How to Replace the Camshaft, Bearings and Lifters on 2003 Ford Focus?

Camshaft, Bearings & Lifters

Removal & Installation

2.0L (VIN 3) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove or disconnect the following:
   
   NOTE

   Mark the camshaft journal caps with a number to identify their location.
   
   
   
   
   Timing belt

   Valve cover and camshaft sprockets

   Oil control solenoid flange
   
   
   
   
   Camshaft journal caps. Loosen the bolts in sequence and in several passes.

   Camshafts

   Oil control sensor and bushing
   
   

   

   

   Fig. Exploded view of the cylinder head and camshaft mounting-2.0L (VIN 3) engine

   
   
   

   

   

   Fig. Camshaft journal cap loosening sequence-2.0L (VIN 3) engine

To install:

1. Install the oil control solenoid bushing and flange on the exhaust camshaft.
2. Coat the surface of the front camshaft journal cap with gasket maker E2AZ-19562-B.
3. Place the camshafts in position and lubricate the bearing surfaces with engine assembly lubricant D9AZ-19579-D.
4. Install new camshaft front oil seals.
5. Apply a thin coat of silicone gasket and sealant F6AZ-19562-AA to the sealing surface of the of the front camshaft journal bearing cap.
6. Install the caps and tighten the bolts in several 2-turn passes in the sequence illustrated to 10-12 ft. lbs. (13-17 Nm).
   
   
   

   

   Fig. Camshaft journal cap torque sequence-2.0L (VIN 3) engine
7. Inspect the oil control solenoid flange O-rings for damage or wear and replace, as necessary.
8. Install the oil control solenoid flange and tighten the bolts to 84-92 inch lbs. (9.5-10.5 Nm) in the sequence.
9. Rotate the camshafts a full turn and check for binding.
10. Install or connect the following:
    
    
    Camshaft sprockets and timing belt

    Valve cover
    
    

    

    

    Fig. Tighten the oil control solenoid flange bolts in this sequence-2.0L (VIN 3) engine

2.0L (VIN 5) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the timing belt.
   
   NOTE

   Hold the camshafts by the hexagon with an open ended wrench to stop them from rotating.
3. Remove the camshaft pulleys.
4. Remove the oil feed flange. Discard the camshaft oil seals and the oil feed flange oil seal.
   
   CAUTION

   Loosen the camshaft bearing caps in the sequence shown.
5. Working in several stages, evenly loosen each bolt two turns at a time in the indicated sequence and remove the bolts.
   
   
   

   

   Fig. Camshaft bolt removal sequence-2.0L (VIN 5) engine
6. Remove the camshafts.
7. Remove the tappets.
   
   NOTE

   Keep the valvetrain components in order for installation.

To install:

1. Install the tappets in their original locations.
2. Install the camshafts.
3. Working in several stages, install the camshaft bearing caps in the indicated sequence, tighten the bolts evenly one half turn at a time.
4. Tighten the bolts in the sequence shown to 11 ft. lbs. (15 Nm).
   
   
   

   

   Fig. Camshaft torque sequence-2.0L (VIN 5) engine
5. Install a new oil feed flange seal.
   
   
   

   

   Fig. Apply sealant to the marked areas on the oil feed flange-2.0L (VIN 5) engine
6. Install the oil feed flange and tighten the bolts to 11 ft. lbs. (15 Nm).
7. Using the Camshaft Oil Seal Installer 303-160, install the camshaft oil seals.
8. Lubricate the camshaft and oil seal lip with clean engine oil.
9. Install the camshaft pulleys.
   
   NOTE

   Do not tighten the camshaft pulley retaining bolts at this stage.
10. Install the timing belt.

2.0L (VIN P) Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Remove the air cleaner and valve cover.
4. Remove the camshaft front seal as follows:
   1. Align the timing marks and remove the timing belt.
   2. Use cam sprocket holding/removing tool T74P-6256-B, and remove the camshaft sprocket.
   3. Unfasten the timing belt tensioner bolt and remove the tensioner.
   4. Remove the inner engine front cover.
   5. Use Seal Removal tool T92C-6700-CH, to remove the camshaft front seal.
      
      
      

      

      Fig. Exploded view of the cylinder head-2.0L (VIN P) engine
      
      
      
      

      

      Fig. Removing the camshaft front seal-2.0L (VIN P) engine
5. Remove or disconnect the following:
   
   
   Ignition coil and bracket

   Rocker arms and valve tappets

   Camshaft thrust plate bolts and the plate

   Cup plug from the rear of the cylinder head and discard

   Camshaft from the rear of the cylinder head
   
   

   

   

   Fig. Remove the camshaft thrust plate retaining bolts (A) and the plate (B)-2.0L (VIN P) engine

   
   
   

   

   

   Fig. Remove and discard the cup plug located at the rear of the cylinder head-2.0L (VIN P) engine

To install:

NOTE

Liberally coat the cam bore in the cylinder with clean 5W-30 motor oil.

1. Install or connect the following:
   
   
   Camshaft through the rear of the cylinder head

   Camshaft thrust plate and the bolts. Tighten the bolts to 71-115 inch lbs. (8-13 Nm).

   New cup plug and the tappets

   Rocker arms

   Ignition coil bracket and coil
2. Install the camshaft front seal as follows:
   1. Apply a thin film of 5W-30 motor oil to the lip of the seal.
   2. Use Seal Replacer T81P-6292-A, to install the camshaft front seal.
      
      NOTE

      The seal depth should be 0.002-0.04 in. (0.05-1.0mm) below flush with the cylinder head front face.
      
      
      
      
      

      

      Fig. Use seal Replacer T81P-6292-A, to install the camshaft front seal 0.002-0.04 in. (0.05-1.0mm) below flush with the cylinder head front face-2.0L (VIN P) engine
   3. Install the inner engine front cover.
   4. Install the timing belt tensioner. Tighten the tensioner bolt to 15-22 ft. lbs. (20-30 Nm).
   5. Install the camshaft sprocket and the timing belt
3. Install the valve cover and the air cleaner assembly.
4. Connect the negative battery cable.

2.3L (VIN Z) Engine

CAUTION

During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, which enters the oil passages, coolant passages or the oil pan can cause engine failure.

CAUTION

The crankshaft, the crankshaft sprocket and the pulley are fitted together by friction, using diamond washers between the flange faces on each part. For that reason, the crankshaft sprocket is also unfastened if you loosen the pulley. Therefore the engine must be retimed each time the damper is removed. Otherwise severe engine damage can occur.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the timing chain and sprockets.
3. Remove the camshaft alignment plate.
   
   NOTE

   Mark the position of the camshaft lobes on the No. 1 cylinder for assembly reference.
   
   
   
   CAUTION

   Failure to follow the camshaft loosening procedure can result in damage to the camshafts.
4. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time.
5. Repeat the first step until all tension is released from the camshaft bearing caps.
6. Remove the camshaft bearing caps.
7. Remove the camshafts.
   
   
   

   

   Fig. Camshaft bolt loosening sequence-2.3L (VIN Z) engine

To install:

CAUTION

Install the camshafts with the alignment slots in the camshafts lined up so the Camshaft Alignment Plate (T94P-6256-CH) 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.

1. Install the camshafts and bearing caps. Tighten the bolts in the sequence shown as follows:
   1. Step 1: Tighten the camshaft bearing bolt caps one turn at a time until tight.
   2. Step 2: Tighten the bolts to 62 inch lbs. (7 Nm)
   3. Step 3: Tighten the bolts to 12 ft. lbs. (16 Nm)
      
      
      

      

      Fig. Camshaft bolt tightening sequence-2.3L (VIN Z) engine
2. Install the camshaft drive gears and hand-tighten the bolts.
3. Install the timing chain and sprockets.

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