Section 1957 (Engine Mechanical - 3.5L): Removal: Camshaft: Material

WARNING: This page is about a different car, the 2010 Lincoln MKX and 2010 Ford Edge. However, it is still accessible from the selected car via links, so may be relevant.

MATERIAL SPECIFICATION

Item	Specification
Motorcraft® Metal Surface Prep ZC-31-A	-
Silicone Gasket Remover ZC-30	-

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: Early build engines have 11 fastener valve covers, late build engines have 9 fastener valve covers. Do not attempt to install bolts in the 2 empty late build valve cover holes or damage to the valve cover will occur.

NOTE: On early build engines, the timing chain rides on the inner side of the RH timing chain guide. Late build engines are equipped with a different design RH timing chain guide that requires the timing chain to ride on the outer side of the RH timing chain guide. For service, all replacement RH timing chain guides will be the late build design.

All vehicles

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
Recover the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
Remove the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
Remove the LH halfshaft and intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
Disconnect the power steering cooler hose and drain the power steering fluid into a suitable drain pan.

Fig 1: Locating Power Steering Cooler Hose
Courtesy of FORD MOTOR CO.
Remove the degas bottle. For additional information, refer to ENGINE COOLING .
Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
Remove the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Disconnect the battery harness electrical connector.

Fig 2: Locating Battery Harness Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the nut and disconnect the power feed from the battery terminal.

Fig 3: Locating Battery Terminal Nut
Courtesy of FORD MOTOR CO.
Remove the bolt and the ground wire.
- Detach the 2 wiring harness retainers from the cowl.
  
  Fig 4: Locating Wiring Harness Retainers
  Courtesy of FORD MOTOR CO.
Disconnect the vacuum hose from the upper intake manifold.

Fig 5: Locating Vacuum Hose
Courtesy of FORD MOTOR CO.
Disconnect the Evaporative Emission (EVAP) tube quick connect coupling from the purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .

Fig 6: Locating Upper Evaporative Emission Tube
Courtesy of FORD MOTOR CO.
Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.

Fig 7: Locating Upper And Lower Radiator Hose
Courtesy of FORD MOTOR CO.
Detach the wiring harness retainer from the transaxle control cable bracket.

Fig 8: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Disconnect the transaxle control cable from the control lever.
- Detach the control cable from the bracket.
  
  Fig 9: Locating Transaxle Control Cable
  Courtesy of FORD MOTOR CO.
Disconnect the transaxle control electrical connector.

Fig 10: Locating Transaxle Control Electrical Connector
Courtesy of FORD MOTOR CO.
If equipped, detach the engine block heater harness retainers from the radiator support and the A/C suction tube.

Fig 11: Locating Engine Block Heater Harness And A/C Suction Tube
Courtesy of FORD MOTOR CO.
Remove the nut and disconnect the A/C pressure tube fitting.
- Discard the O-ring seal.
  
  Fig 12: Locating A/C Pressure Tube Fitting And Nut
  Courtesy of FORD MOTOR CO.
Remove the safety clip from the A/C fitting.
- Disconnect the A/C suction tube fitting.
  
  Fig 13: Locating A/C Suction Tube Safety Clip
  Courtesy of FORD MOTOR CO.
Disconnect the hose from the power steering reservoir.

Fig 14: Locating Hose
Courtesy of FORD MOTOR CO.
Disconnect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .

Fig 15: Locating Fuel Supply Tube
Courtesy of FORD MOTOR CO.
Disconnect the fuel hose routing clip from the transaxle stud and position the fuel hose aside.

Fig 16: Locating Fuel Hose Routing Clip
Courtesy of FORD MOTOR CO.
Disconnect the 2 engine wiring harness electrical connectors.
- Detach the electrical connector from the LH valve cover.
  
  Fig 17: Locating Engine Wiring Harness Electrical Connectors
  Courtesy of FORD MOTOR CO.
Remove the oil level indicator.

Fig 18: Locating Oil Level Indicator
Courtesy of FORD MOTOR CO.
Detach the wiring harness retainer from the RH valve cover stud bolt.

Fig 19: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Remove the bolt and the ground wire from the engine front cover.

Fig 20: Locating Ground Wire Bolt
Courtesy of FORD MOTOR CO.
Remove the nut, the ground wire and the radio interference capacitor wire from the engine front cover stud.

Fig 21: Locating Ground Wire Nut
Courtesy of FORD MOTOR CO.
Loosen the exhaust flexible pipe clamp and disconnect the 2 exhaust hangers.

Fig 22: Locating Exhaust Flexible Pipe Clamp
Courtesy of FORD MOTOR CO.
Remove the 4 nuts and the exhaust flexible pipe and Y-pipe as an assembly.
- Discard the nuts and the gasket.
  
  Fig 23: Locating Exhaust Flexible Pipe Nuts
  Courtesy of FORD MOTOR CO.
Remove the 3 pin-type retainers, the 7 screws and the radiator splash shield.

Fig 24: Locating Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Remove the LH inner splash shield. For additional information, refer to FRONT END BODY PANELS .
Remove the 2 secondary latches from the transmission fluid cooler tubes.

Fig 25: Locating Secondary Latches
Courtesy of FORD MOTOR CO.
Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission cooling tubes.

Fig 26: Disconnecting Transmission Cooling Tubes
Courtesy of FORD MOTOR CO.
Remove the drain plug and drain the engine oil.
- Install the drain plug and tighten to 27 Nm (20 lb-ft).
  
  Fig 27: Locating Drain Plug
  Courtesy of FORD MOTOR CO.
Remove and discard the engine oil filter.

Fig 28: Locating Engine Oil Filter
Courtesy of FORD MOTOR CO.
Remove the power steering cooler bracket bolt from the RH side of the subframe.

Fig 29: Locating Power Steering Cooler Bracket Bolt
Courtesy of FORD MOTOR CO.

All-Wheel Drive (AWD) vehicles

NOTE: Index-mark the driveshaft for installation.

Fig 30: Locating Driveshaft Bolts

Courtesy of FORD MOTOR CO.

Remove the 4 bolts and support the driveshaft with a length of mechanic's wire.
All vehicles

NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).

Fig 31: Identifying Steering Wheel Holding Device

Courtesy of FORD MOTOR CO.

Using a suitable holding device, hold the steering wheel in the straight-ahead position.
Remove the 2 nuts and the roll restrictor heat shield.

Fig 32: Locating Roll Restrictor Heat Shield Nuts
Courtesy of FORD MOTOR CO.
Remove the engine roll restrictor-to-subframe through bolt.

Fig 33: Locating Engine Roll Restrictor-To-Subframe Through Bolt
Courtesy of FORD MOTOR CO.
Remove and discard the Power Steering Pressure (PSP) tube-to-pump banjo bolt and the 2 seals.

Fig 34: Locating Power Steering Pressure Tube-To-Pump Banjo Bolt
Courtesy of FORD MOTOR CO.

NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to CLOCKSPRING .

Remove and discard the steering intermediate shaft bolt.
- Separate the steering intermediate shaft from the steering gear.
  
  Fig 35: Locating Steering Intermediate Shaft Bolt
  Courtesy of FORD MOTOR CO.

NOTE: RH shown in illustration, LH similar.

Remove and discard the cotter pins and tie-rod end nuts.
- Using the Tie-Rod End Remover, separate the tie-rod ends from the wheel knuckles.
  
  Fig 36: Identifying Tie-Rod End Remover
  Courtesy of FORD MOTOR CO.
Remove the 3 RH subframe-to-lower bumper nuts.

Fig 37: Locating RH Subframe-To-Lower Bumper Nuts
Courtesy of FORD MOTOR CO.
Remove the 3 LH subframe-to-lower bumper nuts and separate the lower bumper from the subframe.

Fig 38: Locating LH Subframe-To-Lower Bumper Nuts
Courtesy of FORD MOTOR CO.
Position the Powertrain Lift under the subframe assembly.

Fig 39: Positioning Powertrain Lift Under Subframe Assembly
Courtesy of FORD MOTOR CO.
Remove the 2 nuts, 4 bolts and the subframe support brackets.

Fig 40: Locating Subframe Support Brackets Bolts And Nuts
Courtesy of FORD MOTOR CO.
Remove the 2 front subframe nuts.

Fig 41: Locating Front Subframe Nuts
Courtesy of FORD MOTOR CO.
Remove the 2 middle subframe nuts.

Fig 42: Locating Middle Subframe Nuts
Courtesy of FORD MOTOR CO.
Using the Powertrain Lift, lower the subframe assembly from the vehicle.

Fig 43: Positioning Powertrain Lift Under Subframe Assembly
Courtesy of FORD MOTOR CO.

NOTE: Position a block of wood under the transaxle.

Fig 44: Identifying Powertrain Lift And Universal Adapter Brackets

Courtesy of FORD MOTOR CO.

Install the Powertrain Lift and Universal Adapter Brackets.
Remove the transaxle support insulator through bolt and nut.

Fig 45: Locating Transaxle Support Insulator Through Bolt And Nut
Courtesy of FORD MOTOR CO.
Remove the 3 nuts, the bolt and the transaxle support insulator bracket.

Fig 46: Locating Transaxle Support Insulator Bracket Nuts And Bolt
Courtesy of FORD MOTOR CO.
Remove the nut, bolt and engine mount brace.

Fig 47: Locating Engine Mount Brace Nut And Bolt
Courtesy of FORD MOTOR CO.
Remove the 4 engine mount nuts.

Fig 48: Locating Engine Mount Nuts
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the engine mount.

Fig 49: Locating Engine Mount Bolts
Courtesy of FORD MOTOR CO.
Lower the engine and transaxle assembly from the vehicle.
If equipped, detach the engine block heater wiring harness retainers and position the harness aside.
Disconnect the PCV hose from the PCV valve.

Fig 50: Locating PCV Hose
Courtesy of FORD MOTOR CO.
Disconnect the Throttle Body (TB) electrical connector.

Fig 51: Locating Throttle Body Electrical Connector
Courtesy of FORD MOTOR CO.
Detach the wiring harness retainers from the upper intake manifold.

Fig 52: Locating Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Remove the upper intake manifold support bracket bolt.

Fig 53: Locating Upper Intake Manifold Support Bracket Bolt
Courtesy of FORD MOTOR CO.

NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Remove the 6 bolts and the upper intake manifold in the following sequence.
- Discard the gaskets.
  
  Fig 54: Identifying Upper Intake Manifold Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.

Fig 55: Locating RH Catalyst Monitor Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the PSP switch electrical connector.

Fig 56: Locating PSP Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.

Fig 57: Locating RH Variable Camshaft Timing Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the 3 RH coil-on-plug electrical connectors.

Fig 58: Locating RH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
Disconnect the LH VCT solenoid electrical connector.

Fig 59: Locating LH VCT Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the 3 LH coil-on-plug electrical connectors.

Fig 60: Locating LH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
Detach all of the wiring harness retainers from the LH valve cover and stud bolts.

NOTE: LH shown in illustration, RH similar.

Fig 61: Locating Coil-On-Plugs Bolts

Courtesy of FORD MOTOR CO.

Remove the 6 bolts and the 6 coil-on-plugs.
Early build vehicles
Loosen the 11 stud bolts and remove the LH valve cover.
- Discard the gasket.
  
  Fig 62: Locating LH Valve Cover Stud Bolts
  Courtesy of FORD MOTOR CO.
Loosen the bolt, the 10 stud bolts and remove the RH valve cover.
- Discard the gasket.
  
  Fig 63: Locating RH Valve Cover Stud Bolts
  Courtesy of FORD MOTOR CO.
Late build vehicles
Loosen the 9 stud bolts and remove the LH valve cover.
- Discard the gasket.
  
  Fig 64: Locating LH Valve Cover Stud Bolts
  Courtesy of FORD MOTOR CO.
Loosen the 9 stud bolts and remove the RH valve cover.
- Discard the gasket.
  
  Fig 65: Locating RH Valve Cover Stud Bolts
  Courtesy of FORD MOTOR CO.
All vehicles

NOTE: VCT solenoid seal removal shown in illustration, spark plug tube seal removal similar.

Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged.
- Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
  
  Fig 66: Identifying VCT Spark Plug Tube Seal Remover And Handle
  Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the power steering pump.

Fig 67: Locating Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the accessory drive belt tensioner.

Fig 68: Locating Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
- Discard the bolt.
  
  Fig 69: Locating Crankshaft Pulley Bolt And Washer
  Courtesy of FORD MOTOR CO.
Using the 3 Jaw Puller, remove the crankshaft pulley.

Fig 70: Removing Crankshaft Pulley
Courtesy of FORD MOTOR CO.
Using the Oil Seal Remover, remove and discard the crankshaft front seal.

Fig 71: Removing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the engine mount bracket.

Fig 72: Locating Engine Mount Bracket Bolts
Courtesy of FORD MOTOR CO.

NOTE: Only use hand tools to remove the studs.

Fig 73: Locating Engine Mount Studs

Courtesy of FORD MOTOR CO.

Remove the 2 engine mount studs.
Remove the 3 bolts and the engine mount bracket.

Fig 74: Locating Engine Mount Bracket Bolts
Courtesy of FORD MOTOR CO.
Remove the 22 engine front cover bolts.

Fig 75: Locating Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
Install 6 of the engine front cover bolts (finger-tight) into the 6 threaded holes in the engine front cover.
- Tighten the bolts one turn at a time in a crisscross pattern until the engine front cover-to-cylinder block seal is released.
  - Remove the engine front cover.
    
    Fig 76: Locating Engine Front Cover Bolts
    Courtesy of FORD MOTOR CO.

NOTE: Only use a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover. These tools cause scratches and gouges that make leak paths.

Clean the engine front cover using a 3M™ Roloc® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15,000 rpm.
- Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.

NOTE: Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.

NOTE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.

Clean the sealing surfaces of the cylinder block in the following sequence.
1. Remove any large deposits of silicone or gasket material.
2. Apply silicone gasket remover and allow to set for several minutes.
3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Engines equipped with early build RH timing chain guides
Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown in illustration.

Fig 77: Identifying Timing Marks Location
Courtesy of FORD MOTOR CO.

Engines equipped with late build/replacement RH timing chain guides
Rotate the crankshaft clockwise and align the timing marks on the VCT assemblies as shown in illustration.

Fig 78: Aligning Timing Marks On VCT Assemblies
Courtesy of FORD MOTOR CO.

All vehicles

NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.

Fig 79: Identifying Camshaft Holding Tool

Courtesy of FORD MOTOR CO.

Install the Camshaft Holding Tool onto the flats of the LH camshafts.

NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

Fig 80: Identifying Camshaft Holding Tool

Courtesy of FORD MOTOR CO.

Install the Camshaft Holding Tool onto the flats of the RH camshafts.
Remove the 3 bolts and the RH VCT housing.

Fig 81: Locating RH VCT Housing Bolts
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the LH VCT housing.

Fig 82: Locating LH VCT Housing Bolts
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the primary timing chain tensioner.

Fig 83: Locating Primary Timing Chain Tensioner Bolts
Courtesy of FORD MOTOR CO.
Remove the primary timing chain tensioner arm.

Fig 84: Locating Primary Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the lower LH primary timing chain guide.

Fig 85: Locating Primary Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
Remove the primary timing chain.

Fig 86: Locating Primary Timing Chain
Courtesy of FORD MOTOR CO.

LH camshafts
Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.

Fig 87: Compressing LH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.

NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.

Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt.
- Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
  
  Fig 88: Locating Secondary Timing Chain And LH Exhaust Camshaft Sprocket
  Courtesy of FORD MOTOR CO.

NOTE: When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.

Fig 89: Identifying Camshaft Holding Tool

Courtesy of FORD MOTOR CO.

Remove the Camshaft Holding Tool from the LH camshafts.

NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.

Fig 90: Identifying LH Camshafts Neutral Position

Courtesy of FORD MOTOR CO.

Verify the LH camshafts are in the neutral position.

NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Remove the bolts and the LH camshaft bearing caps.
- Remove the LH camshafts.
  
  Fig 91: Locating LH Camshaft Bearing Caps Bolts
  Courtesy of FORD MOTOR CO.
RH camshafts
Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.

Fig 92: Compressing RH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.

NOTE: The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.

Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt.
- Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
  
  Fig 93: Locating Secondary Timing Chain And RH Exhaust Camshaft Sprocket
  Courtesy of FORD MOTOR CO.
Remove the Camshaft Holding Tool from the RH camshafts.

Fig 94: Identifying Camshaft Holding Tool
Courtesy of FORD MOTOR CO.

NOTE: The camshafts must remain in the neutral position during removal or engine damage may occur.

Fig 95: Identifying RH Camshafts Neutral Position

Courtesy of FORD MOTOR CO.

Rotate the RH camshafts counterclockwise to the neutral position.

NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Remove the bolts and the RH camshaft bearing caps.
- Remove the RH camshafts.
  
  Fig 96: Locating RH Camshaft Bearing Caps Bolts
  Courtesy of FORD MOTOR CO.