Part 1

Camshaft














Installation

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.

NOTICE: 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.

NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.

All camshafts

1. NOTICE: The crankshaft must remain in the freewheeling position (crankshaft dowel pin at 9 o'clock) until after the camshafts are installed and the valve clearance is checked/adjusted. Do not turn the crankshaft until instructed to do so. Failure to follow this process will result in severe engine damage.

Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.






LH camshafts

2. NOTICE: The camshafts must remain in the neutral position during installation or engine damage may occur.

NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the LH cylinder head in the neutral position as shown.






3. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown in the following stages:

- Stage 1: Tighten bolts 1, 2, 3 and 4 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 2: Tighten bolts 5 and 6 to 8 Nm (71 lb-in).

- Stage 3: Tighten bolts 7 and 8 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 4: Loosen bolts 5 and 6.
- Tighten bolts 5 and 6 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 5: Tighten bolts 9, 10, 11 and 12 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 6: Tighten bolts 13 and 14 to 8 Nm (71 lb-in).

- Stage 7: Tighten bolts 15 and 16 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 8: Loosen bolts 13 and 14.
- Tighten bolts 13 and 14 to 8 Nm (71 lb-in) then an additional 45 degrees.






RH camshafts

4. NOTICE: The camshafts must remain in the neutral position during installation or engine damage may occur.

NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the RH cylinder head in the neutral position as shown.






5. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown in the following stages:

- Stage 1: Tighten bolts 1, 2, 3 and 4 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 2: Tighten bolts 5 and 6 to 8 Nm (71 lb-in).

- Stage 3: Tighten bolts 7 and 8 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 4: Loosen bolts 5 and 6.
- Tighten bolts 5 and 6 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 5: Tighten bolts 9, 10, 11 and 12 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 6: Tighten bolts 13 and 14 to 8 Nm (71 lb-in).

- Stage 7: Tighten bolts 15 and 16 to 8 Nm (71 lb-in) then an additional 45 degrees.

- Stage 8: Loosen bolts 13 and 14.
- Tighten bolts 13 and 14 to 8 Nm (71 lb-in) then an additional 45 degrees.






All camshafts

6. NOTICE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.

NOTE: Use a camshaft sprocket bolt to turn the camshafts.

Using a feeler gauge, confirm that the valve tappet clearances are within specification. If valve tappet clearances are not within specification, the clearance must be adjusted by installing new valve tappet(s) of the correct size. For additional information, refer to Valve Clearance Check Adjustments.





LH camshafts

7. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Rotate the LH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.






8. Assemble the LH Variable Camshaft Timing (VCT) assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
- Align the colored links with the timing marks.






9. Position the LH secondary timing assembly onto the camshafts.





10. Install 2 new bolts and the original washer. Tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 10 Nm (89 lb-in).

- Stage 4: Tighten 90 degrees.






11. Remove the lockpin from the LH secondary timing chain tensioner.





RH camshafts

12. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Rotate the RH camshafts to the TDC (Top Dead Center) position and install the Camshaft Holding Tool on the flats of the camshafts.






13. Assemble the RH VCT (Variable Camshaft Timing) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
- Align the colored links with the timing marks.






14. Position the RH secondary timing assembly onto the camshafts.





15. Install 2 new bolts and the original washer. Tighten in 4 stages.
- Stage 1: Tighten to 40 Nm (30 lb-ft).

- Stage 2: Loosen one full turn.

- Stage 3: Tighten to 10 Nm (89 lb-in).

- Stage 4: Tighten 90 degrees.






16. Remove the lockpin from the RH secondary timing chain tensioner.





All camshafts

17. Rotate the crankshaft clockwise 60 degrees to the TDC (Top Dead Center) position (crankshaft dowel pin at 11 o'clock).





18. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Install the primary timing chain with the colored links aligned with the timing marks on the VCT (Variable Camshaft Timing) assemblies and the crankshaft sprocket.






19. Install the lower LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).






20. Install the primary timing chain tensioner arm.





21. 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 and install a suitable lockpin.






22. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
Install the primary tensioner and the 2 bolts.

- Tighten to 10 Nm (89 lb-in).

- Remove the lockpin.






23. As a post-check, verify correct alignment of all timing marks.
- There are 48 links between the RH intake VCT (Variable Camshaft Timing) assembly colored link (1) and the LH intake VCT (Variable Camshaft Timing) assembly colored link (2).

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






24. Inspect the VCT (Variable Camshaft Timing) housing seals for damage and replace as necessary.





25. NOTE: RH shown, LH similar.

NOTE: During removal, the O-ring seal may remain on the cylinder head. If so, remove the O-ring seal from the cylinder head, inspect the seal (replace as necessary) and install the O-ring seal on the VCT (Variable Camshaft Timing) housing.
Inspect the VCT (Variable Camshaft Timing) housing-to-cylinder head O-ring seals for damage and replace as necessary.






26. NOTICE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.

Install the LH VCT (Variable Camshaft Timing) housing and the 3 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






27. NOTICE: Make sure the dowels on the Variable Camshaft Timing (VCT) housing are fully engaged in the cylinder head prior to tightening the bolts. Failure to follow this process will result in severe engine damage.

Install the RH VCT (Variable Camshaft Timing) housing and the 3 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






28. Install the Alignment Pins.





29. 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 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket 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 silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply a 3.0 mm (0.11 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
- Apply a 5.5 mm (0.21 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.






30. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and bolts 17, 18, 19 and 20.

- Tighten in sequence shown to 3 Nm (27 lb-in).






31. Remove the Alignment Pins.





32. NOTE: Do not tighten the bolts at this time.
Install the engine mount bracket and the 3 bolts.






33. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown in 2 stages:
- Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (133 lb-in).

- Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).






34. NOTICE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.

Install the engine mount studs in the following sequence.
1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.

2. Clean all the thread sealer from the engine mount studs (old and new studs).

3. Apply new Threadlock and Sealer to the engine mount stud threads.

4. Install the 2 engine mount studs.
- Tighten to 20 Nm (177 lb-in).






35. Install the Heated Oxygen Sensor (HO2S) connector bracket and stud bolt to the engine front cover.
- Tighten to 10 Nm (89 lb-in).