Part 1
CamshaftSpecial Tool(s)
Material
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.
CAUTION: 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.
All camshafts
1. CAUTION: 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. CAUTION: The camshafts must remain in the neutral position during removal 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 in the sequence shown to 10 Nm (89 lb-in).
RH camshafts
4. CAUTION: The camshafts must remain in the neutral position during removal 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 in the sequence shown to 10 Nm (89 lb-in).
All camshafts
6. CAUTION: 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.
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 special 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 position and install the special tool on the flats of the camshafts.
13. Assemble the RH VCT 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 position (crankshaft dowel pin at 11 o'clock).
18. Install the primary timing chain with the colored links aligned with the timing marks on the VCT 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.
^ Rotate the lever counterclockwise.
^ Using a soft-jawed vise, compress the plunger.
^ Align the hole in the lever with the hole in the tensioner housing.
^ 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.
24. Install new VCT housing seals.
25. CAUTION: 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 housing and the 3 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).
26. CAUTION: 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 housing and the 3 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).
27. Install the special tools.
28. CAUTION: Failure to use Motorcraft 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 tighten 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 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 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.
29. 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).
30. Remove the special tools (alignment pins).
31. NOTE: Do not tighten the bolts at this time.
Install the engine mount bracket and the 3 bolts.
32. CAUTION: Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
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 (11 lb-ft).
^ 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).
33. Install the 2 engine mount studs.
^ Tighten to 18 Nm (13 lb-ft).
34. Install the engine mount bracket and the 2 bolts.
^ Tighten to 24 Nm (18 lb-ft).
35. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Using the special tools, install a new crankshaft front seal.
36. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the special tools, install the crankshaft pulley.
37. Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
^ Stage 1: Tighten to 120 Nm (89 lb-ft).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees.
38. Install the accessory drive belt tensioner and the 3 bolts.
^ Tighten to 10 Nm (89 lb-in).
39. Install the power steering pump and the 3 bolts.
^ Tighten to 25 Nm (18 lb-ft)...
40. Install the power steering pressure (PSP) tube bracket and nut to the RH valve cover stud bolt.
^ Tighten to 7 Nm (62 lb-in).
41. Install the PSP tube bracket bolt.
^ Tighten to 10 Nm (89 lb-in).
42. Connect the PSP switch electrical connector.
43. NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.
NOTE: Spark plug tube seal installation shown, VCT seal installation similar.
Using the special tools, install new VCT solenoid and/or spark plug tube seals.
44. CAUTION: Failure to use Motorcraft 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 silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
45. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).
46. CAUTION: Failure to use Motorcraft 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 silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
47. Using a new gasket, install the LH valve cover and 11 stud bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).
48. NOTE: LH shown, RH similar.
Install the 6 coil-on-plug assemblies and the 6 bolts.
^ Tighten to 7 Nm (62 lb-in).
49. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
50. Connect the 3 LH coil-on-plug electrical connectors.
51. Connect the LH VCT solenoid electrical connector.
52. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
53. If equipped, connect the heated PCV valve electrical connector.
54. Connect the 3 RH coil-on-plug electrical connectors.
55. Connect the RH VCT solenoid electrical connector.
56. Connect the fuel efficient power steering system solenoid electrical connector.
57. Connect the RH catalyst monitor sensor electrical connector.
58. Using a new gasket, install the upper intake manifold and the 6 bolts.
^ Tighten in the sequence shown to 10 Nm (89 lb-in).
59. Install the fuel tube bracket bolt to the upper intake manifold and install the wiring harness pin-type retainer.
^ Tighten to 6 Nm (53 lb-in).
60. Install the upper intake manifold short support bracket and the bolt.
^ Tighten to 10 Nm (89 lb-in).
61. If equipped, install the upper intake manifold long support bracket and the bolt.
^ Tighten to 10 Nm (89 lb-in).
62. Attach the wiring harness retainers to the upper intake manifold.
63. Connect the throttle body electrical connector.
64. Connect the PCV hose to the PCV valve.
