In-Vehicle Repair: Camshafts: Removal

WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: 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.

NOTE: 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.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.5L -- FUSION & MILAN (EXCEPT HYBRID) article.
Remove the front RH wheel and tire. For additional information, refer to WHEELS & TIRES article.
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 - 2.5L -- FUSION & MILAN (EXCEPT HYBRID) article.
Check the valve clearance. For additional information, refer to VALVE CLEARANCE CHECK in this service information.

NOTE: 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.

Fig 2: Turning Crankshaft Pulley So The Hole Is In The 6 O'Clock Position

Courtesy of FORD MOTOR CO.

Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at Top Dead Center (TDC).
- The hole in the crankshaft pulley should be in the 6 o'clock position.

NOTE: The Camshaft Alignment Plate 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 Camshaft Alignment Plate cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

Fig 3: Identifying Camshaft Alignment Plate

Courtesy of FORD MOTOR CO.

Install the Camshaft Alignment Plate in the slots on the rear of both camshafts.
Remove the engine plug bolt.

Fig 4: Locating Engine Plug Bolt
Courtesy of FORD MOTOR CO.

NOTE: The Crankshaft TDC Timing Peg 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 5: Remove/Install Crankshaft TDC Timing Peg

Courtesy of FORD MOTOR CO.

Install the Crankshaft TDC Timing Peg.

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

Fig 6: Locating Crankshaft Pulley Bolt In Hole

Courtesy of FORD MOTOR CO.

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

Fig 7: Locating Lower Front Cover Timing Hole Plug
Courtesy of FORD MOTOR CO.
Remove the upper timing hole plug from the engine front cover.

Fig 8: Locating Upper Timing Hole Plug Of Engine Front Cover
Courtesy of FORD MOTOR CO.
Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.

Fig 9: Identifying Camshaft Alignment Plate
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 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.

Fig 10: Releasing Timing Chain Tensioner Ratchet Through Lower Front Cover Timing Hole

Courtesy of FORD MOTOR CO.

Using a small pick tool, release the timing chain tensioner ratchet through the lower front cover timing hole.
- Have an assistant rotate the exhaust camshaft clockwise (using the flats of the camshaft) to collapse the timing chain tensioner plunger.
- Insert the M6 x 30 mm bolt into the upper front cover timing hole to hold the tensioner arm in the retracted position.
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and the exhaust camshaft drive gear.

Fig 11: Locating Exhaust Camshaft Drive Gear Bolt
Courtesy of FORD MOTOR CO.
Remove the Camshaft Alignment Plate.

Fig 12: Identifying Camshaft Alignment Plate
Courtesy of FORD MOTOR CO.
Remove the timing chain from the intake camshaft drive gear.

Fig 13: Locating Intake Camshaft Drive Gear Timing Chain
Courtesy of FORD MOTOR CO.
Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.

Fig 14: Locating Camshaft Lobe Position On The No. 1 Cylinder
Courtesy of FORD MOTOR CO.

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

NOTE: Mark the location and orientation of each camshaft bearing cap.

Fig 15: Identifying Camshaft Bearing Cap Bolts Loosening Sequence

Courtesy of FORD MOTOR CO.

Remove the camshafts from the engine.
- Loosen the camshaft bearing cap bolts, in the sequence shown in the illustration, 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.
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 16: Locating Marking On Camshaft Phaser And Sprocket
Courtesy of FORD MOTOR CO.