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Section 9 (Engine Mechanical - 3.5L): Removal: Camshaft

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOLS DESCRIPTION

G08976367
 3 Jaw Puller
303-D121 or equivalent
G08976368
 Adjustable Grip Arm, 1735A
014-00001
G08976369
 Disconnect Tool, Transmission Cooler Tube
307-569
G08976370
 Handle
205-153 (T80T-4000-W)
G08976371
 Hold Down, Secondary Chain
303-1530
G08976372
 Installer, Differential Bearing Cone
205-142 (T80T-4000-J)
G08976373
 Powertrain Lift
300-OTC1585AE
G08976374
 Remover, Oil Seal
303-409 (T92C-6700CH)
G08976375
 Remover, VCT Spark Plug Tube Seal
303-1247/1
G08976376
 Strap Wrench
303-D055 (D85L-6000-A) or equivalent
G08976377
 Tool, Camshaft Holding
303-1248
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® Metal Surface Prep
ZC-31-A		 -
Motorcraft® 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, may cause engine failure.

All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. Refer to JACKING & LIFTING .
  2. Remove the engine appearance cover. Refer to ENGINE APPEARANCE COVER - EXPLODED VIEW .
  3. Recover the A/C system. Refer to HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
  4. Release the fuel system pressure. Refer to FUEL SYSTEM - GENERAL INFORMATION .
  5. NOTE: Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).

    Using a suitable holding device, hold the steering wheel in the straight-ahead position.

    Fig 1: Holding Steering Wheel Straight-Ahead Position Using Steering Wheel Holding Device
    G08976378Courtesy of FORD MOTOR CO.
  6. Drain the engine cooling system. Refer to ENGINE COOLING .
  7. Remove the LH and RH front wheels and tires. Refer to WHEELS & TIRES .
  8. Remove the LH and RH inner splash shields. Refer to BODY PANEL SYSTEM - FRONT END BODY PANELS .
  9. Remove the accessory drive belt and the power steering belt. Refer to ACCESSORY DRIVE BELT .
  10. Disconnect the power steering cooler hose and drain the power steering fluid into a suitable drain pan.
    G08976379
  11. Remove the power steering cooler bracket bolt from the RH side of the subframe.
    Fig 2: Locating Power Steering Cooler Bracket Bolt
    G08976380Courtesy of FORD MOTOR CO.
  12. Remove the degas bottle. Refer to ENGINE COOLING .
  13. Disconnect the hose from the power steering reservoir.
    Fig 3: Locating ACL Outlet Pipe Clamp
    G08976381Courtesy of FORD MOTOR CO.
  14. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. Refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM .
  15. Remove the battery tray. Refer to BATTERY, BATTERY MOUNTING & BATTERY CABLES .
  16. Remove the 2 nuts and disconnect the power feed from the battery terminal.
    • Disconnect the wiring harness electrical connector.
      G08976382
  17. Remove the nut and the ground wire.
    • Disconnect the wiring harness electrical connector.
      G08976383
  18. Detach the 2 wiring harness retainers from the stud bolt and bracket.
    G08976384
  19. Disconnect the wiring harness electrical connector.
    G08976385
  20. Detach the 3 wiring harness retainers from the bracket and inner fender.
    G08976386
  21. Disconnect the vacuum hose from the upper intake manifold.
    G08976387
  22. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
    G08976388
  23. Disconnect the transaxle control cable from the control lever.
    • Detach the control cable from the bracket.
      Fig 4: Locating Control Cable Bracket
      G08976389Courtesy of FORD MOTOR CO.
  24. If equipped, detach the engine block heater harness retainers from the radiator support and the A/C suction tube.
    Fig 5: Locating Engine Block Heater Harness Retainers
    G08976390Courtesy of FORD MOTOR CO.
  25. Remove the A/C tube bracket bolt.
    G08976391
  26. Remove the nut and disconnect the A/C pressure tube fitting.
    • Discard the O-ring seal.
      Fig 6: Locating A/C Pressure Tube Fitting Bolt
      G08976392Courtesy of FORD MOTOR CO.
  27. Remove the safety clip from the A/C fitting.
    • Disconnect the A/C suction tube fitting.
      Fig 7: Locating A/C Suction Tube Fitting Safety Clip
      G08976393Courtesy of FORD MOTOR CO.
  28. Disconnect the 2 PCM electrical connectors.
    • Detach the 2 wiring harness retainers from the stud bolts.
      G08976394
  29. Disconnect the wiring harness electrical connector.
    • Detach the wiring harness retainer from the RH valve cover stud bolt.
      G08976395
  30. Remove the bolt and the ground wire from the engine front cover.
    G08976396
  31. Remove the nut and the radio interference capacitor wire from the engine front cover stud.
    G08976397
  32. Remove the 2 secondary latches from the transmission fluid cooler tubes.
    Fig 8: Locating Transmission Fluid Cooler Tubes Secondary Latches
    G08976398Courtesy of FORD MOTOR CO.
  33. Using the Transmission Cooler Tube Disconnect Tool, disconnect the transmission cooling tubes.
    Fig 9: Disconnecting Transmission Cooler Tube Tool
    G08976399Courtesy of FORD MOTOR CO.
  34. NOTE: RH shown, LH similar.
    NOTE: The guide pin bolts are different sizes. The larger bolt is the upper guide pin bolt.

    Remove the 2 RH and 2 LH brake caliper guide pin bolts and position aside the front brake calipers and secure with a length of mechanic's wire.

    G08976400
  35. NOTE: RH shown, LH similar.

    Remove the bolts and position aside the RH and LH front wheel speed sensor.

    G08976401
  36. NOTE: RH shown, LH similar.

    Remove the 2 RH and 2 LH front shock absorber lower flag bolts and nuts.

    G08976402
  37. Remove the exhaust Y-pipe. Refer to EXHAUST SYSTEM .
  38. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
      G08976403
  39. Remove and discard the engine oil filter.
    G08976404

    All-Wheel Drive (AWD) vehicles 

  40. NOTE: Index-mark the driveshaft for installation.

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

    Fig 10: Locating Driveshaft Bolts
    G08976405Courtesy of FORD MOTOR CO.

    All vehicles 

  41. Remove the 2 nuts and the roll restrictor heat shield.
    G08976406
  42. 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 SUPPLEMENTAL RESTRAINT SYSTEM .

    Remove and discard the steering intermediate shaft bolt.

    • Separate the steering intermediate shaft from the steering gear.
      G08976407
  43. Remove the 3 RH subframe-to-lower bumper nuts.
    Fig 11: Locating RH Subframe-To-Lower Bumper Nuts
    G08976408Courtesy of FORD MOTOR CO.
  44. Remove the 3 LH subframe-to-lower bumper nuts and separate the lower bumper from the subframe.
    Fig 12: Locating LH Subframe-To-Lower Bumper Nuts
    G08976409Courtesy of FORD MOTOR CO.
  45. Mark the relationship of the front subframe to the underbody at the mounting locations.
    G08976410
  46. Remove the 2 bolts and the subframe brace.
    G08976411
  47. NOTE: The fuel and vapor tube assembly clip must remain attached to the transaxle case stud during engine removal. Failure to follow these instructions can result in damage to the fuel and vapor tube assembly.

    Disconnect the fuel supply tube and Evaporative Emission (EVAP) tube quick connect couplings. For additional information, refer to the QUICK CONNECT COUPLING procedure.

    G08976412
  48. Position a 2 x 6 board, 60 in (1, 524 mm) in length and two 2 x 6 boards, 24 in (609.6 mm) in length onto the Powertrain Lift.
    G08976413
  49. NOTE: RH shown, LH similar.

    Position the Powertrain Lift and boards.

    1. Position the long board directly under the control arms.
    2. Position the short boards under the engine oil pan and transmission.
      G08976414
  50. Install an Adjustable Grip Arm from the Powertrain Lift to the LH engine-to-transmission bolt hole.
    G08976415
  51. Remove the transaxle support insulator through bolt and nut.
    Fig 13: Locating Transaxle Support Insulator Through Bolt And Nut
    G08976416Courtesy of FORD MOTOR CO.
  52. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
    Fig 14: Locating Transaxle Support Insulator Bracket Bolt
    G08976417Courtesy of FORD MOTOR CO.
  53. Remove the nut, bolt and engine mount brace.
    Fig 15: Locating Engine Mount Brace Nut And Bolt
    G08976418Courtesy of FORD MOTOR CO.
  54. Remove the 4 engine mount nuts.
    G08976419
  55. Remove the 3 bolts and the engine mount.
    G08976420
  56. Remove the 2 nuts, 2 bolts and the 2 subframe support brackets.
    G08976421
  57. Remove the 2 front subframe nuts.
    Fig 16: Locating Front Subframe Nuts
    G08976422Courtesy of FORD MOTOR CO.
  58. Remove the 2 middle subframe nuts and lower subframe onto the Powertrain Lift.
    • Lower the powertrain/subframe assembly from the vehicle.
      Fig 17: Locating Middle Subframe Nuts
      G08976423Courtesy of FORD MOTOR CO.
  59. Remove the 3 bolts and the accessory drive belt tensioner.
    G08976424
  60. Using the Strap Wrench, remove the crankshaft pulley bolt and washer.
    • Discard the bolt.
      Fig 18: Locating Crankshaft Pulley Bolt And Washer
      G08976425Courtesy of FORD MOTOR CO.
  61. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 19: Locating Crankshaft Pulley Jaw Puller
    G08976426Courtesy of FORD MOTOR CO.
  62. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 20: Locating Crankshaft Front Seal Oil Seal Remover
    G08976427Courtesy of FORD MOTOR CO.
  63. Remove the crankcase vent tube. For additional information, refer to the QUICK CONNECT COUPLING procedure.
    G08976428
  64. Disconnect the 3 LH coil-on-plug electrical connectors.
    G08976429
  65. Remove the 3 bolts and the 3 LH-coil-on-plugs.
    G08976430
  66. Detach the wiring harness connector pin-type retainer from the LH valve cover.
    G08976431
  67. Detach the 2 wiring harness retainers from the LH valve cover stud bolts and position the harness aside.
    G08976432
  68. Disconnect the 2 VCT oil control solenoid electrical connectors.
    • Detach the wiring harness pin-type retainer.
      G08976433
  69. Detach the 2 wiring harness pin-type retainers.
    G08976434
  70. Disconnect the LH HO2S electrical connector.
    • Detach the wiring harness connector pin-type retainer from the LH valve cover.
      G08976435
  71. Disconnect the 3 fuel injector electrical connectors.
    • Detach the 2 wiring harness retainers from the LH valve cover stud bolts.
      G08976436
  72. Detach the 2 wiring harness retainers and position the harness aside.
    G08976437
  73. NOTE: While removing the valve cover do not apply excessive force to the Variable Camshaft Timing (VCT) oil control solenoid or damage may occur.
    NOTE: If the VCT oil control solenoid sticks to the VCT seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.

    Loosen the 4 bolts and 7 stud bolts.

    • Remove the LH valve cover.
    • Discard the gasket.
      G08976438
  74. Disconnect the EVAP canister vent solenoid and throttle body electrical connectors.
    • Detach the wiring harness pin-type retainer.
      G08976439
  75. Disconnect the EVAP vapor tube from the EVAP canister vent solenoid. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    • Detach the EVAP tube retainer.
      G08976440
  76. Detach the 2 wiring harness/coolant tube retainers from the upper intake manifold.
    G08976441
  77. Disconnect the crankcase ventilation hose from the upper intake manifold.
    G08976442
  78. Remove the upper intake manifold support bracket bolt.
    G08976443
  79. Remove the 7 bolts and the upper intake manifold.
    • Remove and discard the gasket.
    • Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
      G08976444
  80. Disconnect the 3 RH coil-on-plug electrical connectors and remove the 3 bolts and the 3 RH-coil-on-plugs.
    G08976445
  81. Remove the PCV crankcase vent tube.
    G08976446
  82. Disconnect the HO2S and CMS electrical connectors.
    • Detach the 2 wiring harness retainers from the RH valve cover.
      G08976447
  83. Disconnect the 2 VCT oil control solenoid electrical connectors.
    • Detach the 2 wiring harness retainers.
      G08976448
  84. Disconnect the 3 fuel injector electrical connectors.
    • Detach the 2 wiring harness retainers.
      G08976449
  85. Detach the wiring harness retainer.
    G08976450
  86. Remove the 2 nuts and position aside the power steering hose.
    G08976451
  87. NOTE: While removing the valve cover do not apply excessive force to the Variable Camshaft Timing (VCT) oil control solenoid or damage may occur.
    NOTE: If the Variable Camshaft Timing (VCT) oil control solenoid sticks to the VCT seal, carefully wiggle the valve cover until the bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.

    Loosen the 11 retainers (3 bolts and 8 stud bolts).

    • Remove the RH valve cover.
    • Discard the gasket.
      G08976452
  88. NOTE: LH shown, RH similar.

    Inspect the VCT solenoid seals. Remove any damaged seals.

    • Using the Differential Bearing Cone Installer and Handle, remove and discard the seal(s).
      G08976453
  89. NOTE: LH shown, RH similar.

    Inspect the spark plug tube seals. Remove any damaged seals.

    • Using the Spark Plug Tube Seal Remover and Handle, remove and discard the seal(s).
      G08976454
  90. Clean the valve covers, cylinder heads and engine front cover sealing surfaces with metal surface prep.
  91. NOTE: Power steering hoses removed from graphic for clarity.

    Remove the 3 bolts and the power steering pump.

    G08976455
  92. Remove the 26 front cover bolts.
    G08976456
  93. Using a suitable pry tool, locate the 7 pry pads shown below and pry the engine front cover loose and remove.
    G08976457
  94. Rotate the crankshaft clockwise and align the timing marks on the intake VCT assemblies as shown below.
    G08976458
  95. Remove the 3 bolts and the LH valve train oil tube.
    G08976459
  96. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

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

    G08976460
  97. Remove the 3 bolts and the RH valve train oil tube.
    G08976461
  98. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

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

    G08976462
    NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
  99. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown below.
    G08976463
  100. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown below.
    G08976464
  101. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.

    Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown below.

    G08976465
  102. Remove the 2 bolts and the primary timing chain tensioner.
    G08976466
  103. Remove the primary timing chain tensioner arm.
    G08976467
  104. Remove the 2 bolts and the lower LH primary timing chain guide.
    G08976468
  105. NOTE: Removal of the VCT oil control solenoid will aid in the removal of the primary timing chain.
    NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

    Remove the bolt and the LH intake VCT oil control solenoid.

    G08976469
  106. NOTE: Removal of the VCT oil control solenoid will aid in the removal of the primary timing chain.
    NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

    Remove the bolt and the RH intake VCT oil control solenoid.

    G08976470
  107. Remove the primary timing chain.
    G08976471

    LH camshafts 

  108. NOTE: The 2 VCT oil control solenoids are removed for clarity.
    NOTE: The Secondary Chain Hold Down is inserted through a hole in the top of the mega cap.

    Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.

    G08976472
  109. Remove and discard the 2 LH VCT assembly bolts.
    G08976473
  110. Remove the 2 LH VCT assemblies and secondary timing chain.
    • Remove the Secondary Chain Hold Down.
      G08976474
  111. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the LH camshafts approximately 3 degrees to a neutral position.

    Remove the Camshaft Holding Tool from the LH camshafts.

    G08976475
  112. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
    NOTE: Mark the exhaust and intake camshafts for installation into their original locations.

    Remove the 12 bolts, 6 camshaft caps, mega cap and the LH camshafts.

    Fig 21: Locating LH Exhaust And Intake Camshafts Bolts
    G08976476Courtesy of FORD MOTOR CO.

    RH camshafts 

  113. NOTE: The 2 VCT oil control solenoids are removed for clarity.
    NOTE: The Secondary Chain Hold Down is inserted through a hole in the top of the mega cap.

    Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.

    G08976477
  114. Remove and discard the 2 RH VCT assembly bolts.
    G08976478
  115. Remove the 2 RH VCT assemblies and secondary timing chain.
    • Remove the Secondary Chain Hold Down.
      G08976479
  116. NOTE: When the Camshaft Holding Tool is removed, valve spring pressure may rotate the RH camshafts approximately 3 degrees to a neutral position.

    Remove the Camshaft Holding Tool from the RH camshafts.

    G08976480
  117. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
    NOTE: Mark the exhaust and intake camshafts for installation into their original locations.

    Remove the 12 bolts, 6 camshaft caps, mega cap and the RH camshafts.

    Fig 22: Locating RH Exhaust And Intake Camshafts Bolts
    G08976481Courtesy of FORD MOTOR CO.
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