.

CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.

Remove the camshafts from the engine.
- Loosen the camshaft bearing cap bolts, in the sequence shown, one turn at a time until all tension is released from the camshaft bearing caps.
- Remove the bolts and the camshaft bearing caps.
- Remove the camshafts.
  
  Fig 16: Identifying Loosening Sequence Of Camshaft Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
If removal of the camshaft phaser and sprocket is necessary, mark the sprocket and camshaft for reference during installation.
- If necessary, place the camshaft in a soft-jawed vise. Remove the bolt and the camshaft phaser and sprocket.
  
  Fig 17: Locating Mark On Sprocket
  Courtesy of FORD MOTOR CO.