Ford Fusion: Engine - 1.5L EcoBoost (118kW/160PS) – I4 / Camshafts. Removal and Installation

Special Tool(s) / General Equipment

	303-1532 Installer, Camshaft Seal TKIT-2010B-FLM TKIT-2010B-ROW
	303-393-02 Adapter for 303-393 TKIT-2012A-FL TKIT-2012A-ROW
	303-393A Locking Tool, Flywheel TKIT-2012A-FL TKIT-2012A-ROW
	303-409 (T92C-6700-CH) Remover, Crankshaft Seal TKIT-1992-FH/FMH/FLMH TKIT-1993-LMH/MH
	303-748 Locking Tool, Crankshaft TKIT-2010B-FLM TKIT-2010B-ROW
Feeler Gauge
Hot Air Gun

Materials

Removal

NOTICE: 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.

NOTICE: 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.

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

1. Using the special tool, remove and discard the camshaft seals.
   Use Special Service Tool: 303-409 (T92C-6700-CH)  Remover, Crankshaft Seal.

1. NOTICE: Use a heat gun to soften the flange sealant, this will aid in the removal of the camshaft mega cap. Failure to follow these directions may result in damage to the camshaft mega cap.

   NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference.

   • Remove the bolts and the camshaft caps.
     
   • Heat and remove the mega cap.
     Use the General Equipment: Hot Air Gun
   • Remove the camshafts.
     

1. Remove and discard the O-ring seal.
   

1. Clean the camshaft mega cap mating surface.
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

1. Clean the camshaft mega cap surface.
   Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

Installation

1. NOTICE: If any new parts are being installed (cylinder head, valves, tappets, camshafts) it is necessary to check the valve clearance, follow the next 12 steps exactly or serious damage to the engine may occur. If the original parts are being installed it is not necessary to check the valve clearance so proceed to step 13.

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

1. Remove Special Service Tool: 303-393A  Locking Tool, Flywheel. , 303-393-02  Adapter for 303-393.

1. Remove Special Service Tool: 303-748  Locking Tool, Crankshaft.

1. NOTE: Rotating the crankshaft will position all of the pistons below the deck of the cylinder block and allow the camshafts to be installed and the valve clearance checked without the possibility of damage to the valves or pistons.

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

1. NOTICE: Failure to follow the camshaft tightening procedure can result in damage to the camshafts.

   NOTICE: Make sure that the components are installed to the location and orientation noted before removal.

   NOTE: Make sure that the mating faces are clean and free of foreign material.

   NOTE: Apply clean engine oil to the bearing surfaces of the camshafts, camshaft bearing caps and the VCT bridge.

   Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT bridge are seated against the cylinder head.
   Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
   Torque:
     Stage 1:  1 - 16:   62 lb.in (7 Nm)
     Stage 2:  17 - 20:   89 lb.in (10 Nm)
     Stage 3:  1 - 16:   45 °
     Stage 4:  17 and 18:   70°
     Stage 5:  19 and 20:   53°

1. 1. Using the flats of the camshaft, rotate the camshaft to place the cam lobe at base circle, with the lobe pointed away from the tappet.
      
   2. Use a feeler gauge to measure the clearance of each valve and record its location.
      Use the General Equipment: Feeler Gauge
   3. Repeat to measure all of the lobe/tappet clearances.
      

1. NOTE: Select tappets using this formula: ideal tappet thickness = measured clearance + the existing tappet thickness - nominal clearance. Select the closest tappet size to the ideal tappet thickness available and mark the installation location.

   NOTE: The nominal clearance is 0.0112  in ( .285  mm) for intake and 0.0167  in ( .425  mm) for exhaust.

   NOTE: The acceptable clearances after being fully installed is 0.009 –0.013  in ( .24 –.33  mm) for intake and 0.015 –0.019  in ( .38 –.47  mm) for exhaust.

1. NOTE: Note the location and orientation of each camshaft bearing cap and the position of the camshaft lobes on the No. 1 cylinder for installation reference.

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

1. Install Special Service Tool: 303-748  Locking Tool, Crankshaft.

1. NOTE: Rotating the crankshaft will position the engine at TDC and allow you to install the camshafts in the same position as noted during the disassembly.

   Rotate the crankshaft clockwise 90 degrees so the crankshaft contacts the Timing Peg, Crankshaft TDC 303-748.
   

1. If necessary, replace any tappets with the correct tappets selected during the valve clearance check.
   

1. NOTE: Verify the crankshaft contacts the Timing Peg and the engine is still at TDC.

   Install Special Service Tool: 303-393A  Locking Tool, Flywheel. , 303-393-02  Adapter for 303-393.

1. Remove the crankshaft bolt and washer.
   

1. Install a new O-ring seal.
   

1. NOTE: The component must be installed within 5 minutes of applying the sealant.

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

1. NOTE: Make sure that the components are installed to the position noted before removal.

   NOTE: Make sure that new bolts are installed.

   NOTE: Apply clean engine oil to the bearing surfaces of the camshafts, camshaft bearing caps and the VCT bridge.

   Tighten the bolts evenly, half a turn at a time, until the camshaft bearing caps and the VCT bridge are seated against the cylinder head.
   Material: Engine Oil - SAE 5W-20 - Synthetic Blend Motor Oil / XO-5W20-Q1SP (WSS-M2C945-B1)
   Torque:
     Stage 1:  1 - 16:   62 lb.in (7 Nm)
     Stage 2:  17 - 20:   89 lb.in (10 Nm)
     Stage 3:  1 - 16:   45°
     Stage 4:  17 and 18:   70°
     Stage 5:  19 and 20:   53°

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

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