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In-Vehicle Repair: Camshafts: Removal

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 unless instructed to in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed can cause serious damage to the valves and pistons.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Disconnect the battery negative cable. For additional information, refer to BATTERY MOUNTING AND CABLES .
  3. Remove the degas bottle. For additional information, refer to ENGINE COOLING .
  4. Check the valve clearance. For additional information, refer to VALVE CLEARANCE CHECK  in this article.
  5. Remove the accessory drivebelt. For additional information, refer to ACCESSORY DRIVE .
    6. 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.
  6. 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 1: Turning Crankshaft Clockwise
      G04652004Courtesy of FORD MOTOR CO.
    7. 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 2: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  7. Install the special tool in the slots on the rear of both camshafts.
  8. Remove the engine plug bolt.
    Fig 3: Locating Engine Plug Bolt
    G04319319Courtesy of FORD MOTOR CO.
    9. 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 4: Identifying Special Tool (303-507)
    G04617907Courtesy of FORD MOTOR CO.
  9. Install the special tool.
    10. CAUTION: Only hand-tighten the bolt or damage to the front cover can occur.
    Fig 5: Aligning Crankshaft Pulley Bolt Holes
    G03897704Courtesy of FORD MOTOR CO.
  10. 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.
  11. Remove the lower front cover timing hole plug from the engine front cover.
    Fig 6: Locating Lower Front Cover Timing Hole Plug
    G04652009Courtesy of FORD MOTOR CO.
  12. Remove the upper front cover timing hole plug from the engine front cover.
    Fig 7: Locating Upper Front Cover Timing Hole Plug
    G04652010Courtesy of FORD MOTOR CO.
  13. Reposition the special tool to the slot on the rear of the intake camshaft only.
    Fig 8: Identifying Special Tool (303-465)
    G04652011Courtesy of FORD MOTOR CO.
    14. NOTE: Releasing the ratcheting mechanism in the timing chain tensioner allows the plunger to collapse and create slack in the timing chain. Installing an M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole will hold the tensioner arm in a retracted position and allow enough slack in the timing chain for removal of the exhaust camshaft gear.
  14. Using a small pick tool, unlock the chain tensioner ratchet through the lower front cover timing hole.
    • Using the flats of the camshaft, have an assistant rotate the exhaust camshaft clockwise to collapse the timing chain tensioner plunger.
    • Insert an M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in place.
      Fig 9: Unlocking Chain Tensioner Ratchet Through Lower Front Cover Timing Hole
      G04652012Courtesy of FORD MOTOR CO.
  15. Remove the special tool.
    Fig 10: Identifying Special Tool (303-465)
    G04652013Courtesy of FORD MOTOR CO.
  16. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.
    Fig 11: Locating Camshaft Bolt, Bolt And Exhaust Camshaft Drive Gear
    G04652014Courtesy of FORD MOTOR CO.
  17. Remove the timing chain from the intake camshaft drive gear.
    Fig 12: Locating Timing Chain
    G04652015Courtesy of FORD MOTOR CO.
  18. Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and intake camshaft drive gear.
    Fig 13: Locating Camshaft Bolt And Intake Camshaft Drive Gear
    G04652016Courtesy of FORD MOTOR CO.
  19. Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.
    Fig 14: Locating Camshaft Lobe
    G03898791Courtesy of FORD MOTOR CO.
    20. CAUTION: Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
  20. Remove the camshafts from the engine.
    • Loosen the camshaft bearing cap bolts, in sequence, one turn at a time.
    • Repeat the first step until all tension is released from the camshaft bearing caps.
    • Remove the camshaft bearing caps.
    • Remove the camshafts.
      Fig 15: Identifying Loosening/Tightening Sequence Of Camshaft Bearing Bolts
      G03897808Courtesy of FORD MOTOR CO.

    Installation 

    CAUTION: 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. 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).
      Fig 16: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
      G04652019Courtesy of FORD MOTOR CO.
  2. Install the special tool.
    Fig 17: Identifying Special Camshaft Tool (303-465)
    G03898006Courtesy of FORD MOTOR CO.
  3. Install the intake camshaft drive gear and hand-tighten the bolt.
    Fig 18: Locating Intake Camshaft Drive Gear Bolt
    G04652021Courtesy of FORD MOTOR CO.
  4. Install the timing chain on the intake camshaft drive gear.
    Fig 19: Locating Timing Chain
    G04652022Courtesy of FORD MOTOR CO.
    5. 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.
      Fig 20: Locating Exhaust Camshaft Drive Gear Bolt
      G04652023Courtesy of FORD MOTOR CO.
    6. 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 unlock the tensioner arm.
    7. CAUTION: 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).
      Fig 21: Locating Camshaft Bolts
      G04652024Courtesy of FORD MOTOR CO.
  8. Remove the special tool.
    Fig 22: 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.
    Fig 23: Aligning Crankshaft Pulley Bolt Holes
    G03897704Courtesy of FORD MOTOR CO.
  10. Remove the special tool.
    Fig 24: Identifying Special Tool
    G03897707Courtesy of FORD MOTOR CO.
  11. Install the upper front cover timing hole plug.
    • Tighten to 10 Nm (89 lb-in).
      Fig 25: Locating Upper Front Cover Timing Hole Plug
      G04652028Courtesy 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).
      Fig 26: Locating Lower Front Cover Timing Hole Plug
      G04652029Courtesy of FORD MOTOR CO.
  13. Install the engine plug bolt.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 27: Locating Engine Plug Bolt
      G04319319Courtesy of FORD MOTOR CO.
  14. Install the accessory drivebelt. For additional information, refer to ACCESSORY DRIVE .
  15. Install the valve cover. For additional information, refer to VALVE COVER  in this article.
  16. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  17. Connect the battery negative cable. For additional information, refer to BATTERY MOUNTING AND CABLES .
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