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Autopapyrus · Ford Mondeo 2.5 (2016)
https://autopapyrus.com/guides/ford/mondeo/camshaft-seal-replacement/
Compiled automatically from service literature and owner experience. Specs are for the typical configuration — check them against your exact car before you start.

Ford Mondeo 2.5 (2016): Camshaft Seal Replacement

On the 2.5 Duratec with a timing chain drive, the camshaft seals sit in the cylinder head behind the sprockets or phasers. To replace them, you need to remove the valve cover and take the load off the chain without losing valve timing. Detailed procedures and lock tools for this engine are poorly documented in public service sources, so what follows is the general principle. Check torque values and tightening sequences against the manufacturer's service manual.

Difficulty: Hard Time: 4-7 hours Steps: 12

Parts

6
№Part
01 Camshaft seal, intake (Duratec 2.5)
02 Camshaft seal, exhaust (Duratec 2.5)
03 Valve cover gasket
04 Spark plug well seal kit
05 Engine oil 5W-20 WSS-M2C948-B
06 Camshaft phaser and sprocket boltsif the chain is removed; single-use if specified

Tools

9
  • Socket and wrench set
  • torque wrench
  • camshaft timing lock tool set for Duratec 2.5 (OE or equivalent)
  • seal puller or thin screwdriver
  • seal installer (driver)
  • pulley/sprocket holding tool
  • oil-resistant sealant
  • shop fluid and rags
  • marker
There's a full repair manual for this car Every system, wiring diagrams and torque specs — not just this job. Haynes and 10 more. See manuals →

Step by step

12 steps
  1. Shut off the engine, let it cool, and disconnect the negative battery terminal. Remove the engine cover and air intake duct, plus any hoses that block access to the valve cover.
  2. Disconnect the ignition coil connectors and wiring harness, then remove the coils. Loosen the valve cover bolts in a spiral pattern from the edges toward the center, then remove the cover and the old gasket. Clean the mating surface of any leftover sealant.
  3. Rotate the crankshaft in its normal direction of rotation to TDC on cylinder 1 and install the camshaft lock tools in the timing slots. Make sure the marks line up. Do not turn the crankshaft backward while parts are removed.
  4. Use a marker to put reference marks on the chain and the sprockets (phasers) so you can check their positions later.
  5. If the design allows, lock the chain tensioner (with the stop set to the compressed position) and loosen the sprocket or phaser fasteners while holding the camshafts with a wrench on the hex flats. Do not hold a camshaft by its lobes.
  6. Remove the sprockets or phasers from the camshafts. Support the chain with wire or a clamp so it does not fall into the engine block. Do not let the chain slip off the lower sprocket.
  7. Carefully pry out the old seals with a screwdriver or puller, taking care not to damage the seal bore in the cylinder head or the camshaft journal. Wipe the seal seats and journals clean.
  8. Lubricate the lips of the new seals with engine oil and press them in evenly with the installer, without tilting, until they reach the same depth as the old seals. Do not stretch the lip or let it fold over.
  9. Reinstall the sprockets or phasers, start the fasteners by hand, then tighten them to final torque with a torque wrench. The torque for the phaser and sprocket bolts is given in the manufacturer's service manual. Tighten while holding the camshaft on the hex flats. Replace any single-use bolts.
  10. Release the tensioner stop and check chain tension. Remove the camshaft lock tools, turn the crankshaft two full turns in its normal direction of rotation, and confirm that the marks and the lock tool slots line up again. If they do not, repeat the timing setup.
  11. Apply a thin layer of sealant at the joints specified by the manufacturer (usually at the corners by the camshaft half-round plugs and at the joint of the front cover). Install the new gasket and the valve cover, and tighten the bolts in a spiral pattern from the center outward. The valve cover bolt torque is low, about 8-12 N·m (6-9 lb-ft); confirm it in the service manual.
  12. Install the coils, reconnect the connectors, and reassemble the air intake duct and engine cover. Reconnect the battery. Start the engine and check for leaks and unusual noises. If needed, scan for valve timing fault codes.

Common mistakes and warnings

  • If the timing is set incorrectly, the chain can jump and the valves can hit the pistons
  • If you have no experience with timing chain drives and do not have the required lock tools, have a repair shop do the job
  • Do not start the engine until you have verified that the marks line up after turning the crankshaft two full turns