This procedure replaces the variable valve timing (VVT) actuators (cam phasers) on the 3.5L EcoBoost V6 engine, requiring timing chain access and proper cam timing alignment.

Warnings

Tools required

Parts

• Variable valve timing actuator (cam phaser) - Bank 1 intake × 1 — Ford DG1Z-6A257-A or equivalent
• Variable valve timing actuator (cam phaser) - Bank 1 exhaust × 1 — Ford DG1Z-6A257-B or equivalent
• Variable valve timing actuator (cam phaser) - Bank 2 intake × 1 — Ford DG1Z-6A257-A or equivalent
• Variable valve timing actuator (cam phaser) - Bank 2 exhaust × 1 — Ford DG1Z-6A257-B or equivalent
• Valve cover gasket set (both banks) × 1 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Crankshaft front seal × 1 — Use OEM specification
• VVT solenoid O-rings (if disturbed) × 4 — Use OEM specification
• Engine oil and filter × 1 — Motorcraft FL500S filter or equivalent

Fluids

• Motorcraft 0W-20 Full Synthetic — 6 qt

Preparation

1. Ensure engine is completely cold and vehicle is on level ground
2. Disconnect negative battery cable and wait 10 minutes for system power-down
3. Raise and support vehicle securely on jack stands
4. Drain engine oil completely and remove oil filter
5. Remove engine cover (plastic cover on top of engine)
6. Remove air intake tube and air filter housing for access
7. Disconnect all necessary electrical connectors from ignition coils and sensors on valve covers
8. Label and photograph all vacuum lines and electrical connections before removal
9. Rotate engine to TDC on cylinder #1 using crankshaft pulley bolt (harmonic balancer timing mark aligned with pointer)

Procedure

1. 1

   Remove valve covers from both banks
   Remove ignition coils from all cylinders. Unbolt and remove valve covers from both Bank 1 (passenger side) and Bank 2 (driver side). Note the tightening sequence for reassembly. Clean all old gasket material from valve cover mating surfaces using plastic scraper.
   Torque spec

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

   Remove accessory drive belt and crankshaft pulley
   Release accessory belt tensioner and remove serpentine belt. Using harmonic balancer holding tool or impact wrench, remove crankshaft pulley bolt. Remove crankshaft pulley/harmonic balancer from front of engine. Mark pulley orientation if not keyed.
   ⚠Crankshaft pulley bolt is very tight (133 lb-ft minimum). May require impact wrench for removal.
   Torque spec

   Crankshaft Pulley Bolt180 Nm (133 lb-ft)
3. 3

   Remove timing cover
   Remove all timing cover bolts, noting different lengths and locations. Carefully remove timing cover from engine block. Pay attention to 8mm bolts which require specific torque sequence. Clean all gasket material from timing cover and block mating surfaces. Inspect and replace crankshaft front seal.
   Torque spec

   Cover Bolts19 Nm (14 lb-ft)
4. 4

   Verify and mark timing chain alignment
   With engine at TDC cylinder #1, verify all timing marks on camshaft sprockets align with marks on cylinder head or timing chain. Take detailed photos of timing chain position, colored links alignment with sprocket marks, and crankshaft sprocket alignment. Mark chain and sprockets with paint pen as backup reference.
   ⚠️Do NOT proceed if timing marks are not properly aligned. Incorrect timing will destroy engine.
5. 5

   Remove timing chain tensioners
   Locate timing chain tensioners on both banks. Install retaining pins or clips to compress tensioner before removal (some tensioners have manual release). Remove tensioner mounting bolts and carefully extract tensioners. Keep tensioners compressed with pins installed.
   ⚠Tensioners are spring-loaded. Ensure they are properly locked/pinned before and during removal.
   Torque spec

   Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
6. 6

   Remove VVT solenoids
   Disconnect electrical connectors from all four VVT solenoids (intake and exhaust on both banks). Remove solenoid mounting bolts and extract solenoids from cylinder heads. Inspect O-rings and replace if damaged.
   Torque spec

   VVT Solenoid Bolt10 Nm (7 lb-ft)
7. 7

   Remove camshaft sprocket bolts and cam phasers
   Starting with Bank 1, hold camshaft stationary using wrench on camshaft hex (located behind sprocket). Remove cam phaser bolt while preventing camshaft rotation. Carefully remove cam phaser/sprocket assembly with timing chain still engaged. Repeat for all four camshafts (intake/exhaust on both banks). Keep timing chain supported to prevent dropping into engine.
   ⚠Support timing chain with wire or zip ties to prevent it from falling into crankcase when removing sprockets.
   Torque spec

   Cam Phaser Bolt65 Nm (48 lb-ft)
8. 8

   Install new cam phasers
   Clean camshaft nose and phaser mounting surface thoroughly. Apply medium-strength threadlocker to new cam phaser bolts. Install new cam phasers onto camshafts in reverse order of removal, ensuring timing chain remains properly positioned on colored links and reference marks. Hold camshaft with wrench on hex section while hand-threading bolts.
   ⚠️Verify timing chain alignment marks match original photos and marks before tightening cam phaser bolts.
   Torque spec

   Cam Phaser Bolt65 Nm (48 lb-ft)
9. 9

   Torque cam phaser bolts
   Hold each camshaft stationary with wrench on hex section. Torque cam phaser bolts to specification in the following order: Bank 1 exhaust, Bank 1 intake, Bank 2 exhaust, Bank 2 intake. Double-check timing alignment after each bolt is torqued.
   Torque spec

   Cam Phaser Bolt65 Nm (48 lb-ft)
10. 10

    Reinstall timing chain tensioners
    With tensioners still compressed and pinned, install tensioners into their mounting locations. Torque tensioner bolts to specification. Remove retaining pins/clips to allow tensioners to apply proper chain tension. Verify chain has appropriate tension and timing marks remain aligned.
    Torque spec

    Timing Chain Tensioner Bolt25 Nm (18 lb-ft)
11. 11

    Manually rotate engine and verify timing
    Using breaker bar on crankshaft pulley bolt, manually rotate engine two complete revolutions clockwise (as viewed from front). Verify engine rotates smoothly without binding. Check that all timing marks realign at TDC cylinder #1. If marks do not align, remove cam phasers and repeat timing procedure.
    ⚠️Do NOT attempt to start engine if timing marks do not align perfectly after two rotations.
12. 12

    Reinstall VVT solenoids
    Install new O-rings on VVT solenoids if replacing. Lubricate O-rings with clean engine oil. Install solenoids into cylinder heads and torque bolts to specification. Reconnect electrical connectors.
    Torque spec

    VVT Solenoid Bolt10 Nm (7 lb-ft)
13. 13

    Reinstall timing cover
    Install new timing cover gasket and crankshaft front seal. Position timing cover onto engine block, ensuring proper alignment with dowel pins. Install all timing cover bolts finger-tight, then torque in proper sequence starting from center and working outward. Tighten 8mm bolts to their specific torque value.
    Torque spec

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

    Reinstall crankshaft pulley and accessory belt
    Install crankshaft pulley/harmonic balancer onto crankshaft, aligning keyway or orientation marks. Install crankshaft pulley bolt and torque to specification (verify if torque-to-yield and replace if required). Reinstall accessory drive belt over all pulleys and release tensioner.
    Torque spec

    Crankshaft Pulley Bolt180 Nm (133 lb-ft)
15. 15

    Reinstall valve covers
    Install new valve cover gaskets onto valve covers or cylinder heads per manufacturer design. Position valve covers and install bolts finger-tight. Torque valve cover bolts in proper sequence (typically center-out pattern) to specification. Reinstall ignition coils and reconnect all electrical connectors.
    Torque spec

    Cover Bolts19 Nm (14 lb-ft)

Reassembly

1. Reinstall air intake tube and air filter housing
2. Install new engine oil filter and refill engine with 6 quarts Motorcraft 0W-20 synthetic oil
3. Reconnect negative battery cable
4. Lower vehicle from jack stands
5. Reinstall engine cover

Verification

• Start engine and verify it runs smoothly without unusual noises, knocking, or rattling from timing chain area
• Check for oil leaks around valve covers and timing cover while engine is running
• Allow engine to reach operating temperature and verify no warning lights appear on dashboard
• Using scan tool, verify VVT system operation and check for any fault codes related to cam timing (P0011, P0021, P0012, P0022)
• Test drive vehicle and verify smooth acceleration, proper power delivery, and no hesitation or rough running
• Recheck oil level after test drive and top off if necessary
• Monitor for oil leaks and unusual noises over next 100 miles of operation

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