Ford repair professionals: How to Remove Camshaft and Valve Lifters on 2003 Ford Focus?

Camshaft & Valve Lifters

Removal & Installation

2.0L (VIN N) & 2.3L (VIN Z) Engine

Fig. Exploded view of the cylinder head, showing the camshafts, lifters and related components-2.0L (VIN N) and 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.

CAUTION

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.

Before servicing the vehicle, refer to the Precautions Section.

With the vehicle in NEUTRAL, position it on a hoist.

Disconnect the battery negative cable.

Remove the degas bottle.

Check the valve clearance.

Remove the accessory drive belt.

CAUTION
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 TDC. The hole in the crankshaft pulley should be in the 6 o'clock position.

CAUTION
The special tool 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 special tool cannot be installed, rotate the crankshaft one complete revolution clockwise to correctly position the camshafts.

Fig. Using the crankshaft pulley bolt, turn the crankshaft clockwise to position the No. 1 piston at TDC, with the hole in the crankshaft pulley at the 6 o'clock position -2.0L (VIN N) and 2.3L (VIN Z) engine

Install the special tool in the slots on the rear of both camshafts.

Fig. Install the special tool in the slots on the rear of both camshafts

Remove the engine plug bolt.

NOTE
The special tool will contact the crankshaft and prevent it from turning past TDC. However, the crankshaft can still be rotated in the counterclockwise direction. The crankshaft must remain at the TDC position during the camshaft removal and installation.

Fig. Remove the engine plug bolt

Install the special tool.

Fig. Install the special tool

Install a standard 6 mm (0.23 in) x 18 mm (0.7 in) bolt through the crankshaft pulley and thread it into the front cover.

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

Remove the lower and upper front cover timing hole plugs from the engine front covers.

Reposition the special camshaft holding tool to the slot on the rear of the intake camshaft only.

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 place.

Fig. Insert an M6 x 30 mm (1.18 in) bolt into the upper front cover timing hole to hold the tensioner arm in place

Remove the camshaft holding tool.

Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and exhaust camshaft drive gear.

Remove the timing chain from the intake camshaft drive gear.

Using the flats on the camshaft to prevent camshaft rotation, remove the bolt and intake camshaft drive gear.

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

WARNING
Failure to follow the camshaft loosening procedure can result in damage to the camshafts.

Remove the camshafts from the engine, using only the following procedure:
1. Loosen the camshaft bearing cap bolts, in sequence, one turn at a time.
2. Repeat the first step until all tension is released from the camshaft bearing caps.
3. Remove the camshaft bearing caps.
4. Remove the camshafts.
  
  Fig. Showing the camshaft bolt loosening sequence

To install:

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 bearing caps in the sequence shown in 3 stages:
1. Stage 1: Tighten the camshaft bearing cap bolts one turn at a time until finger tight.
2. Stage 2: Tighten to 62 inch lbs. (7 Nm).
3. Stage 3: Tighten to 12 ft. lbs. (16 Nm).
  
  Fig. Showing the camshaft bolt tightening sequence

Install the special camshaft holding tool to the rear of the camshafts.

Install the intake camshaft drive gear and hand-tighten the bolt.

Install the timing chain on the intake camshaft drive gear.

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.

Releasing the tensioner arm will remove the slack from the timing chain release.

Remove the M6 x 30 mm bolt from the upper front cover timing hole to unlock 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.