The roar of the engine, the exhilarating acceleration, and the seamless power delivery are just a few of the hallmarks of Ford’s renowned 3.5L EcoBoost engine. Widely embraced for its blend of performance and fuel efficiency, this powerplant has found its way into a range of Ford vehicles, from rugged pickups to spirited SUVs. However, beneath the hood of this engineering marvel lies a component crucial to its operation and efficiency – the cam phaser.
In the intricate workings of engine mechanics, cam phasers play a pivotal role, ensuring precise timing of the engine’s valves for optimal performance. However, one of the most prevalent issues that have surfaced over time with this engine revolves around cam phaser malfunctions, causing a ripple effect that impacts engine performance, fuel economy, and overall driving experience.
Article updated on 06.10.2024
What Exactly Are Cam Phasers?
Cam phasers are integral to modern engines, particularly those equipped with variable valve timing (VVT) systems like the Ford 3.5L EcoBoost series. Understanding their function and importance is key to appreciating their role in engine performance.
Breaking It Down: What Do Cam Phasers Actually Do?
At the heart of the 3.5L Ecoboost engine’s performance lies the cam phaser — a precision-engineered component designed to optimize the engine’s valve timing. Cam phasers are a type of variable valve timing mechanism, a technology that has revolutionized modern engines’ efficiency and power output.
Cam phasers work in conjunction with the camshaft, which controls the opening and closing of the engine’s intake and exhaust valves. By adjusting the position of the camshaft in relation to the crankshaft, cam phasers can alter the valve timing to suit different driving conditions. This dynamic timing adjustment ensures optimal air-fuel mixture combustion, enhancing power, fuel economy, and reduced emissions.
Why They Matter for Your Engine’s Performance
The importance of cam phasers in an engine cannot be overstated. They are critical in maximizing engine performance, fuel efficiency, and reducing emissions. Here are some specific reasons why cam phasers matter:
Optimized Power Delivery — Cam phasers adjust valve timing to ensure the engine delivers optimal power at various speeds. This means better acceleration and overall performance.
Fuel Efficiency — Proper valve timing helps the engine run more efficiently, leading to better fuel economy. This is particularly beneficial in larger engines like the Ford 3.5L EcoBoost.
Reduced Emissions — Efficient combustion, facilitated by accurate valve timing, leads to lower emissions. This is crucial for meeting environmental regulations and ensuring the vehicle remains eco-friendly.
Smooth Engine Operation — Cam phasers contribute to smoother engine operation by ensuring valves open and close at the right times. This reduces engine knock and enhances driving comfort.
Spotting Cam Phaser Problems
Identifying issues with cam phasers early on can prevent more significant engine problems down the road. Knowing what to look for can save you time and money by addressing the issue before it escalates.
How to Tell if Your Cam Phasers Are Acting Up
Cam phasers can develop problems that affect engine performance and longevity. Recognizing these issues early is crucial for maintaining your vehicle’s health. Here are some ways to tell if your cam phasers might be malfunctioning:
Check Engine Light — One of the most common indicators is the check engine light. When cam phasers fail, they often trigger this warning.
Rattling Noise — A noticeable rattling or ticking noise from the engine, especially during startup, can indicate cam phaser issues. This noise is often caused by the phasers failing to adjust properly.
Poor Engine Performance — If your vehicle experiences sluggish acceleration, reduced power, or hesitation during acceleration, cam phaser problems might be the cause.
Rough Idling — An unstable or rough idle can be a symptom of cam phaser failure, as the engine struggles to maintain proper timing.
Fuel Economy Drop — A sudden decrease in fuel efficiency can also be a sign, as improper valve timing affects the engine’s ability to run efficiently.
Common Signs and Symptoms to Watch For
Recognizing the symptoms of cam phaser problems early can help you address them before they lead to more severe engine damage. Here are some common signs to watch for:
Engine Misfires — Misfires occur when the combustion process is disrupted. Faulty cam phasers can cause timing issues that lead to misfires.
Excessive Exhaust Smoke — If you notice more exhaust smoke than usual, particularly during startup, it could be due to cam phaser issues affecting the engine’s timing and combustion process.
Oil Pressure Problems — Since cam phasers rely on oil pressure to function, issues with oil pressure can directly impact their performance. Low or inconsistent oil pressure can lead to phaser malfunctions.
Engine Stalling — In severe cases, faulty cam phasers can cause the engine to stall, particularly at low RPMs or when coming to a stop.
Knocking Noise (Low-Speed Pre-Ignition) — A knocking noise similar to that of a diesel engine, often described as low-speed pre-ignition, can be a sign of cam phaser issues. This noise occurs when fuel ignites prematurely in the combustion chamber, which can be exacerbated by faulty cam phasers affecting valve timing.
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Why Do Cam Phasers Fail?
Understanding why cam phasers fail in the Ford 3.5L EcoBoost engine can help owners effectively prevent and address these issues. Here are the main causes of cam phaser failure.
What’s Causing the Trouble?
Cam phasers in the Ford 3.5L EcoBoost engine can fail due to a combination of design flaws, mechanical wear, and maintenance issues. These factors can lead to improper valve timing, which affects engine performance.
Common Reasons Behind Cam Phaser Issues in the 3.5L EcoBoost
Design Flaws — The cam phasers on the 3.5L EcoBoost have a known design weakness in the locking pin mechanism. This pin is supposed to lock the cam phasers in place when the engine is off, but it can fail, causing the phasers to rattle and misalign during startup until oil pressure builds up.
Oil Pressure Problems — Cam phasers rely on adequate oil pressure to function correctly. Low oil pressure or dirty oil can hinder their operation and lead to failure. This is often due to oil pump issues, clogged oil passages, or not using the correct oil viscosity.
Mechanical Wear — Over time, the mechanical components of the cam phasers can wear out. This wear is accelerated by harsh driving conditions, frequent short trips, and poor maintenance practices, such as infrequent oil changes.
Software Issues — In some cases, attempts to fix cam phaser problems through ECU updates have introduced new issues. For instance, some updates aimed at reducing cold start rattle have led to low-speed pre-ignition or “dieseling” noises, complicating the problem further.
Recall and Repair Challenges — While Ford has issued recalls and customer satisfaction programs to address cam phaser issues, not all vehicles qualify, and repairs can be costly. Additionally, improper repair techniques or lack of mechanical work experience can result in recurring problems.
Diagnosing the Problem
Diagnosing cam phaser issues in your Ford 3.5L EcoBoost engine requires a systematic approach to ensure accurate identification and effective resolution. Knowing the right tools and techniques can make the process more efficient.
How to Figure Out If Your Cam Phasers Are the Issue
If you suspect cam phaser problems, look for common symptoms such as rattling noises during startup, rough idling, and reduced engine performance. These signs often indicate timing chain issues that could also be related to faulty cam phasers. A check engine light with relevant codes can also point to cam phaser issues.
Tools and Techniques for a Proper Diagnosis
Visual Inspection — Conduct a visual inspection of the cam phasers and related components. Look for signs of wear, oil leaks, or damage to the cam phasers, timing chain, and tensioners.
Mechanic’s Stethoscope — Listen for unusual noises around the cam phaser area using a mechanic’s stethoscope. A distinctive rattle or ticking noise during startup can indicate cam phaser issues.
OBD-II Scanner — An OBD-II scanner can help identify diagnostic trouble codes (DTCs) related to cam phaser issues. Common codes include P0011, P0012, P0016, and P0017, which indicate problems with camshaft position timing.
Oil Pressure Test — Perform an oil pressure test to ensure the engine maintains adequate oil pressure, as cam phasers rely on proper oil pressure to function correctly.
By utilizing these tools and techniques, you can effectively diagnose cam phaser issues and take the necessary steps to address them.
Fixing Cam Phaser Problems
When cam phasers fail, it’s important to decide whether to tackle the repair yourself or call a professional. Here’s what you need to know to make an informed decision and a step-by-step guide for those who choose to DIY.
Should You DIY or Call a Pro?
Replacing cam phasers can be a complex task that requires mechanical knowledge and the right tools. If you’re confident in your mechanical skills and have access to the necessary equipment, you might choose to do it yourself. However, if you’re not experienced with engine repairs, it’s advisable to seek professional help to avoid potential mistakes and ensure the job is done correctly.
Repair Options and Costs
If you are looking to buy a vehicle with this engine, namely the Ford F-150 2017-2020, Ford Expedition 2018-2020, or Ford Navigator 2018-2020, you need to be aware of two Ford recalls — the 21B10 reprogram and the Customer Satisfaction Program 21N03. The former represents the software update that has proven effective in some cases.
In some instances, these software updates can cause the dieseling effect we’ve mentioned before. In that case, the Customer Satisfaction Program 21N03 would be necessary, and Ford would replace the cam phasers with new ones.
However, to be eligible for the Customer Satisfaction Program 21N03, your vehicle had to have the 21B10 software update performed. Worst of all, this recall was active until January 2023. If your vehicle shows signs of cam phaser issues after this deadline, you may need to replace the cam phasers on your own dime.
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Step-by-Step Guide to Replacing Cam Phasers
This guide provides a broad overview of replacing the cam phaser on a 3.5L Ford EcoBoost engine and is intended for experienced DIY mechanics. This advanced repair procedure requires specific tools, precision, and a comprehensive understanding of engine components.
Therefore, having the repair manual on hand is crucial for detailed instructions, diagrams, and safety precautions. Attempting this repair without the proper manual and expertise may result in damage to the engine or personal injury. Always follow all safety guidelines and consult a professional mechanic if unsure about any step in the process.
That said, here is an overview of the removal and replacement procedure with individual steps. For more precise guidelines, torque specs, and diagrams, consult your vehicle’s repair manual.
Safety Instructions
Ensure Cleanliness — During engine repair procedures, cleanliness is crucial. Any foreign material entering the oil or coolant passages can cause engine failure.
Use Proper Tools — Use the specified tools for removal and installation to avoid component damage.
Follow Torque Specifications — Adhere to the torque specifications to prevent damage and ensure proper assembly.
Required Tools
- Work gloves
- Safety goggles
- Drain pan
- Ratchet and socket set
- Spanner set
- Pliers set
- Screwdriver set
- Pry bar
- Torque wrench
- Camshaft Holding Tool
- Secondary Chain Hold-Down Tool
- 3 Jaw Puller
- Crankshaft Vibration Damper Installer
- Front Cover Oil Seal Installer
- Oil Seal Remover
Removal Procedure
- Prepare the Vehicle
- With the vehicle in neutral, position it on a hoist and safely lift the car up.
- Remove the Engine Front Cover
- Remove the air filter outlet pipe and the right and left air cleaner pipe-to-turbocharger pipes.
- Remove the left turbocharger-to-charge air cooler tube and the charge air cooler-to-throttle body pipe.
- Remove the Crankshaft Pulley
- Remove the crankshaft pulley using a 3 Jaw Puller.
- Remove the Front Crankshaft Seal
- Use the Oil Seal Remover to remove and discard the front crankshaft seal. Clean all sealing surfaces with metal surface prep.
- Remove the Valve Covers
- Remove the valve covers to gain access to the camshaft and timing components.
- Remove the Engine Front Timing Cover
- Remove the bolts securing the front timing cover.
- Carefully remove the front timing cover to expose the timing components.
- Remove Timing Drive Components
- Rotate the crankshaft clockwise to align the timing marks on the intake Variable Camshaft Timing (VCT) assemblies.
- Remove the three bolts and the left-hand (LH) valve train oil tube.
- Install the Camshaft Holding Tool on the flats of the LH camshafts.
- Remove the three bolts and the right-hand (RH) valve train oil tube.
- Install the Camshaft Holding Tool on the flats of the RH camshafts.
- Remove the primary timing chain tensioner, tensioner arm, and lower primary timing chain guides.
- Remove the VCT oil control solenoids.
- Remove the primary timing chain and the crankshaft timing chain sprocket.
- Remove the upper primary timing chain guide.
- Compress the secondary timing chain tensioners and install the Secondary Chain Hold Down Tool.
- Remove the VCT assemblies with the secondary timing chains.
Installation Procedure
- Install VCT Assembly
- Assemble the RH VCT assembly, exhaust camshaft sprocket, and secondary timing chain. Afterward, tighten the new RH VCT bolts.
- Activate the RH secondary timing chain tensioner.
- Install the RH exhaust VCT oil control solenoid and tighten it.
- Repeat steps for the LH secondary timing chain tensioner, shoe, VCT assembly, and solenoid.
- Install Primary Timing Chain
- Install the upper primary timing chain guide and bolt.
- Install the crankshaft timing chain sprocket with the timing mark out.
- Install the primary timing chain with the colored links aligned with the timing marks.
- Install the lower primary timing chain guide and bolts.
- Install the primary timing chain tensioner arm.
- Reset the primary timing chain tensioner, install it, tighten the bolts, and remove the lock pin.
- Install the VCT Oil Control Solenoids
- Install the LH intake and RH intake VCT oil control solenoids.
- Install Valve Train Oil Tubes
- Remove the camshaft holding tools.
- Install the LH and RH valve train oil tubes and tighten the bolts.
- Reinstall the Engine Front Cover and Crankshaft Pulley
- Install the engine front cover.
- Using the Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
- Install the crankshaft pulley.
Final Steps
- Verify the correct alignment of all timing marks.
- Always replace all removed gaskets and O-rings.
- Follow the tightening torques and procedure during the installation.
- Reinstall any remaining components removed during the process.
- Lower the vehicle from the hoist and perform a final check.
Keeping Your Cam Phasers in Good Shape
Proper maintenance of cam phasers is essential for ensuring the longevity and performance of your Ford 3.5L EcoBoost engine. Following some key maintenance tips and best practices can prevent future issues and keep your engine running smoothly.
Maintenance Tips to Prevent Future Issues
Regular Oil Changes — Its no secret that regular oil change is recommended to ensure proper lubrication and function of the cam phasers. Clean oil is crucial for maintaining the hydraulic operation of the phasers.
Monitor Oil Pressure — Keep an eye on your engine’s oil pressure. Low oil pressure can lead to inadequate lubrication and cause cam phaser malfunctions. Address any oil pressure issues promptly.
Use Correct Oil Viscosity — Always use the oil viscosity recommended by Ford for the 3.5L EcoBoost engine. Incorrect engine oil viscosity can affect the performance of the cam phasers and the entire VVT system.
Inspect for Wear and Tear — Regularly inspect the cam phasers, timing chain, and related components for signs of wear and tear. Early detection of worn parts can prevent larger issues down the road.
Keep the Engine Clean — A clean engine reduces the risk of contaminants entering the lubricating system, which can impair the function of cam phasers. Regularly clean the engine bay and check for leaks.
Best Practices for a Healthy Engine
Drive Smoothly — Avoid harsh driving habits such as rapid acceleration and sudden braking. Smooth driving reduces the stress on the engine and its components.
Warm Up the Engine — Allow the engine to warm up properly before driving, especially in cold weather. This ensures that oil circulates thoroughly and reaches the cam phasers efficiently.
Follow Service Intervals — Adhere to the service intervals recommended by Ford for the 3.5L EcoBoost engine. Regular maintenance checks can catch potential issues early and keep your engine in optimal condition.
Use Quality Parts — When replacing engine components, use high-quality OEM parts to ensure compatibility and longevity.
Stay Informed — Keep up with any recalls or service bulletins issued by Ford related to the cam phasers or the VVT system. Addressing these promptly can prevent major issues.
Tips For Buying a Vehicle with This Engine
The whole cam phaser problem should not deter you from getting a 3.5L Ecoboost-powered Ford product. That said, here are several tips on how to go about finding a vehicle with this engine that won’t give you too much trouble.
Always do a cold start — Insist on starting the vehicle when cold. If you suspect the owner has warmed up the car, simply pop the hood and put your hand on the engine. A cold start is the best way to tell if the cam phasers are rattling.
Ask for service documentation — Get the vehicle’s full service history, looking for the 21B10 and 21N03 recalls. If these weren’t performed, have the owner explain the situation.
If possible, try to find a vehicle in which Ford replaced the cam phasers under warranty. This way, you will have 0 issues with your 3.5L Ecoboost, as this fix has proven to be pretty thorough.
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