Camshaft R&R

This procedure covers the removal and replacement of the intake and exhaust camshafts on the 3.5L EcoBoost V6 engine, including timing chain system disassembly and reassembly with proper timing alignment.

Warnings

Tools required

Parts

• Camshaft (specify intake or exhaust, left or right bank) × 1 — Use OEM specification
• Timing chain kit (chains, guides, tensioners) × 1 — Use OEM specification
• Valve cover gaskets (both banks) × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Camshaft phaser seals × 4 — Use OEM specification
• VVT solenoid O-rings × 4 — Use OEM specification
• Oil drain plug crush washer × 1 — Use OEM specification
• Engine oil and filter × 1 — Motorcraft FL-910S or equivalent
• Coolant × 1 — Motorcraft Orange Coolant VC-3DIL-B
• RTV silicone sealant (Motorcraft TA-31) × 1 — Use OEM specification

Fluids

• Motorcraft 5W-20 Synthetic Blend — 6 qt
• Motorcraft Orange Coolant — 13 qt

Preparation

1. Ensure engine is completely cold and vehicle is on a level surface
2. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
3. Remove engine cover and air intake system
4. Drain engine oil completely and remove oil filter
5. Drain cooling system by removing lower radiator hose
6. Remove radiator, cooling fans, and upper radiator support
7. Remove serpentine belt and tensioner
8. Support engine weight using engine support bar or hoist attached to lifting eyes
9. Remove right-side engine mount to allow engine rotation for access
10. Label all electrical connectors and vacuum lines before disconnection
11. Take detailed photos of timing chain routing and all timing marks

Procedure

1. 1

   Remove valve covers and accessory components
   Disconnect ignition coils, fuel injector harness, and VVT solenoid connectors on the affected bank. Remove valve cover bolts in reverse sequence (outside to inside) and carefully lift off valve cover. Remove spark plugs to allow easier engine rotation. Disconnect crankshaft position sensor and camshaft position sensors on both banks.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)

   Camshaft Position Sensor10 Nm (7 lb-ft)

   Crankshaft Position Sensor10 Nm (7 lb-ft)
2. 2

   Remove crankshaft pulley and timing cover
   Using a breaker bar or impact wrench, remove the crankshaft pulley bolt (typically requires holding flywheel or using impact). Remove harmonic balancer. Remove all timing cover bolts, noting different lengths and sizes (8mm and 10mm bolts). Carefully pry timing cover away from engine block, being careful not to damage sealing surfaces. Clean all RTV residue from mating surfaces.
   ⚠The crankshaft pulley bolt is extremely tight (180 Nm). Use impact wrench or prevent crankshaft rotation by placing transmission in gear with parking brake applied.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)

   Harmonic Balancer Bolt180 Nm (133 lb-ft)

   Cover Bolts19 Nm (14 lb-ft)
3. 3

   Rotate engine to TDC and install timing pins
   Rotate crankshaft clockwise using a socket on the crankshaft bolt until cylinder #1 is at TDC on compression stroke. Both intake and exhaust valves should be closed. Install crankshaft timing pin through block into crankshaft. Install camshaft timing pins through rear of cylinder heads into each of the four camshafts (both intake and exhaust on both banks). All pins must seat fully without forcing. If pins don't align, rotate crankshaft exactly one full revolution and retry.
   ⚠️Never force timing pins. If they don't seat easily, timing is not correct. Forcing pins will damage engine components.
4. 4

   Remove timing chain tensioners and guides
   Remove VVT solenoids from cylinder heads. Remove timing chain tensioners by first compressing them and inserting retaining pins, then remove mounting bolts. Remove timing chain guides by removing their mounting bolts. Note orientation and position of all guides for reassembly. Inspect all components for wear; replace timing chain kit if guides show grooves or tensioners don't hold compression.
   Torque spec

   VVT Solenoid Bolt10 Nm (7 lb-ft)

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)

   Timing Chain Guide Bolts12 Nm (9 lb-ft)
5. 5

   Remove cam phasers and timing chains
   On the affected bank, hold each camshaft stationary using the hex feature on the camshaft (behind the phaser). Remove cam phaser bolts. Carefully remove cam phasers along with timing chains. Mark which phaser goes to which camshaft (intake vs exhaust). Remove timing chain idler sprocket if needed for access.
   ⚠Cam phasers are side-specific and intake/exhaust specific. Mark them clearly during removal and do not interchange.
   Torque spec

   Cam Phaser Bolt65 Nm (48 lb-ft)

   Timing Chain Idler Sprocket25 Nm (18 lb-ft)
6. 6

   Remove camshaft bearing caps
   Note the numbering and directional arrows on each camshaft bearing cap. They are numbered 1-6 or 1-7 from front to back and have arrows pointing toward the front of engine. Loosen camshaft bearing cap bolts in reverse sequence (outside to inside, 3 passes, evenly) to prevent warping. Remove bearing caps and store them in order. Do not mix caps between positions or camshafts.
   ⚠️Camshaft bearing caps are NOT interchangeable. Each cap is machined with its corresponding journal. Mixing caps will cause immediate camshaft seizure and engine destruction.
   Torque spec

   Camshaft Bearing Cap Bolts14 Nm (10 lb-ft)
7. 7

   Remove camshafts and inspect components
   Carefully lift camshafts straight up out of cylinder head. Inspect camshaft lobes for scoring, pitting, or abnormal wear patterns. Measure camshaft lobe height if replacement criteria is uncertain. Inspect camshaft journals and bearing surfaces in cylinder head for damage. Check rocker arms for wear on contact surfaces. If rocker arms show excessive wear, they should be replaced. Clean all oil passages in cylinder head.
   ℹ️If replacing only one camshaft due to lobe wear, inspect the mating rocker arms carefully. Worn rockers will quickly damage a new camshaft.
8. 8

   Install new or refurbished camshafts
   Lubricate all camshaft journals and lobes with clean engine oil or assembly lube. Carefully lower camshafts into position in cylinder head, ensuring they are in the correct positions (intake vs exhaust). Verify camshaft timing pin holes are accessible and properly oriented. Apply clean engine oil to all bearing cap contact surfaces.
   ⚠Ensure camshafts are installed in correct positions. Intake and exhaust camshafts have different lobe profiles and are not interchangeable.
9. 9

   Install camshaft bearing caps
   Install camshaft bearing caps in their original positions, following the numbering and directional arrows. Ensure arrows point toward front of engine. Install bearing cap bolts finger tight. Tighten bearing cap bolts in sequence from center outward in 3 passes: first pass to 5 Nm, second pass to 10 Nm, final pass to 14 Nm. Ensure camshafts rotate freely after tightening. Install camshaft timing pins to verify alignment.
   ⚠Tightening sequence is critical. Always tighten from center caps outward in multiple passes to prevent camshaft journal damage.
   Torque spec

   Camshaft Cap Bolts14 Nm (10 lb-ft)
10. 10

    Install cam phasers and timing chains
    Verify crankshaft and all four camshaft timing pins are still properly installed. Route timing chains over crankshaft sprocket and up to cam phasers, ensuring correct routing around guides. Install cam phasers onto camshafts, aligning timing marks. Apply medium-strength threadlocker to cam phaser bolts. Hold camshaft using hex feature and tighten cam phaser bolts to specification. Install timing chain idler sprocket if removed.
    ⚠️Verify all timing marks align perfectly before tightening cam phaser bolts. Double-check that timing pins are fully seated in all camshafts and crankshaft.
    Torque spec

    Cam Phaser Bolt65 Nm (48 lb-ft)

    Timing Chain Idler Sprocket25 Nm (18 lb-ft)
11. 11

    Install timing chain guides and tensioners
    Install timing chain guides in their original positions and tighten guide bolts to specification. Compress timing chain tensioners fully and insert retaining pins or clips. Install tensioners and tighten mounting bolts to specification. Remove tensioner retaining pins to allow tensioners to apply pressure to timing chains. Verify chains have proper tension and no slack.
    Torque spec

    Timing Chain Guide Bolts12 Nm (9 lb-ft)

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
12. 12

    Verify timing and remove timing pins
    With all timing components installed and tensioned, carefully attempt to remove all timing pins (crankshaft and all four camshafts). All pins should remove without force. If any pin binds, timing is incorrect and must be corrected. Rotate crankshaft by hand two complete revolutions clockwise. Reinstall all timing pins; they should all seat easily again. If not, timing is incorrect. Repeat verification until confirmed correct.
    ⚠️This is the most critical verification step. If timing is incorrect and engine is started, catastrophic valve-to-piston contact will occur. Take your time and verify multiple times.
13. 13

    Install timing cover and crankshaft pulley
    Clean all old RTV from timing cover and engine block mating surfaces. Apply 3mm bead of RTV sealant to timing cover in specified locations per service manual. Install new timing cover gasket. Install timing cover and hand-tighten all bolts. Tighten 8mm bolts to specification, then tighten 10mm bolts to specification, following tightening sequence. Allow RTV to cure for 30 minutes. Install harmonic balancer and new crankshaft pulley bolt. Tighten crankshaft pulley bolt to specification using impact wrench or while preventing crankshaft rotation.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

    Harmonic Balancer Bolt180 Nm (133 lb-ft)

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
14. 14

    Reinstall sensors and valve covers
    Install VVT solenoids with new O-rings and tighten to specification. Install crankshaft position sensor and camshaft position sensors and tighten to specification. Clean valve cover mating surfaces and install new valve cover gaskets. Apply small dab of RTV at front corners where timing cover meets cylinder head. Install valve covers and tighten bolts in sequence from center outward to specification. Install spark plugs with anti-seize on threads.
    Torque spec

    VVT Solenoid Bolt10 Nm (7 lb-ft)

    Crankshaft Position Sensor10 Nm (7 lb-ft)

    Camshaft Position Sensor10 Nm (7 lb-ft)

    Cover Bolts19 Nm (14 lb-ft)
15. 15

    Complete assembly and fill fluids
    Reinstall engine mount and remove engine support. Reinstall serpentine belt and tensioner. Reinstall radiator, cooling fans, and all cooling system components. Reconnect all electrical connectors and vacuum lines using photos taken during disassembly. Install new oil filter and fill engine with 6 quarts of 5W-20 oil. Fill cooling system with proper 50/50 mix of Motorcraft Orange Coolant. Reconnect battery. Install engine cover and air intake system.
    Torque spec

    Oil Drain Plug35 Nm (26 lb-ft)

Reassembly

1. Double-check that all electrical connectors are properly seated and locked
2. Verify all timing cover bolts are tightened and no tools are left in engine bay
3. Ensure cooling system is properly bled of air by running engine with heater on high until thermostat opens
4. Check for oil and coolant leaks around all gasket surfaces after initial start

Verification

• Before starting engine, manually rotate crankshaft two full revolutions by hand using socket on crankshaft bolt. It should rotate smoothly with no hard stops or resistance
• Start engine and listen for abnormal noises. Engine should start immediately and run smoothly without valve train noise or timing chain rattle
• Allow engine to reach operating temperature and verify proper oil pressure on instrument cluster
• Check for oil leaks around valve covers and timing cover while engine is running
• Check for coolant leaks around all cooling system connections
• Use scan tool to verify proper camshaft position sensor signals and VVT operation
• Test drive vehicle and verify proper acceleration and no check engine lights
• After test drive, recheck oil and coolant levels and top off as needed
• Monitor engine for first 500 miles for any unusual noises or performance issues

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