In-Vehicle Repair: Camshafts: Removal

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. 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.
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.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
Disconnect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION .

CAUTION: Before removing the high voltage cables, the vehicle electrical system must be completely shut down for at least 5 minutes to allow for the high voltage capacitors to discharge.

Depower the vehicle high voltage traction battery electrical system. For additional information, refer to HIGH VOLTAGE TRACTION BATTERY .
Remove the degas bottle. For additional information, refer to REMOVAL AND INSTALLATION .
Remove the direct current/direct current (DC/DC) converter. For additional information, refer to REMOVAL AND INSTALLATION .
Check the valve clearance. For additional information, refer to VALVE CLEARANCE CHECK .
Remove the accessory drive belt. For additional information, refer to REMOVAL AND INSTALLATION .

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 1: Locating Hole In Crankshaft Pulley
  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 2: Identifying Special Camshaft Tool (303-465)

Courtesy of FORD MOTOR CO.

Install the special tool in the slots on the rear of both camshafts.
Remove the engine plug bolt.

Fig 3: 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 4: 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 5: 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 front cover timing hole plug from the engine front cover.

Fig 6: Locating Lower Front Cover Timing Hole Plug
Courtesy of FORD MOTOR CO.
Remove the upper front cover timing hole plug from the engine front cover.

Fig 7: Locating Upper Front Cover Timing Hole Plug
Courtesy of FORD MOTOR CO.
Reposition the special tool to the slot on the rear of the intake camshaft only.

Fig 8: Identifying Special Tool (303-465)
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 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.

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 the retracted position.
  
  Fig 9: Unlocking Chain Tensioner Ratchet Using Small Pick Tool
  Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 10: Identifying Special Tool (303-465)
Courtesy of FORD MOTOR CO.
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.

Fig 11: Locating Exhaust Camshaft Drive Gear Bolt
Courtesy of FORD MOTOR CO.
Remove the timing chain from the intake camshaft drive gear.

Fig 12: Locating Timing Chain
Courtesy of FORD MOTOR CO.
Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and intake camshaft drive gear.

Fig 13: Locating Intake Camshaft Drive Gear Bolt
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
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 sequence, 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 15: Identifying Loosening/Tightening Sequence Of Camshaft Bearing Bolts
  Courtesy of FORD MOTOR CO.