In-Vehicle Repair: Camshafts: Removal

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 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 .
Remove the degas bottle. For additional information, refer to ENGINE COOLING - HYBRID .
Remove the Variable Camshaft Timing (VCT) oil control solenoid. For additional information, refer to ELECTRONIC ENGINE CONTROLS - HYBRID .
Check the valve clearance. For additional information, refer to VALVE CLEARANCE CHECK .
Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - HYBRID .

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.

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.
  
  Fig 1: Turning Crankshaft Clockwise Using Crankshaft Pulley Bolt
  Courtesy of FORD MOTOR CO.

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

Fig 2: Checking Position Of Camshafts Using 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 3: Location of Engine Plug Bolt
Courtesy of FORD MOTOR CO.
Install the Crankshaft TDC Timing Peg.

Fig 4: Installing Crankshaft TDC Timing Peg
Courtesy of FORD MOTOR CO.

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

Fig 5: Location of Crankshaft Pulley Mounting Bolt

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 front cover timing hole plug from the engine front cover.

Fig 6: Location of 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: Location of Engine Front Cover Upper Timing Hole Plug
Courtesy of FORD MOTOR CO.
Reposition the Camshaft Alignment Plate to the slot on the rear of the intake camshaft only.

Fig 8: 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 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: Rotating Exhaust Camshaft Clockwise
  Courtesy of FORD MOTOR CO.
Remove the Camshaft Alignment Plate.

Fig 10: Identifying Camshaft Alignment Plate
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: Location of Exhaust Camshaft Drive Gear Bolt
Courtesy of FORD MOTOR CO.
Remove the timing chain from the camshaft phaser and sprocket.

Fig 12: Location of Sprocket Timing Chain
Courtesy of FORD MOTOR CO.
Mark the position of the camshaft lobes on the No. 1 cylinder for installation reference.

Fig 13: Location of Camshaft Lobe Position
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.

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 14: Identifying Camshaft Bearing Cap Bolts Loosening Sequence
  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 15: Location of Sprocket And Camshaft Reference Mark
  Courtesy of FORD MOTOR CO.