Replace a single hydraulic lifter on the 3.5L EcoBoost V6 engine, requiring removal of the valve cover, timing components, and camshaft to access the lifter.

Warnings

Tools required

Parts

• Hydraulic valve lifter × 1 — Use OEM specification for 3.5L EcoBoost
• Valve cover gasket × 1 — Use OEM specification
• Valve cover spark plug tube seals × 6 — Use OEM specification
• Camshaft cap bolts × 10 — Replace if removed, use OEM
• VVT solenoid O-ring × 1 — Replace if disturbed
• Engine oil × 1 — Motorcraft 5W-20
• Engine coolant × 1 — Motorcraft Orange Premium

Fluids

• engine_oil — 6 qt
• coolant — 2 qt

Preparation

1. Allow engine to cool completely for at least 4 hours
2. Disconnect negative battery cable and wait 10 minutes for airbag system to discharge
3. Remove engine cover by pulling upward on front edge
4. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it stalls
5. Drain engine coolant from radiator and engine block into appropriate container
6. Document which cylinder and valve position has the failed lifter for reference
7. Position vehicle on level surface with parking brake engaged

Procedure

1. 1

   Remove valve cover from affected bank
   Disconnect ignition coils and spark plug connectors from the affected bank (driver side is bank 1, passenger side is bank 2). Remove six ignition coils. Disconnect PCV hose and any vacuum lines attached to valve cover. Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift valve cover away, breaking gasket seal if necessary.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
2. 2

   Rotate engine to TDC and lock crankshaft
   Remove the crankshaft position sensor from front of engine. Rotate crankshaft clockwise using a breaker bar on crankshaft pulley bolt until cylinder 1 is at TDC (compression stroke). Install crankshaft locking tool through CKP sensor opening. Verify crankshaft cannot rotate. Check that camshaft lobes for cylinder 1 are pointing outward (not on base circle).
   ⚠Ensure engine is at exact TDC position before locking. Incorrect positioning will result in timing errors.
   Torque spec

   Sensor Bolts12 Nm (9 lb-ft)
3. 3

   Lock camshafts in position
   Install cam holding tool (303-1248 or equivalent) across the rear of both camshafts on the affected bank. This tool fits into machined flats on the camshaft ends. Ensure both camshafts are locked and cannot rotate. Mark the position of cam phasers relative to camshafts using paint pen for reference.
   ⚠️Both camshafts must be positively locked before proceeding. Any rotation during timing chain removal will cause engine damage.
4. 4

   Remove timing components
   Remove the primary timing chain tensioner by compressing and locking it, then removing mounting bolts. Remove the VVT solenoids from the cam phasers. Mark and remove the timing chain from the affected cam phaser(s). You may need to remove only one cam phaser or both depending on which lifter is being replaced. Keep timing chain engaged on crankshaft sprocket. Support chain with wire to prevent it from falling.
   ⚠Do not allow timing chain to fall into engine. Use wire or zip ties to support chain tension.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)
5. 5

   Remove camshaft caps and camshaft
   Before removing caps, clearly mark each camshaft cap with its position number and orientation using permanent marker. Loosen camshaft cap bolts evenly in multiple passes, starting from the ends and working toward the center. Remove all caps and keep them in order. Carefully lift the camshaft from the head, noting position of cam phaser on front. Remove and set aside rocker arms from the affected cylinder only if needed for access.
   ⚠Camshaft caps are not interchangeable. Each must be returned to its exact original position or bearing damage will occur.
6. 6

   Remove and replace hydraulic lifter
   Using a magnetic lifter removal tool, carefully extract the failed lifter from its bore. Note any debris or damage in the bore. Clean the lifter bore thoroughly with lint-free cloth and brake cleaner. Install the new lifter into the bore, ensuring it moves freely. Prime the new lifter by working it up and down several times to ensure hydraulic plunger operates correctly. Apply clean engine oil to lifter body before installation.
   ℹ️New lifter should compress with moderate finger pressure when primed. If it feels solid or excessively loose, it may be defective.
7. 7

   Reinstall camshaft and rocker arms
   Apply clean engine oil to all camshaft journals and lobes. Place rocker arms back in their original positions if removed. Carefully position camshaft back into head, aligning with cam phaser timing marks made earlier. Install camshaft caps in their exact original positions with arrows pointing toward front of engine. Tighten cap bolts evenly in multiple passes from center outward, following the reverse of removal sequence.
   ⚠Tighten camshaft cap bolts gradually in 3-4 passes to avoid binding or damaging the camshaft.
   Torque spec

   Rocker Arm Shaft Bolts25 Nm (18 lb-ft)
8. 8

   Verify camshaft end play and position
   With caps torqued, verify camshaft rotates smoothly by hand (with cam holding tool removed temporarily). Check that timing marks on camshaft align with previous marks. Reinstall cam holding tool to lock camshafts. Verify crankshaft is still locked in TDC position.
   ⚠If camshaft does not rotate smoothly or binds, remove and inspect for incorrectly positioned caps or debris.
9. 9

   Reinstall timing components
   Reinstall cam phaser(s) onto camshaft with timing marks aligned as marked during removal. Engage timing chain onto cam phaser sprocket, verifying proper tooth engagement. Install and torque cam phaser bolts. Reinstall VVT solenoids with new O-rings if needed. Remove chain support wire. Install timing chain tensioner and release locking mechanism to apply tension.
   ⚠️Verify timing chain is properly seated on all sprockets with alignment marks correct before releasing tensioner.
   Torque spec

   Mounting Bolts55 Nm (40 lb-ft)
10. 10

    Verify timing and remove locking tools
    Double-check all timing marks are correctly aligned with crankshaft at TDC. Remove cam holding tool and crankshaft locking tool. Manually rotate engine two complete revolutions clockwise. Reinstall locking tools to verify timing is still correct at TDC. If tools do not fit, timing is incorrect and must be repeated.
    ⚠️Do not proceed if engine timing cannot be verified. Starting engine with incorrect timing will cause catastrophic damage.
11. 11

    Reinstall valve cover
    Clean valve cover and cylinder head mating surfaces thoroughly. Install new valve cover gasket and new spark plug tube seals into valve cover. Position valve cover onto cylinder head, ensuring gasket seats properly. Install valve cover bolts and tighten in proper sequence (inside to outside, alternating pattern) to specified torque. Reconnect PCV hose and vacuum lines.
    ℹ️Use proper tightening sequence to avoid distorting valve cover and causing oil leaks.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)
12. 12

    Reinstall accessories and refill fluids
    Reinstall crankshaft position sensor with new O-ring if needed. Torque to specification. Reinstall ignition coils and reconnect all electrical connectors. Refill cooling system with Motorcraft Orange coolant, bleeding air from system. Replace engine oil and filter with Motorcraft 5W-20 synthetic blend (6 quarts total). Reconnect negative battery cable.
    Torque spec

    Sensor Bolts12 Nm (9 lb-ft)

Reassembly

1. Verify all electrical connectors are properly seated and locked
2. Ensure all timing locking tools have been removed before attempting to start engine
3. Check that no tools or rags are left in engine compartment
4. Verify oil drain plug and oil filter are properly tightened

Verification

• Before first start: Remove spark plugs and crank engine briefly to verify no unusual resistance (indicates correct valve timing)
• Reinstall spark plugs and start engine - should start normally without hesitation
• Listen for abnormal valve train noise - properly replaced lifter should be silent after 30-60 seconds of running
• Check for oil leaks around valve cover gasket while engine runs
• Verify no coolant leaks from areas disturbed during repair
• Allow engine to reach operating temperature and verify cooling system is properly bled (no air pockets)
• Perform test drive and verify smooth operation with no misfires or unusual noises
• Scan for diagnostic trouble codes - there should be none related to camshaft timing or VVT operation
• Recheck valve cover bolt torque after engine has cooled from first heat cycle

More procedures for this vehicle