Fig. 5.39. Duratec-V15 engine with 2.5 l capacity and variable valve timing system elements: 1 – timing mechanism drive cover; 2 – cylinder head cover; 3 – intake camshaft position sensor; 4 – exhaust camshaft position sensor; 5 – electromagnetic valve for adjusting the position of the intake camshaft; 6 – electromagnetic valve for adjusting the position of the exhaust camshaft; 7 – mechanism for adjusting the position of the exhaust camshaft; 8 – intake camshaft position adjustment mechanism; 9 – intermediate pulley of the timing belt; 10 – toothed pulley of the timing belt on the crankshaft; 11 – timing belt tensioner; 12 – toothed pulley of the coolant pump; 13 – timing belt drive.
Fig. 5.46. The procedure for loosening the cylinder head cover mounting bolts.
You will need: all the tools necessary to remove the battery, cylinder head cover, timing belt.
The camshafts are replaced in the following cases: – the pressure in the engine lubrication system has dropped; - valve knocking with normal clearances in the valve drive mechanism. Caused by increased wear of the camshaft cams due to the use of low-quality motor oil or damage to the oil filter.
1. Disconnect the wire from the negative terminal of the battery.
2. Remove the VCT solenoid valves by disconnecting the wiring harness connectors from them and unscrewing one bolt each securing them to the VCT caliper.
3. Remove the camshaft position sensors by disconnecting the wiring harness connectors from them and unscrewing one bolt each securing them to the cylinder head cover. Remove the ignition coils and spark plugs.
4. Remove the timing belt (see Replacing the timing belt of the 2.5L Duratec-V15 engine).
5. Remove VCT control mechanisms 7 and 8 (see Fig. 5.39) of the exhaust and intake camshafts.
6. Remove the cylinder head cover by unscrewing the forty-six cylinder head cover mounting bolts in the order shown in Fig. 5.46.
7. Loosen the camshaft bearing cap mounting bolts and remove the caps.
8. Remove the camshafts.
9. Inspect the camshafts.
If signs of seizure, overheating, deep scratches or wear in the form of faceting are found on the working surfaces of the cams, replace the shafts.
10. Lubricate the camshaft bearings with clean engine oil and install the camshafts.
11. Clean the cylinder head cover grooves and the mating surface of the cylinder head from the remains of the old seal.
12. Apply sealant-gasket (FORD WSE-M4G323-A4 or its equivalent) to the cylinder head surface with a roller with a diameter of 3–4 mm, and the line of application of the sealant-gasket should pass from the inside of the mounting holes.
13. No later than 10 minutes after applying the sealant, install the cylinder head cover.
14. Tighten the cover mounting bolts to a torque of 17 Nm in the reverse order to that shown in Fig. 5.46.
15. Install all removed parts in the reverse order of removal.
16. Adjust the timing belt tension (see Replacing the timing belt of the 2.5L Duratec-V15 engine).
(The material was copied from an information website FORDBOOK)