Part 3

Engine

Special Tool(s)














Material(s)






85. Reset the primary timing chain tensioner.

1. Release the ratchet detent.

2. Using a soft-jawed vise, compress the ratchet plunger.

3. Align the hole in the ratchet plunger with the hole in the tensioner housing.

4. Install a suitable lockpin.






86. NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.
Install the primary tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Remove the lockpin.





87. As a post-check, verify correct alignment of all timing marks.

1. There are 48 links in between the RH (Right Hand) intake VCT (Variable Camshaft Timing) assembly colored link (1) and the LH (Left Hand) intake VCT (Variable Camshaft Timing) assembly colored link (2).

2. There are 35 links in between LH (Left Hand) intake VCT (Variable Camshaft Timing) assembly colored link (2) and the 2 crankshaft sprocket links (3).






88. NOTICE: Do not use excessive force when installing the VCT (Variable Camshaft Timing) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT (Variable Camshaft Timing) oil control solenoid, inspect the bore and VCT (Variable Camshaft Timing) oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.

NOTE: A slight twisting motion will aid in the installation of the VCT (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.
Install the LH (Left Hand) intake VCT (Variable Camshaft Timing) oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.





89. NOTICE: Do not use excessive force when installing the VCT (Variable Camshaft Timing) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT (Variable Camshaft Timing) oil control solenoid, inspect the bore and VCT (Variable Camshaft Timing) oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the mating surface. Only clean the external surfaces as necessary.

NOTE: A slight twisting motion will aid in the installation of the VCT (Variable Camshaft Timing) oil control solenoid.

NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.
Install the RH (Right Hand) intake VCT (Variable Camshaft Timing) oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.





90. Remove the RH (Right Hand)303-1248.





91. Install the RH (Right Hand) valve train oil tube and the 3 bolts and tighten in 2 stages.
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.





92. Remove the LH (Left Hand)303-1248.





93. Install the LH (Left Hand) valve train oil tube and the 3 bolts and tighten in 2 stages.
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.





94. NOTICE: 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.

NOTICE: Do not use wire brushes, power abrasive discs or 3M Roloc(R) Bristle Disk (2-in white part number 07528) to clean the sealing surfaces of engine block, cylinder heads, and oil pan. These tools can cause contamination that will cause premature engine failure. Remove all traces of the gasket.

Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.

1. Remove any large deposits of silicone or gasket material.

2. Apply Motorcraft(R) Silicone Gasket Remover and allow to set for several minutes.

3. Remove the Motorcraft(R) Silicone Gasket Remover. A second application of Motorcraft(R) Silicone Gasket Remover may be required if residual traces of silicone or gasket material remain.

4. Apply Motorcraft(R) 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.

95. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install 307-399.





96. NOTICE: Failure to use Motorcraft(R) High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: The engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts must be installed and tightened within 35 minutes of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant reapplied. To clean the sealing area, use Motorcraft(R) Silicone Gasket Remover and Motorcraft(R) Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.

Apply a 3 mm (0.1181 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the sealing surface of the front cover.

- Apply a 5.5 mm (0.22 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the oil pan-to-cylinder block joint and the cylinder head-to-cylinder block joint areas of the engine front cover in 5 places as indicated.






97. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22.
- Tighten in sequence shown to 3 Nm (27 lb-in).





98. Remove 307-399.





99. Install the M6 engine front cover bolt. Do not tighten at this time.





100. Install the 2 upper M10 engine front cover bolts. Do not tighten the bolts at this time.





101. Install the lower M10 bolt. Do not tighten at this time.





102. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts in the sequence shown in 7 stages.
- Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in).
- Stage 2: Tighten bolts 23 thru 25 to 15 Nm (133 lb-in).
- Stage 3: Tighten bolt 26 to 10 Nm (89 lb-in).
- Stage 4: Loosen bolt 26 one full turn.
- Stage 5: Tighten bolts 23 thru 25 to 30 Nm (22 lb-ft) plus an additional 90 degrees.
- Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lb-in) plus an additional 45 degrees.
- Stage 7: Tighten bolt 26 to 10 Nm (89 lb-in) plus an additional 45 degrees.





103. NOTE: Installation of new seals is only required if damaged seals were removed.
Using 303-1247/2 and 205-153 (T80T-4000-W) install the new spark plug tube seal(s).





104. NOTE: Installation of new seals is only required if damaged seals were removed.
Using 205-142 (T80T-4000-J) and 205-153 (T80T-4000-W) install the new VCT (Variable Camshaft Timing) seal(s).





105. NOTICE: Failure to use Motorcraft(R) High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Motorcraft(R) Silicone Gasket Remover and Motorcraft(R) Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.315 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the engine front cover-to- RH (Right Hand) cylinder head joints.





106. Using a new gasket, install the RH (Right Hand) valve cover and tighten the 3 bolts and 8 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).





107. Make sure the VCT (Variable Camshaft Timing) seals in the valve cover are below the top of the VCT (Variable Camshaft Timing) oil control solenoid electrical connector or the VCT (Variable Camshaft Timing) seal may leak oil.





108. Install the 3 RH (Right Hand) coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).





109. NOTE: Installation of new seals is only required if damaged seals were removed.
Using 303-1247/2 and 205-153 (T80T-4000-W) install the new spark plug tube seal(s).





110. NOTE: Installation of new seals is only required if damaged seals were removed.
Using 205-142 (T80T-4000-J) and 205-153 (T80T-4000-W) install the new VCT (Variable Camshaft Timing) seal(s).





111. NOTICE: Failure to use Motorcraft(R) High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

NOTE: If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Motorcraft(R) Silicone Gasket Remover and Motorcraft(R) Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.

Apply an 8 mm (0.315 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the engine front cover-to- LH (Left Hand) cylinder head joints.





112. Using a new gasket, install the LH (Left Hand) valve cover and tighten the 4 bolts and 7 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).





113. Make sure the VCT (Variable Camshaft Timing) seals in the valve cover are below the top of the VCT (Variable Camshaft Timing) oil control solenoid electrical connector or the VCT (Variable Camshaft Timing) seal may leak oil.





114. Install the 3 LH (Left Hand) coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).





115. NOTE: Engine without oil cooler shown, engine with oil cooler similar.
Using a new gasket, install the oil filter adapter and the 3 bolts.
- Tighten to 10 Nm (89 lb-in).





116. NOTICE: A new oil cooler must be installed or severe damage to the engine may occur.

If equipped, install a new oil cooler, new gaskets and the 6 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).





117. NOTE: Apply Thread Sealant with PTFE to the EOP (Engine Oil Pressure) switch threads.
Install the EOP (Engine Oil Pressure) switch.
- Tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.





118. Install the CKP (Crankshaft Position) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).





119. Install and connect the CHT (Cylinder Head Temperature) sensor jumper harness.