Complete replacement of the timing chain kit on the 3.5L EcoBoost V6, including chains, tensioners, guides, and cam phasers. This is a complex internal engine procedure requiring precise timing alignment.

Warnings

Tools required

Parts

• Complete timing chain kit (chains, guides, tensioners, sprockets) × 1 — Use OEM Ford specification
• Cam phaser assemblies (both banks) × 2 — Use OEM Ford specification
• Timing cover gasket × 1 — Use OEM Ford specification
• Valve cover gaskets (both banks) × 2 — Use OEM Ford specification
• Crankshaft seal (front) × 1 — Use OEM Ford specification
• Oil drain plug crush washer × 1 — Use OEM Ford specification
• RTV silicone gasket maker × 1 — Motorcraft TA-31
• Medium-strength threadlocker × 1 — Loctite 242 or equivalent

Fluids

• Motorcraft 0W-20 Full Synthetic — 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 beauty panels
4. Drain engine oil completely and remove oil filter
5. Drain cooling system by opening petcock and removing lower radiator hose
6. Remove front bumper cover for access to radiator and cooling components
7. Remove radiator, cooling fans, and intercooler assembly
8. Remove accessory drive belt and tensioner
9. Remove power steering pump and A/C compressor (do not disconnect lines, secure aside)
10. Support engine with fixture or hoist from above
11. Remove right-side engine mount to allow engine lowering/tilting for access
12. Take multiple photos of all timing mark positions before disassembly

Procedure

1. 1

   Remove crankshaft pulley and harmonic balancer
   Use a crankshaft holding tool to prevent rotation. Remove the crankshaft pulley bolt with a high-output impact wrench (clockwise rotation to loosen). Once bolt is removed, use a harmonic balancer puller to carefully remove the balancer from the crankshaft snout. Do not pry or hammer on the balancer.
   ⚠The crankshaft bolt is extremely tight (180 Nm). Do not attempt removal with hand tools as this may damage components.
   Torque spec

   Crankshaft pulley bolt (stretch, replace)90 Nm (66 lb-ft)
2. 2

   Remove valve covers from both banks
   Disconnect ignition coils and fuel injector harnesses. Remove ignition coils. Disconnect any breather hoses and PCV connections from valve covers. Remove valve cover bolts in reverse of tightening sequence (outside to inside pattern). Carefully lift valve covers and remove old gaskets. Clean all gasket surfaces thoroughly.
3. 3

   Remove timing cover
   Remove all timing cover bolts, noting their locations as different sizes are used (6mm, 8mm, and 10mm). Carefully separate the timing cover from the engine block. You may need to gently tap with a plastic mallet. Remove the old gasket and front crankshaft seal. Thoroughly clean all RTV residue and gasket material from both the cover and block mating surfaces using a plastic scraper and brake cleaner.
   ⚠Do not use metal scrapers on aluminum surfaces as this will cause damage and leaks. Use only plastic scrapers.
4. 4

   Verify and document timing alignment
   Rotate the crankshaft to TDC (Top Dead Center) on cylinder #1. Verify that all timing marks on the crankshaft sprocket, camshaft sprockets, and cam phasers align with their respective marks on the engine block and cylinder heads. Take detailed photos. The crankshaft keyway should point upward at 12 o'clock. Both cam phasers should have their timing marks aligned with the marks on the cam sprockets.
   ⚠️This is your last chance to verify correct factory timing before disassembly. Improper reassembly will destroy the engine.
5. 5

   Remove timing chain tensioners and guides
   Remove the timing chain tensioner bolts from both primary and secondary tensioners. Carefully remove tensioners - note the installed position. Remove the timing chain guide bolts and remove all guides. Inspect guides for wear grooves - if present, replacement is mandatory (should be included in kit).
   Torque spec

   Chain guide bolts12 Nm (9 lb-ft)
6. 6

   Remove cam phasers and camshaft sprockets
   Hold each camshaft stationary using a wrench on the camshaft hex (between lobes 3 and 4). Remove the cam phaser bolts from all four cam phasers. Remove the phasers and set aside. Remove the camshaft sprocket bolts while holding the camshaft hex. Remove all four camshaft sprockets.
   ⚠Do not allow camshafts to rotate once timing chains are removed. Mark cam positions relative to cylinder head if necessary.
7. 7

   Remove timing chains and crankshaft sprockets
   Remove both primary timing chains from the crankshaft sprockets and guides. Remove the timing chain idler sprocket bolt and remove the idler. Remove both crankshaft sprockets. Inspect the crankshaft snout for wear or damage. Clean all components with brake cleaner.
8. 8

   Install new crankshaft sprockets and idler
   Install new crankshaft sprockets onto the crankshaft with timing marks facing outward. Ensure they are fully seated. Install the new timing chain idler sprocket and torque the bolt to specification. Verify the crankshaft is still at TDC with keyway at 12 o'clock position.
9. 9

   Install new timing chains
   Route the new primary timing chains around the crankshaft sprockets, idler sprocket, and up to where the camshaft sprockets will be installed. Ensure the colored links on the new chains (typically copper or gold) align with the timing marks on the crankshaft sprockets. Do not fully seat chains yet.
   ℹ️New timing chains often have colored links to indicate timing mark positions. Verify chain orientation per kit instructions.
10. 10

    Install camshaft sprockets with timing alignment
    Hold each camshaft with a wrench on the hex section. Install camshaft sprockets onto the camshafts, aligning the timing marks on the sprockets with the colored links on the timing chains. Ensure camshafts are in their original TDC position. Install and torque camshaft sprocket bolts to specification while holding the camshaft stationary.
    ⚠️Timing mark alignment is critical. Colored chain links must align with sprocket marks and camshafts must be in TDC position for cylinder #1.
11. 11

    Install timing chain guides
    Install all new timing chain guides in their original positions. Ensure guides are properly seated in their locating features. Install guide bolts and torque to specification. Verify chains run smoothly through guides without binding.
    Torque spec

    Chain guide bolts12 Nm (9 lb-ft)
12. 12

    Install and compress timing chain tensioners
    Compress each new timing chain tensioner using a tensioner compression tool or by carefully clamping in a vise. Insert the tensioner pin or clip to hold it in the compressed position. Install tensioners into their mounting positions and torque bolts to specification. Do not remove pins yet.
    ⚠Tensioners must be installed compressed with pins in place. Premature pin removal will tension chains before verification.
13. 13

    Install cam phasers with threadlocker
    Apply medium-strength threadlocker to the cam phaser bolt threads. Align each cam phaser onto its respective camshaft sprocket, ensuring the phaser timing marks align with the sprocket timing marks. Hold the camshaft stationary with a wrench on the hex. Install and torque cam phaser bolts to specification.
    ⚠Threadlocker is mandatory on cam phaser bolts. Failure to use threadlocker can result in bolt loosening and phaser failure.
14. 14

    Verify all timing marks and release tensioners
    Triple-check that all timing marks are properly aligned: crankshaft at TDC, all camshaft sprockets aligned with colored chain links, and cam phasers aligned with sprockets. Rotate the crankshaft by hand two complete revolutions clockwise (viewed from front). Verify all timing marks realign at TDC. If correct, carefully remove the tensioner pins to apply tension. Rotate crankshaft two more revolutions and recheck all marks.
    ⚠️If timing marks do not realign after rotation, DO NOT proceed. Disassemble and correct the timing before continuing.
15. 15

    Install new timing cover with gasket and seal
    Install the new front crankshaft seal into the timing cover using a seal driver. Apply a thin bead of RTV silicone to the engine block surface at the oil pan junction points (per Ford service manual). Install the new timing cover gasket. Carefully position the timing cover onto the engine block, ensuring the crankshaft seal aligns with the crankshaft snout. Install all timing cover bolts finger-tight, then torque in sequence: 6mm bolts, then 8mm bolts, then 10mm bolts.
    ℹ️Allow RTV to set for 30 minutes before adding oil. Check Ford service manual for exact RTV application points.
16. 16

    Install harmonic balancer and crankshaft pulley
    Clean the crankshaft snout and apply a thin film of clean engine oil. Install the harmonic balancer onto the crankshaft, ensuring it seats fully against the timing cover. Install the crankshaft pulley bolt and torque to specification using an impact wrench. If the bolt is TTY (torque-to-yield), follow the additional angle specification from the service manual.
    ⚠Verify if crankshaft bolt is TTY. TTY bolts must not be reused and require angle tightening after initial torque.
    Torque spec

    Crankshaft pulley bolt (stretch, replace)90 Nm (66 lb-ft)
17. 17

    Install valve covers with new gaskets
    Install new valve cover gaskets onto both valve covers. Ensure gaskets are properly seated in their grooves. Position valve covers onto cylinder heads. Install valve cover bolts and torque in sequence (typically center to outside pattern) to specification. Do not overtighten as this will damage the gasket.

Reassembly

1. Reinstall ignition coils and reconnect all electrical connectors
2. Reinstall right-side engine mount and remove engine support fixture
3. Reinstall power steering pump and A/C compressor with mounting bolts
4. Reinstall accessory drive belt tensioner and belt
5. Reinstall intercooler assembly, radiator, and cooling fans
6. Reinstall front bumper cover
7. Install new oil filter and install oil drain plug with new crush washer, torque to specification
8. Refill engine oil with 6 quarts of Motorcraft 0W-20 synthetic
9. Refill cooling system with 13 quarts of Motorcraft Orange coolant and bleed air
10. Reinstall engine covers and beauty panels
11. Reconnect battery negative cable

Verification

• With ignition OFF, rotate the engine by hand at least four complete revolutions to verify no binding or interference
• Verify oil level on dipstick is at proper level
• Start the engine and listen for any abnormal noises - timing chain noise or rattles indicate incorrect installation
• Check for oil leaks around timing cover, valve covers, and oil pan within first 5 minutes of operation
• Check for coolant leaks around all cooling system connections
• Allow engine to reach operating temperature and verify proper operation of variable cam timing (smooth idle, no codes)
• Use a scan tool to verify no timing-related diagnostic trouble codes are present
• Test drive vehicle under light load and verify smooth acceleration with no misfires or performance issues
• Recheck oil and coolant levels after test drive and top off if necessary
• Recheck all fastener torques after first 100 miles of operation

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