Installation
1. Clean and inspect valve cover, engine front cover and cylinder head sealing surfaces.2. Position camshaft on cylinder head. Apply oil to journals and lobes of camshaft.
NOTE: Steps 2 through 11 will install only one camshaft. If both camshafts are being serviced, repeat Steps 2 through 11 to install the other camshaft.
3. Install and seat camshaft bearing caps. Hand-start 14 bolts.
4. Tighten camshaft bearing cap retaining bolts in sequence to 8-12 Nm (71-106 inch lbs.).
NOTE: Each camshaft bearing cap is tightened individually.
5. Loosen 14 camshaft bearing cap retaining bolts approximately two turns or until head of bolt is free.
6. Retighten all bolts in sequence to 8-12 Nm (71-106 inch lbs.).
NOTE: Camshaft should turn freely with a slight drag.
7. Check camshaft end play using Rotunda Dial Indicator with Bracketry 014-00282 or equivalent.
8. If necessary, install Cam Positioning Tool Adapters T92P-6256-A and Cam Positioning Tool T91P-6256-A on flats of camshaft and install camshaft sprocket spacer (6265) and camshaft sprocket (6256). Install bolt and washer and tighten to 110-130 Nm (82-95 ft. lbs.).
9. Install Valve Spring Compressor T91P-6565-A under camshaft and on top of valve spring, retainer. Install valve tappet (6500).
NOTE: Valve Spring Spacer T91P-6565-AH must be installed between valve spring coils and the camshaft MUST be at base circle prior to compressing valve spring. Rotate camshaft as necessary until all rocker arms are installed.
10. Compress valve spring far enough to install rocker arm.
11. Repeat Steps 8 through 10 until all rocker arms are installed. Remove Valve Spring Spacer from valve spring.
12. Rotate crankshaft clockwise 45 degrees.
CAUTION: Crankshaft must only be rotated in the clockwise direction and only as far as top dead center (TDC).
NOTE: This will position crankshaft at top dead center (TDC).
13. Install timing chains.
CAUTION: Timing chain procedures must be followed exactly or damage to valves or pistons will result.
14. Inspect and replace crankshaft front seal (6700) and engine front cover as necessary.
15. Apply a 8-12 mm (0.32-0.47 inch) bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 in locations shown.
NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residue that may interfere with the sealer's ability to adhere.
16. Install the engine front cover.
17. Position and, using Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6, secure gaskets into valve covers.
18. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 at both places engine front cover meets cylinder head.
NOTE:
^ Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residue that may interfere with the sealer's ability to adhere.
^ Install valve covers and retainers no more than four minutes after applying sealer.
19. Install RH valve cover, bolts and stud bolts. Tighten to 8-12 Nm (71-106 inch lbs.) in no more than four minutes after applying sealer.
20. Install LH valve cover, bolts and stud bolts. Tighten to 8-12 Nm (71-106 inch lbs.) in no more than four minutes after applying sealer.
21. Raise vehicle.
22. Connect the fuel charging wiring to the electronic variable orifice sensor and oil pressure sensor.
Crankshaft Pulley Keyway Silicone Gasket Sealant Application Locations:
23. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 in keyway of crankshaft pulley as shown.
NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residue that may interfere with the sealer's ability to adhere.
24. Position crankshaft pulley on crankshaft. Make sure crankshaft key and keyway are aligned.
25. Using Crankshaft Damper Replacer T74P-6316-B, install crankshaft pulley.
26. Install crankshaft pulley bolt and crankshaft pulley retaining washer. Tighten in four steps:
a. Tighten to 90 Nm (67 ft. lbs.).
b. Loosen one full turn.
c. Tighten to 50 Nm (37 ft. lbs.).
d. Tighten an additional 90 degrees.
27. Install oil pan with new oil pan gasket.
28. Position power steering pump on engine and install four retaining bolts. Tighten to 20-30 Nm (15-22 ft. lbs.).
29. Lower vehicle.
30. Connect fuel charging wiring to the A/C clutch, crankshaft position sensor and evaporative emission canister purge valves.
31. Position and connect 42-pin engine harness connector and 8-pin connector.
32. Position A/C line and install retaining nut.
33. Install positive crankcase ventilation valve in RH valve cover.
34. Connect vent hose to evaporative emission canister purge valve.
35. Install water pump pulley and tighten bolts to 20-30 Nm (15-22 ft. lbs.).
36. Position RH ignition coil bracket, ignition wires and ignition wire separators onto mounting studs.
37. Install three nuts retaining ignition coil bracket to engine front cover. Tighten to 20-30 Nm (15-22 ft. lbs.).
38. Install LH ignition coil bracket. Tighten nuts to 20-30 Nm (15-22 ft. lbs.).
39. Install LH ignition coil and ignition wires as an assembly.
40. Position and install power steering oil reservoir.
41. Connect both ignition coils and camshaft position sensor.
42. Connect ignition wires to spark plugs and install brackets onto valve cover studs.
43. Install drive belt.
44. Connect fuel lines.
45. Install cooling fan motor/fan blade and fan shroud assembly. Fill cooling system.
46. Install air cleaner outlet tube.
47. Connect battery ground cable.
48. Start engine and check for leaks.
49. Check and add oil as needed.