In-Vehicle Repair: Camshafts: Installation

WARNING: This page is about a different car, the 2006 Mercury Milan and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles

NOTE: If new parts are installed, transfer the reference marks made during disassembly to the new parts.

If necessary, position the camshaft in a soft-jawed vise and install the camshaft phaser and sprocket and the bolt.
- Align the reference marks on the camshaft phaser and sprocket and the camshaft. Tighten the bolt to 72 Nm (53 lb-ft).
  
  Fig 1: Locating Mark On Sprocket
  Courtesy of FORD MOTOR CO.

CAUTION: Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate can be installed without rotating the camshafts. Make sure the lobes on the No. 1 cylinder are in the same position as noted in the removal procedure. Rotating the camshafts when the timing chain is removed, or installing the camshafts 180 degrees out of position can cause severe damage to the valves and pistons.

NOTE: Lubricate the camshaft journals and bearing caps with clean engine oil.

Install the camshafts and bearing caps. Tighten the camshaft bearing caps in the sequence shown in 3 stages:
- Stage 1: Tighten the camshaft bearing cap bolts until finger tight.
- Stage 2: Tighten to 7 Nm (62 lb-in).
- Stage 3: Tighten to 16 Nm (12 lb-ft).
  
  Fig 2: Identifying Tightening Sequence Of Camshaft Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 3: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
Install the timing chain on the intake camshaft drive gear.

Fig 4: Locating Timing Chain On Intake Camshaft Drive Gear
Courtesy of FORD MOTOR CO.

NOTE: The timing chain must be correctly engaged on the teeth of the crankshaft timing sprocket and the intake camshaft drive gear in order to install the exhaust camshaft drive gear onto the exhaust camshaft.

Position the exhaust camshaft drive gear in the timing chain and install the gear and bolt on the exhaust camshaft.
- Hand-tighten the bolt.
  
  Fig 5: Locating Timing Chain Gear And Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Releasing the tensioner arm will remove the slack from the timing chain.

Remove the M6 x 30 mm (1.18 in) bolt from the upper front cover timing hole to release the tensioner arm.

CAUTION: The special tool 303-465 is for camshaft alignment only. Using this tool to prevent engine rotation can result in engine damage.

Fig 6: Locating Camshaft Drive Gear Bolt

Courtesy of FORD MOTOR CO.

Using the flats on the camshaft to prevent camshaft rotation, tighten the exhaust camshaft drive gear bolt to 72 Nm (53 lb-ft).
Remove the special tool.

Fig 7: Identifying Special Camshaft Tool (303-465)
Courtesy of FORD MOTOR CO.
Remove the 6 mm (0.23 in) x 18 mm (0.7 in) bolt.

Fig 8: Aligning Crankshaft Pulley Bolt Holes
Courtesy of FORD MOTOR CO.
Remove the special tool.

Fig 9: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Install the upper timing hole plug in the engine front cover.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 10: Locating Upper Front Cover Timing Hole Plug
  Courtesy of FORD MOTOR CO.
Apply silicone gasket and sealant to the threads of the lower timing hole plug.
- Install the lower timing hole plug in the engine front cover.
  - Tighten to 12 Nm (9 lb-ft).
    
    Fig 11: Locating Lower Front Cover Timing Hole Plug
    Courtesy of FORD MOTOR CO.
Install the engine plug bolt.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 12: Locating Engine Plug Bolt
  Courtesy of FORD MOTOR CO.

Automatic transaxle vehicles

Install the RH halfshaft and the 2 half shaft carrier bearing bracket bolts.
- Tighten to 40 Nm (30 lb-ft).

All vehicles

If equipped, install the underbody cover and the 7 screws.

Fig 13: Locating Underbody Cover Screws
Courtesy of FORD MOTOR CO.
Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE - 2.3L .
Install the variable camshaft timing (VCT) solenoid. For additional information, refer to ELECTRONIC ENGINE CONTROLS - 2.3L .