Removal And Installation: Camshafts: Installation

RH camshafts 

1. NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

   Using the crankshaft bolt, rotate counterclockwise to the 9 o'clock position.

   Courtesy of FORD MOTOR COMPANY

2. Lubricate the camshafts with clean engine oil and position the camshafts onto the RH cylinder head in the neutral position as shown.

   Courtesy of FORD MOTOR COMPANY

3. NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

   Position the camshaft seals gaps at 12 o'clock.

   Courtesy of FORD MOTOR COMPANY

4. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
   • Install the camshaft caps, oil tube and the bolts.

     Torque: Stage 1: Tighten bolts 1, 2, 4, 5, 6 and 7 to: 8 Nm Stage 2: Tighten bolts 1, 2, 4, 5, 6 and 7 an additional: 45deg. Stage 3: Tighten bolts 8, 9, 10 and 11 to: 8 Nm Stage 4: Tighten bolts 12, 13, 14 and 15 to: 8 Nm Stage 5: Tighten bolts 12, 13, 14 and 15 an additional: 45deg.

   • The camshaft torque sequence (bolt 3) will be finished after the timing chain is installed.

   Courtesy of FORD MOTOR COMPANY

5. Loosen the camshaft cap bolts.

   Courtesy of FORD MOTOR COMPANY

6. Tighten the camshaft cap bolts in sequence shown.

   Torque: Stage 1: 8 Nm Stage 2: 60deg.

   Courtesy of FORD MOTOR COMPANY

7. NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
   NOTE: Use a camshaft sprocket bolt to turn the camshafts.

   Confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to: Valve Clearance Adjustment 

   (303-01B Engine - 3.5L Duratec (202kW/275PS), General Procedures).Use the General Equipment: Feeler Gauge

   Courtesy of FORD MOTOR COMPANY

8. • Remove the bolts and the RH oil tube.
   • Loosen the 2 bolts.

   Courtesy of FORD MOTOR COMPANY

9. Rotate the RH camshafts to the TDC.

   Courtesy of FORD MOTOR COMPANY

10. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install Special Service Tool: 303-1248 Camshaft holding tools.

    Courtesy of FORD MOTOR COMPANY

11. NOTE: The VCT oil control solenoids are removed for clarity.

    Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

    Courtesy of FORD MOTOR COMPANY

    LH camshafts 

12. NOTE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

    Using the crankshaft bolt, rotate counterclockwise to the 9 o'clock position.

    Courtesy of FORD MOTOR COMPANY

13. Lubricate the camshafts with clean engine oil and position the camshafts onto the LH cylinder head in the neutral position as shown.

    Courtesy of FORD MOTOR COMPANY

14. NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

    Position the camshaft seals gaps at 12 o'clock.

    Courtesy of FORD MOTOR COMPANY

15. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
    • Install the camshaft caps, oil tube and the bolts.

      Torque: Stage 1: Tighten bolts 1, 2, 4, 5, 6 and 7 to: 8 Nm Stage 2: Tighten bolts 1, 2, 4, 5, 6 and 7 an additional: 45deg. Stage 3: Tighten bolts 8, 9, 10 and 11 to: 8 Nm Stage 4: Tighten bolts 12, 13, 14 and 15 to: 8 Nm Stage 5: Tighten bolts 12, 13, 14 and 15 an additional: 45deg.

    • The camshaft torque sequence (bolt 3) will be finished after the timing chain is installed.

    Courtesy of FORD MOTOR COMPANY

16. Loosen the camshaft cap bolts.

    Courtesy of FORD MOTOR COMPANY

17. Tighten the camshaft cap bolts in sequence shown.

    Torque: Stage 1: 8 Nm Stage 2: 60deg.

    Courtesy of FORD MOTOR COMPANY

18. NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.
    NOTE: Use a camshaft sprocket bolt to turn the camshafts.

    Confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. Refer to: Valve Clearance Adjustment 

    Courtesy of FORD MOTOR COMPANY

19. • Remove bolts and the LH oil tube.
    • Loosen the 2 bolts.

    Courtesy of FORD MOTOR COMPANY

20. Rotate the LH camshafts to the TDC.

    Courtesy of FORD MOTOR COMPANY

21. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install Special Service Tool: 303-1248 Camshaft holding tools.

    Courtesy of FORD MOTOR COMPANY

22. NOTE: The VCT oil control solenoids are removed for clarity.

    Install Special Service Tool: 303-1530 Tool, Chain Tensioner Hold Down.

    Courtesy of FORD MOTOR COMPANY

    All camshafts 

23. Using the crankshaft bolt, rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).

    Courtesy of FORD MOTOR COMPANY

24. Install the LH or RH VCT unit. Refer to: Variable Camshaft Timing (VCT) Unit .
25. Road test the Vehicle.