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Home >> Ford >> 2015 >> Explorer Limited, 3.5L Eng VIN 8, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine - 3.5L Ti-VCT >> Removal And Installation >> Camshaft >> Removal

Removal And Installation: Camshaft: Removal

WARNING: Before beginning any service procedure in this article, refer to Safety Warnings in SAFETY WARNINGS .
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.
  1. With the vehicle in NEUTRAL, position it on a hoist. REFER to JACKING AND LIFTING , Lifting Points.
  2. Recover the A/C system. REFER to CLIMATE CONTROL DATC .
  3. Remove the cowl panel. REFER to FRONT END BODY PANELS .
  4. Release the fuel system pressure. REFER to FUEL SYSTEM PRESSURE RELEASE .
  5. Remove the engine ACL assembly and ACL outlet pipe. REFER to INTAKE AIR DISTRIBUTION AND FILTERING .
  6. Remove the battery tray. REFER to BATTERY, MOUNTING AND CABLES .
  7. Remove the nut and disconnect the 2 battery feed cables from the positive battery terminal.
    G09527643
  8. Remove the retainer and the ground wire cable.
    G09527644
  9. Remove the retainer and the ground wire cable.
    G09527645
  10. Disconnect the engine wiring harness electrical connector.
    G09527646
  11. Remove the front wheels and tires. REFER to WHEELS AND TIRES .
  12. NOTE: RH shown in illustration, LH similar.

    Remove the 2 RH and 2 LH lower pin-type retainers from the engine splash shields and position the shields aside.

    G09527647
  13. Remove the accessory drive belt. REFER to ACCESSORY DRIVE BELT .
  14. Drain the cooling system. REFER to ENGINE COOLING .
  15. Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal and gasket seal.
      G09527648
  16. Disconnect the A/C pressure switch electrical connector.
    G09527649
  17. Remove the nut and disconnect the A/C tube.
    • Discard the O-ring seal and gasket seal.
      G09527650
  18. Remove degas bottle. REFER to ENGINE COOLING .
  19. Disconnect the degas bottle coolant hose from the engine coolant tube.
    G09527651
  20. Disconnect the brake booster vacuum hose from the upper intake manifold.
    G09527652
  21. Disconnect the EVAP  tube and the fuel supply tube quick connect coupling. REFER to FUEL SYSTEM GENERAL INFORMATION .
    G09527653
  22. Disconnect the 2 PCM  electrical connectors.
    G09527654
  23. Disconnect the engine harness electrical connector.
    • Detach the wiring harness retainer.
      G09527655
  24. Remove the engine wiring harness retainer from the bulkhead.
    • Push the wiring harness retainer tab in.
    • Slide the wiring harness up and out of the bulkhead.
      G09527656
  25. Remove the bolt and ground wire from the RH shock tower.
    G09527657
  26. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
    G09527658
  27. Disconnect the transaxle control cable from the control lever.
    G09527659
  28. Disconnect the transaxle control cable from the shift cable bracket.
    G09527660
  29. If equipped, detach the engine block heater harness.
  30. 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.

    G09527661
  31. Remove the 3 twist lock retainers and the underbody air duct.
    G09527662
  32. NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may 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 .
    NOTE: Index-mark the steering column shaft position to the steering gear for reference during installation.

    Remove the bolt and disconnect the steering column shaft from the steering gear.

    • Discard the bolt.
      G09527663
  33. Remove the exhaust Y-pipe. For additional information, refer to EXHAUST SYSTEM .
  34. NOTE: Index-mark the driveshaft for installation.

    If equipped with All-Wheel Drive (AWD), remove and discard the 4 bolts and support the driveshaft with a length of mechanic's wire.

    G09527664
  35. Remove the drain plug and drain the engine oil.
    • Install the drain plug and tighten to 27 Nm (20 lb-ft).
      G09527665
  36. Remove and discard the engine oil filter.
    G09527666
  37. If equipped, disconnect the 2 PTU cooler hoses. For additional information, refer to FUEL SYSTEM GENERAL INFORMATION .
    G09527667
  38. If equipped, disconnect the oil cooler coolant hoses.
    G09527668
  39. If equipped, unlatch the cooler hose retainer latch and pry up on the oil cooler hose retainer to release the retainer and remove it from the subframe.
    G09527669
  40. Remove the 2 secondary latches from the transmission fluid cooler tubes at the transmission fluid cooler thermal bypass valve.
    G09527670
  41. Using 307-569, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal bypass valve.
    G09527671
  42. NOTE: LH shown in illustration, RH similar.

    Remove the bolt and the wheel speed sensor.

    G09527672
  43. NOTE: LH shown in illustration, RH similar.

    Remove and discard the upper stabilizer link nut.

    G09527673
  44. NOTE: Do not allow the brake caliper to hang from the brake flexible hose or damage to the hose may occur.
    NOTE: LH shown in illustration, RH similar.

    Remove the brake caliper guide pin bolts and calipers.

    • Support the calipers.
      G09527674
  45. NOTE: RH shown in illustration, LH similar.

    Using a wax pencil, mark the relationship of the front and rear subframe to the underbody at the mounting locations on both side.

    G09527675
  46. NOTE: LH shown in illustration, RH similar.

    Remove the LH and RH halfshaft nuts.

    • Do not discard at this time.
      G09527676
  47. NOTE: LH shown in illustration, RH similar.

    Separate the LH and RH halfshaft from the wheel hubs.

    G09527677
  48. Position a 2 x 6 board, 36 in (914.4 mm) in length and two 2 x 6 boards 24 in (609.6 mm) in length onto the powertrain lift.
    • Position the powertrain lift table with:
      • the long board towards the rear of the subframe.
      • the short boards under the engine and transmission.
        G09527678
  49. Install the Adjustable Grip Arm from the powertrain lift table to the LH engine-to-transmission bolt hole.
    G09527679
  50. Install a ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe, to secure the subframe to the powertrain lift table.
  51. NOTE: LH shown in illustration, RH similar.
    NOTE: The halfshafts are not being remove from the transmission.

    Remove the strut-to-wheel knuckle nuts and bolts.

    • Remove the strut from the wheel knuckle and the halfshafts from the wheel knuckle.
      G09527680
  52. Remove the 4 transmission support insulator-to-frame rail bolts.
    G09527681
  53. Remove the 3 nuts, the bolt and the transaxle support insulator assembly.
    G09527682
  54. Remove the 4 engine mount nuts, the 3 engine mount bolts and the engine mount.
    G09527683
  55. NOTE: RH shown in illustration, LH similar.

    Remove the subframe bracket-to-body bolts.

    G09527684
  56. NOTE: RH shown in illustration, LH similar.

    Remove the rear subframe bolts and the subframe brackets.

    G09527685
  57. NOTE: RH shown in illustration, LH similar.

    Remove the front subframe bolts.

    G09527686
  58. Lower the subframe and powertrain assembly from the vehicle.
  59. Remove the 3 bolts and the accessory drive belt tensioner.
    G09527687
  60. Remove the crankshaft front seal. Refer to CRANKSHAFT FRONT SEAL .
  61. Remove the crankcase vent tube. REFER to FUEL SYSTEM GENERAL INFORMATION .
    G09527688
  62. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Disconnect the 3 LH coil-on-plug electrical connectors and remove the 3 bolts and the 3 LH coil-on-plugs.

    • Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
      G09527689
  63. Remove the oil level indicator.
    G09527690
  64. Remove the ground wire bolt from the engine front cover.
    G09527691
  65. Remove the engine wiring harness from the LH valve cover.
    • Disconnect the 2 VCT  oil control solenoid electrical connectors.
    • Detach and disconnect the LH HO2S electrical connector.
    • Disconnect the 3 fuel injector electrical connectors.
    • Detach the 11 wiring harness retainers from the LH valve cover and stud bolts and position the harness aside.
      G09527692
  66. NOTE: When removing valve cover do not apply excessive force to the VCT  oil control solenoid.
    NOTE: If the VCT  solenoid seal sticks to the VCT  oil control solenoid, then carefully wiggle the valve cover until the bond breaks free.
    NOTE: The plastic electrical connector on the VCT  oil control solenoid will rotate approximately 12 degrees inside the steel housing, which is normal.

    Loosen the 4 bolts and 7 stud bolts and remove the LH valve cover.

    • Discard the gasket.
      G09527693
  67. Inspect the 2 VCT  solenoid seals. Remove any damaged seals.
    • Using 205-142 T80T-4000-J and 205-153 T80T-4000-W remove and discard the damaged seal(s).
      G09527694
  68. Inspect the spark plug tube seals. Remove any damaged seals.
    • Using 303-1247/1 and 205-153 T80T-4000-W remove and discard the damaged seal(s).
      G09527695
  69. Disconnect the EVAP  canister purge valve and throttle body electrical connectors.
    • Detach the wiring harness pin-type retainer.
      G09527696
  70. Disconnect the EVAP  vapor tube from the EVAP  canister purge valve. REFER to FUEL SYSTEM GENERAL INFORMATION .
    • Detach the EVAP  vapor tube from the 2 retainers.
      G09527697
  71. Disconnect the crankcase ventilation hose from the upper intake manifold.
    G09527698
  72. Detach the 2 coolant tube retainers from the upper intake manifold.
    G09527699
  73. Remove the upper intake manifold support bracket bolt.
    G09527700
  74. 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.
      G09527701
  75. NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.

    Disconnect the 3 RH coil-on-plug electrical connectors and remove the 3 bolts and the 3 RH coil-on-plugs.

    • Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
      G09527702
  76. Remove the PCV  crankcase vent tube.
    G09527703
  77. Remove the engine wiring harness from the RH valve cover.
    • Disconnect the 2 VCT  oil control solenoid electrical connectors.
    • Detach and disconnect the RH CMS  electrical connector.
    • Disconnect the 3 fuel injector electrical connectors.
    • Disconnect the CHT  sensor wiring harness jumper electrical connector.
    • Detach the 9 wiring harness retainers from the RH valve cover and stud bolts and position the harness aside.
      G09527704
  78. NOTE: When removing valve cover do not apply excessive force to the VCT  oil control solenoid.
    NOTE: If the VCT  solenoid seal sticks to the VCT  oil control solenoid, then carefully wiggle the valve cover until the bond breaks free.
    NOTE: The plastic electrical connector on the VCT  oil control solenoid will rotate approximately 12 degrees inside the steel housing, which is normal.

    Loosen the 11 retainers and remove the RH valve cover.

    • Discard the gasket.
      G09527705
  79. Inspect the 2 VCT  solenoid seals. Remove any damaged seals.
    • Using 205-142 T80T-4000-J and 205-153 T80T-4000-W remove and discard the damaged seal(s).
      G09527706
  80. Inspect the spark plug tube seals. Remove any damaged seals.
    • Using 303-1247/1 and 205-153 T80T-4000-W remove and discard the damaged seal(s).
      G09527707
  81. NOTE: It may be necessary to use the floor jack and lower the engine slightly to gain enough access to remove the bolt.

    Remove the lower M10 engine front cover bolt.

    G09527708
  82. NOTE: It may be necessary to use the floor jack and raise the engine slightly to gain enough access to remove the bolts.

    Remove the 2 M10 engine front cover bolts.

    G09527709
  83. Remove the 22 M8 engine front cover bolts.
    G09527710
  84. Remove the M6 engine front cover bolt.
    G09527711
  85. Using a suitable pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.
    G09527712
  86. Rotate the crankshaft clockwise and align the timing marks on the intake VCT  assemblies as shown in illustration.
    G09527713
  87. Remove the 3 bolts and the LH valve train oil tube.
    G09527714
  88. NOTE: The 303-1248 will hold the camshafts in the TDC position.

    Install 303-1248 onto the flats of the LH camshafts.

    G09527715
  89. Remove the 3 bolts and the RH valve train oil tube.
    G09527716
  90. NOTE: The 303-1248 will hold the camshafts in the TDC position.

    Install 303-1248 onto the flats of the RH camshafts.

    G09527717
  91. NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.

    Mark the timing chain link that aligns with the timing mark on the LH intake VCT  assembly as shown in illustration.

    G09527718
  92. Mark the timing chain link that aligns with the timing mark on the RH intake VCT  assembly as shown in illustration.
    G09527719
  93. 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 in illustration.

    G09527720
  94. Remove the 2 bolts and the primary timing chain tensioner.
    G09527721
  95. Remove the primary timing chain tensioner arm.
    G09527722
  96. Remove the 2 bolts and the lower LH primary timing chain guide.
    G09527723
  97. 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.

    G09527724
  98. 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.

    G09527725
  99. Remove the primary timing chain.
    G09527726
  100. NOTE: The following steps are to remove the LH camshafts.
    NOTE: The 2 VCT  oil control solenoids are removed for clarity.
    NOTE: The 303-1530 is inserted through a hole in the top of the mega cap.

    Compress the LH secondary timing chain tensioner and install the 303-1530 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.

    G09527727
  101. Remove and discard the 2 LH VCT  assembly bolts.
    G09527728
  102. Remove the 2 LH VCT  assemblies and secondary timing chain.
    • Remove the 303-1530.
      G09527729
  103. NOTE: When the 303-1248 is removed, valve spring pressure may rotate the LH camshafts approximately 3 degrees to a neutral position.

    Remove the 303-1248 from the LH camshafts.

    G09527730
  104. 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.

    G09527731
  105. NOTE: The following steps are to remove the RH camshafts.
    NOTE: The 2 VCT  oil control solenoids are removed for clarity.
    NOTE: The 303-1530 is inserted through a hole in the top of the mega cap.

    Compress the RH secondary timing chain tensioner and install the 303-1530 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.

    G09527732
  106. Remove and discard the 2 RH VCT  assembly bolts.
    G09527733
  107. Remove the 2 RH VCT  assemblies and secondary timing chain.
    • Remove the 303-1530.
      G09527734
  108. NOTE: When the 303-1248 is removed, valve spring pressure may rotate the RH camshafts approximately 3 degrees to a neutral position.

    Remove the 303-1248 from the RH camshafts.

    G09527735
  109. 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.

    G09527736
G00578722Courtesy of FORD MOTOR COMPANY
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