Camshafts. Removal and Installation

Special Service Tools / General Equipment

	303-1532 Installer, Camshaft Seal TKIT-2010B-FLM TKIT-2010B-RYAD
	303-393-02 Adapter, 303-393 TKIT-2012A-FL TKIT-2012A-RHD
	303-393A Flywheel Locking Tool TKIT-2012A-FL TKIT-2012A-RHD
	303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FX/FMX/FLMX TKIT-1993-LMX/MX
	303-748 Crankshaft Locking Tool TKIT-2010B-FLM TKIT-2010B-RHD
Feeler gauge
Heat gun

Materials

Removal

NOTICE: When performing engine repairs, cleanliness is extremely important. Any foreign material (including any material created during gasket surface cleaning) that enters the oil passages, coolant passages or oil pan may cause engine failure.

NOTICE: Do not rotate the camshafts unless specified in this procedure. Rotating the camshafts or crankshaft with timing components loosened or removed may cause serious damage to the valves and pistons.

1. 1
   Remove the VCT unit.
   Refer to: Variable Camshaft Timing (VCT) Unit (303-01A Engine – 1.5 L EcoBoost (118 kW/160 L PS) – I4, Removal and Installation).
2. 2
   Using the special tool, remove and discard the camshaft seals.
   Use special service tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.

   

3. 3

   NOTICE: Use a heat gun to soften the flange sealant; this will assist in removing the camshaft cap. Failure to follow these instructions may damage the camshaft cap.

   • Remove the bolts and the camshaft caps.

   • Heat and remove the camshaft cap.
     Use common service equipment: heat gun.

   • Remove the camshafts.

   

4. 4
   Remove and discard the O-ring.

   

5. 5
   Clean the mating surface of the camshaft cap.
   Material: Motorcraft® Metal Surface Preparation Wipes / ZC-31-B

   

6. 6
   Clean the camshaft cap surface.
   Material: Motorcraft® Metal Surface Preparation Wipes / ZC-31-B

   

Installation

1. 1

   NOTICE: If any new components (cylinder head, valves, lifters, camshafts) are installed, the valve clearance must be checked. Follow the next 12 steps exactly, otherwise serious engine damage may occur. If original components are installed, it is not necessary to check the valve clearance; proceed to step 13.

   Paint a mark on the crankshaft at the 12 o'clock position.

   

2. 2
   Remove the special service tools: 303-393A Flywheel Locking Tool, 303-393-02 Adapter, 303-393.

   

3. 3
   Remove the special service tool: 303-748 Crankshaft Locking Tool.

   

4. 4
   Using the crankshaft bolt and a washer, rotate the crankshaft clockwise 270 degrees until the paint mark is at the 9 o'clock position.

   

5. 5

   NOTICE: Failure to follow the camshaft tightening procedure may damage the camshafts.

   NOTICE: Before removal, make sure components are installed in accordance with the marked locations and orientation.

   Tighten the bolts evenly, one-half turn at a time, until the camshaft bearing caps and the VCT bridge seat on the cylinder head.
   Material: Engine Oil – SAE 5W-20 – Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
   Torque:
   Step 1: 1 - 16: 62 lb-in (7 N·m)
   Step 2: 17 - 20: 89 lb-in (10 N·m)
   Step 3: 1 - 16: 45°
   Step 4: 17 and 18: 70°
   Step 5: 19 and 20: 53°

   

6. 6
   1. Using the camshaft flats, rotate the camshaft to place the cam lobe on the base circle so that the lobe points away from the tappet.

   2. Using a feeler gauge, measure the clearance of each valve and record its position.
      Use general equipment: Feeler Gauge

   3. Repeat to measure all cam/tappet clearances.

   

7. 7
8. 8
   Loosen the camshaft bearing caps sequentially, 2 turns at a time, until all tension is released from the camshaft bearing caps in the sequence shown.

   

9. 9
   Install the special service tool: 303-748 Crankshaft Locking Tool.

   

10. 10
    Rotate the crankshaft clockwise 90 degrees until the crankshaft contacts the timing pin, TDC crankshaft 303-748.

    

11. 11
    If necessary, replace all tappets with the tappets selected during the valve clearance check.

    

12. 12
    Install the special service tools: 303-393A Flywheel Locking Tool, 303-393-02 Adapter, 303-393.

    

13. 13
    Remove the crankshaft bolt and washer.

    

14. 14
    Install a new O-ring.

    

15. 15
    Apply a 2.0 mm bead of flange sealant.
    Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

    

16. 16
    Tighten the bolts evenly, one-half turn at a time, until the camshaft bearing caps and the VCT bridge seat on the cylinder head.
    Material: Engine Oil – SAE 5W-20 – Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
    Torque:
    Step 1: 1 - 16: 62 lb-in (7 N·m)
    Step 2: 17 - 20: 89 lb-in (10 N·m)
    Step 3: 1 - 16: 45°
    Step 4: 17 and 18: 70°
    Step 5: 19 and 20: 53°

    

17. 17
    Using the special tool, lubricate and install the camshaft seals.
    Use special service tool: 303-1532 Camshaft Seal Installer.
    Material: Engine Oil – SAE 5W-20 – Synthetic Engine Oil / XO-5W20-Q1SP (WSS-M2C945-B1)

    

18. 18
    Install the VCT unit.
    Refer to: Variable Camshaft Timing (VCT) Unit (303-01A Engine – 1.5 L EcoBoost (118 kW/160 L PS) – I4, Removal and Installation).