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Home >> Ford >> 2015 >> Explorer Limited, 3.5L Eng VIN 8, AWD >> Repair and Diagnosis >> Engine Mechanical >> Mechanical >> Engine - 3.5L Ti-VCT >> Removal And Installation >> Camshaft >> Installation

Removal And Installation: Camshaft: Installation

    NOTE: Coat the camshafts with clean engine oil prior to installation.
    NOTE: The following steps are for the RH camshafts only.

  1. 1.
    Position the camshafts onto the RH cylinder head in the neutral position as shown.
GFD34517Courtesy of FORD MOTOR COMPANY
    NOTE: 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.

  1. 2.
    Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
GFD34518Courtesy of FORD MOTOR COMPANY
    NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

  1. 3.
    Position the 4 camshaft seals gaps as shown.
GFD34519Courtesy of FORD MOTOR COMPANY
    NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

  1. 4.
    Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown.
    • Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
Fig 1: RH Camshaft Caps Bolts Tightening Sequence
GFD34520Courtesy of FORD MOTOR CO.

  1. 5.

    Loosen the 4 camshaft caps bolts.
GFD34521Courtesy of FORD MOTOR COMPANY

  1. 6.

    Tighten the 4 bolts in the sequence shown.
    • Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
Fig 2: RH Camshaft Caps Bolts Tightening Sequence
GFD34522Courtesy of FORD MOTOR CO.
    NOTE: Use a camshaft sprocket bolt to turn the camshafts.
    NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.

  1. 7.
    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. Refer to Valve Clearance Check .
GFD34409Courtesy of FORD MOTOR COMPANY

  1. 8.

    Remove the 3 bolts and the RH valve train oil tube.
GFD34498Courtesy of FORD MOTOR COMPANY

  1. 9.

    Rotate the RH camshafts to the TDC position as shown.
GFD34523Courtesy of FORD MOTOR COMPANY
    NOTE: The 303-1248 will hold the camshafts in the TDC position.

  1. 10.
    Install 303-1248 onto the flats of the RH camshafts.
GFD34499Courtesy of FORD MOTOR COMPANY

  1. 11.

    Compress the RH secondary timing chain tensioner and install the 303-1530 to retain the tensioner in the collapsed position.
GFD34524Courtesy of FORD MOTOR COMPANY

  1. 12.

    Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
GFD34525Courtesy of FORD MOTOR COMPANY
    NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.

  1. 13.
    Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
GFD34515Courtesy of FORD MOTOR COMPANY

  1. 14.

    Install the 2 new RH VCT bolts and tighten in 4 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 25 Nm (18 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.
GFD34526Courtesy of FORD MOTOR COMPANY
    NOTE: The 2 VCT oil control solenoids are removed for clarity.

  1. 15.
    Compress the RH secondary timing chain tensioner and remove the 303-1530. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
GFD34513Courtesy of FORD MOTOR COMPANY
    NOTE: Coat the camshafts with clean engine oil prior to installation.
    NOTE: The following steps are for the Left Hand (LH) camshafts only.

  1. 16.
    Position the camshafts onto the LH cylinder head in the neutral position as shown.
GFD34527Courtesy of FORD MOTOR COMPANY
    NOTE: 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.

  1. 17.
    Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
GFD34518Courtesy of FORD MOTOR COMPANY
    NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

  1. 18.
    Position the 4 camshaft seals gaps as shown.
GFD34528Courtesy of FORD MOTOR COMPANY
    NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

  1. 19.
    Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown.
    • Tighten to 8 Nm (71 lb-in) then an additional 45 degrees.
Fig 3: LH Camshaft Caps Bolts Tightening Sequence
GFD34529Courtesy of FORD MOTOR CO.

  1. 20.

    Loosen the 4 camshaft caps bolts.
GFD34530Courtesy of FORD MOTOR COMPANY

  1. 21.

    Tighten the 4 bolts in the sequence shown.
    • Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
Fig 4: LH Camshaft Caps Bolts Tightening Sequence
GFD34531Courtesy of FORD MOTOR CO.
    NOTE: Use a camshaft sprocket bolt to turn the camshafts.
    NOTE: If any components are installed new, the engine valve clearance must be checked/adjusted or engine damage may occur.

  1. 22.
    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. Refer to Valve Clearance Check .
GFD34409Courtesy of FORD MOTOR COMPANY

  1. 23.

    Remove the 3 bolts and the LH valve train oil tube.
GFD34496Courtesy of FORD MOTOR COMPANY

  1. 24.

    Rotate the LH camshafts to the TDC position as shown.
GFD34532Courtesy of FORD MOTOR COMPANY
    NOTE: The 303-1248 will hold the camshafts in the TDC position.

  1. 25.
    Install 303-1248 onto the flats of the LH camshafts.
GFD34497Courtesy of FORD MOTOR COMPANY

  1. 26.

    Compress the LH secondary timing chain tensioner and install the 303-1530 to retain the tensioner in the collapsed position.
GFD34533Courtesy of FORD MOTOR COMPANY

  1. 27.

    Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.
GFD34534Courtesy of FORD MOTOR COMPANY
    NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.

  1. 28.
    Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
GFD34511Courtesy of FORD MOTOR COMPANY

  1. 29.

    Install the 2 new LH VCT bolts and tighten in 4 stages.
    • Stage 1: Tighten to 40 Nm (30 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 25 Nm (18 lb-ft).
    • Stage 4: Tighten an additional 180 degrees.
GFD34510Courtesy of FORD MOTOR COMPANY
    NOTE: The 2 VCT oil control solenoids are removed for clarity.

  1. 30.
    Compress the LH secondary timing chain tensioner and remove the 303-1530. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
GFD34509Courtesy of FORD MOTOR COMPANY

  1. 31.

    Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the TDC position (crankshaft dowel pin at 11 o'clock).
GFD34535Courtesy of FORD MOTOR COMPANY
    NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.

  1. 32.
    Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
GFD34536Courtesy of FORD MOTOR COMPANY

  1. 33.

    Install the 2 bolts and the lower LH primary timing chain guide.
    • Tighten to 10 Nm (89 lb-in).
GFD34505Courtesy of FORD MOTOR COMPANY

  1. 34.

    Install the primary timing chain tensioner arm.
GFD34504Courtesy of FORD MOTOR COMPANY

  1. 35.

    Reset the primary timing chain tensioner.
    • Release the ratchet detent.
    • Using a soft-jawed vise, compress the ratchet plunger.
    • Align the hole in the ratchet plunger with the hole in the tensioner housing.
    • Install a suitable lockpin.
GFD34537Courtesy of FORD MOTOR COMPANY
    NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.

  1. 36.
    Install the 2 bolts and the primary timing chain tensioner.
    • Tighten to 10 Nm (89 lb-in) and remove the lock pin.
GFD34538Courtesy of FORD MOTOR COMPANY

  1. 37.

    As a post-check, verify correct alignment of all timing marks.
    • There are 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
    • There are 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
GFD34539Courtesy of FORD MOTOR COMPANY
    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
    NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
    NOTE: Do not use excessive force when installing the VCT oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT 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.

  1. 38.
    Install the LH intake VCT oil control solenoid and the bolt.
    • Tighten to 8 Nm (71 lb-in).
GFD34506Courtesy of FORD MOTOR COMPANY
    NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
    NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
    NOTE: Do not use excessive force when installing the VCT oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the bore and VCT 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.

  1. 39.
    Install the LH intake VCT oil control solenoid and the bolt.
    • Tighten to 8 Nm (71 lb-in).
GFD34507Courtesy of FORD MOTOR COMPANY

  1. 40.

    Remove the RH 303-1248.
GFD34499Courtesy of FORD MOTOR COMPANY

  1. 41.

    Install the RH 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.
GFD34498Courtesy of FORD MOTOR COMPANY

  1. 42.

    Remove the LH 303-1248.
GFD34497Courtesy of FORD MOTOR COMPANY

  1. 43.

    Install the LH 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.
GFD34496Courtesy of FORD MOTOR COMPANY
    NOTE: Only use a 3M Roloc ® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean front cover.

  1. 44.
    Clean the engine front cover using a 3M Roloc ® Bristle Disk (2-in white, part number 07528) in a suitable tool turning at the recommended speed of 15, 000 RPM. Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles created during the cleaning process.
    NOTE: Do not use wire brushes, power abrasive discs or 3M Roloc ® 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.
    NOTE: 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.

  1. 45.
    Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.
    • Remove any large deposits of silicone or gasket material.
    • Apply Motorcraft ®Silicone Gasket Remover and allow to set for several minutes.
    • Remove the Motorcraft ®Silicone Gasket Remover. A second application of Motorcraft ®Silicone Gasket Remover may be required if residual traces of silicone or gasket material remain.
    • Apply Motorcraft ® 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.
    NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

  1. 46.
    Install 307-399
GFD34540Courtesy of FORD MOTOR COMPANY
    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 ®Silicone Gasket Remover and Motorcraft ® Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.
    NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

  1. 47.
    Apply a 3 mm (0.1181 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the sealing surface of the front cover.
    • Apply a 5.5 mm (0.22 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.
GFD34541Courtesy of FORD MOTOR COMPANY
    NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

  1. 48.
    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).
Fig 5: Engine Front Cover Bolts Tightening Sequence
GFD34542Courtesy of FORD MOTOR CO.

  1. 49.

    Remove 307-399.
GFD34543Courtesy of FORD MOTOR COMPANY

  1. 50.

    Install the M6 engine front cover bolt.
    • Do not tighten at this time.
GFD34493Courtesy of FORD MOTOR COMPANY

  1. 51.

    Install the 3 upper M10 engine front cover bolts.
    • Do not tighten the bolts at this time.
GFD34544Courtesy of FORD MOTOR COMPANY

  1. 52.

    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.
Fig 6: Engine Front Cover Bolts Tightening Sequence
GFD34545Courtesy of FORD MOTOR CO.
    NOTE: Installation of new seals is only required if damaged seals were removed.

  1. 53.
    Using 303-1247/2 and 205-153 T80T-4000-W install the new spark plug tube seal(s).
GFD34546Courtesy of FORD MOTOR COMPANY
    NOTE: Installation of new seals is only required if damaged seals were removed.

  1. 54.
    Using 205-142 T80T-4000-J and 205-153 T80T-4000-W install the new VCT seal(s).
GFD34547Courtesy of FORD MOTOR COMPANY
    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 ®Silicone Gasket Remover and Motorcraft ® Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.
    NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

  1. 55.
    Apply an 8 mm (0.315 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-Right Hand (RH) cylinder head joints.
GFD34548Courtesy of FORD MOTOR COMPANY

  1. 56.

    Using a new gasket, install the RH valve cover and tighten the 11 retainers.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 7: RH Valve Cover Retainers Tightening Sequence
GFD34549Courtesy of FORD MOTOR CO.

  1. 57.

    Ensure the VCT seals in the valve cover are below the top of the connector (flat portion) on the VCT oil control valve otherwise the interface may leak.
GFD34550Courtesy of FORD MOTOR COMPANY

  1. 58.

    Install the engine wiring harness to the RH valve cover.
    • Position the wiring harness and attach the 9 wiring harness retainers to the RH valve cover and stud bolts.
    • Connect the CHT sensor wiring harness jumper electrical connector.
    • Connect the 3 fuel injector electrical connectors.
    • Connect and attach the RH CMS electrical connector.
    • Connect the 2 VCT oil control solenoid electrical connectors.
GFD34486Courtesy of FORD MOTOR COMPANY

  1. 59.

    Install the PCV crankcase vent tube.
GFD34485Courtesy of FORD MOTOR COMPANY
    NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before attaching to the spark plugs.

  1. 60.
    Install the 3 RH -coil-on-plugs and the 3 bolts.
    • Tighten to 7 Nm (62 lb-in).
    • Connect the 3 coil-on-plug electrical connectors.
GFD34484Courtesy of FORD MOTOR COMPANY

  1. 61.

    Using a new gasket, install the intake manifold and the 7 bolts and tighten in the sequence shown in 2 stages.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
Fig 8: Intake Manifold Bolts Tightening Sequence
GFD34551Courtesy of FORD MOTOR CO.

  1. 62.

    Install the upper intake manifold support bolt.
    • Tighten to 10 Nm (89 lb-in).
GFD34482Courtesy of FORD MOTOR COMPANY

  1. 63.

    Attach the 2 coolant tube retainers to the upper intake manifold.
GFD34481Courtesy of FORD MOTOR COMPANY

  1. 64.

    Connect the crankcase ventilation hose to the upper intake manifold.
GFD34480Courtesy of FORD MOTOR COMPANY

  1. 65.

    Connect the EVAP vapor tube to the EVAP canister purge valve. REFER TO FUEL SYSTEM GENERAL INFORMATION .
    • Attach the EVAP vapor tube to the 2 retainers.
GFD34479Courtesy of FORD MOTOR COMPANY

  1. 66.

    Connect the EVAP canister purge valve and throttle body electrical connectors.
    • Attach the wiring harness pin-type retainer to the upper intake manifold.
GFD34478Courtesy of FORD MOTOR COMPANY
    NOTE: Installation of new seals is only required if damaged seals were removed.

  1. 67.
    Using 303-1247/2 and 205-153 T80T-4000-W install the new spark plug tube seal(s).
GFD34552Courtesy of FORD MOTOR COMPANY
    NOTE: Installation of new seals is only required if damaged seals were removed.

  1. 68.
    Using 205-142 T80T-4000-J and 205-153 T80T-4000-W install the new VCT seal(s).
GFD34553Courtesy of FORD MOTOR COMPANY
    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 ®Silicone Gasket Remover and Motorcraft ® Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.
    NOTE: Failure to use Motorcraft ® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

  1. 69.
    Apply an 8 mm (0.315 in) bead of Motorcraft ® High Performance Engine RTV Silicone to the engine front cover-to-Left Hand (LH) cylinder head joints.
GFD34554Courtesy of FORD MOTOR COMPANY

  1. 70.

    Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
Fig 9: LH Valve Cover Retainers Tightening Sequence
GFD34555Courtesy of FORD MOTOR CO.

  1. 71.

    Ensure the VCT seals in the valve cover are below the top of the connector (flat portion) on the VCT oil control valve otherwise the interface may leak.
GFD34550Courtesy of FORD MOTOR COMPANY

  1. 72.

    Install the engine wiring harness to the LH valve cover.
    • Position the wiring harness and attach the 11 wiring harness retainers to the LH valve cover and stud bolts.
    • Connect the 3 fuel injector electrical connectors.
    • Connect and attach the LH HO2S electrical connector.
    • Connect the 2 VCT oil control solenoid electrical connectors.
GFD34474Courtesy of FORD MOTOR COMPANY

  1. 73.

    Install the ground wire bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).
GFD34473Courtesy of FORD MOTOR COMPANY

  1. 74.

    Install the LH ignition coils.
    • Tighten to 7 Nm (62 lb-in).
    • Connect the 3 coil-on-plug electrical connectors.
GFD34471Courtesy of FORD MOTOR COMPANY

  1. 75.

    Install the oil level indicator.
GFD34472Courtesy of FORD MOTOR COMPANY

  1. 76.

    Connect the crankcase vent tube to the LH valve cover.
GFD34470Courtesy of FORD MOTOR COMPANY

  1. 77.

    Install a new crankshaft front seal. Refer to CRANKSHAFT FRONT SEAL .

  1. 78.

    Install the accessory drive belt tensioner.
    • Tighten to 11 Nm (97 lb-in).
GFD34469Courtesy of FORD MOTOR COMPANY

  1. 79.

    Raise the subframe and powertrain assembly into the vehicle.

  1. 80.

    Install the engine mount, the 3 bolts and the 4 engine mount nuts hand tight.
    • Tighten the 3 engine mount bolts to 90 Nm (66 lb-ft).
    • Tighten the 4 engine mount nuts to 63 Nm (46 lb-ft).
GFD34465Courtesy of FORD MOTOR COMPANY

  1. 81.

    Install the transaxle support insulator assembly the 3 nuts and the bolt.
    • Tighten the nuts to 63 Nm (46 lb-ft).
    • Tighten the bolt to 80 Nm (59 lb-ft).
GFD34464Courtesy of FORD MOTOR COMPANY

  1. 82.

    Install the 4 transmission support insulator-to-frame rail bolts.
    • Tighten the 2 bottom bolts to 55 Nm (41 lb-ft).
    • Tighten the 2 top bolts to 70 Nm (52 lb-ft).
GFD34463Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 83.
    Align the subframe and install the new front subframe bolts.
    • Tighten to 200 Nm (148 lb-ft).
GFD34556Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 84.
    Install the rear subframe brackets and the new subframe bracket-to-body bolts.
    • Finger tight at this stage.
GFD34557Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 85.
    Install the new subframe bracket bolts.
    • Tighten to 150 Nm (111 lb-ft).
GFD34558Courtesy of FORD MOTOR COMPANY
    NOTE: RH shown, LH similar.

  1. 86.
    Tighten the subframe bracket-to-body bolts to 55 Nm (41 lb-ft).
GFD34559Courtesy of FORD MOTOR COMPANY

  1. 87.

    Remove the ratchet strap from the front of the subframe to the rear of the subframe.

  1. 88.

    Remove the Adjustable Grip Arm and the powertrain lift table.
GFD34461Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 89.
    Install the strut to the wheel knuckle and install the strut-to-wheel knuckle nuts and bolts.
    • Tighten to 250 Nm (184 lb-ft).
GFD34462Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 90.
    Install the brake caliper and the guide pin bolts.
    • 432 mm (17 in) brakes: Tighten to 72 Nm (53 lb-ft).
    • 457 mm (18 in) brakes: Tighten to 75 Nm (55 lb-ft).
GFD34560Courtesy of FORD MOTOR COMPANY
    NOTE: Apply the brake to keep the halfshaft from rotating.
    NOTE: LH shown, RH similar.
    NOTE: Do not tighten the wheel hub nut with the vehicle on the ground. The nut must be tightened to specification before the vehicle is lowered onto the wheels. Wheel bearing damage will occur if the wheel bearing is loaded with the weight of the vehicle applied.

  1. 91.
    Using the previously removed wheel hub nut, seat the LH and RH halfshafts.
    • Tighten to 350 Nm (258 lb-ft).
    • Remove and discard the wheel hub nuts.
GFD33835Courtesy of FORD MOTOR COMPANY
    NOTE: Apply the brake to keep the halfshaft from rotating.
    NOTE: LH shown, RH similar.
    NOTE: The wheel hub nut contains a one time locking chemical that is activated by the heat created when it is tightened. Install and tighten the new wheel hub nut to specification within 5 minutes of starting it on the threads. Always install a new wheel hub nut after loosening or when not tightened within the specified time or damage to the components can occur.

  1. 92.
    Install a new wheel hub nuts.
    • Tighten to 350 Nm (258 lb-ft).
GFD34459Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 93.
    Install the new upper stabilizer link nut.
    • Tighten to 150 Nm (111 lb-ft).
GFD34561Courtesy of FORD MOTOR COMPANY
    NOTE: LH shown, RH similar.

  1. 94.
    Install the wheel speed sensor and the bolt.
    • Tighten to 15 Nm (133 lb-in).
GFD34455Courtesy of FORD MOTOR COMPANY

  1. 95.

    Connect the transaxle cooler tubes and install the 2 secondary latches.
GFD34453Courtesy of FORD MOTOR COMPANY

  1. 96.

    If equipped, install the oil cooler hose retainer to the subframe.
GFD34452Courtesy of FORD MOTOR COMPANY

  1. 97.

    If equipped, connect the oil cooler coolant hoses.
GFD34451Courtesy of FORD MOTOR COMPANY

  1. 98.

    If equipped, connect the 2 PTU cooler hoses. For additional information, REFER TO FUEL SYSTEM GENERAL INFORMATION .
GFD34450Courtesy of FORD MOTOR COMPANY
    NOTE: Do not lubricate the engine oil filter gasket.

  1. 99.
    Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
GFD34562Courtesy of FORD MOTOR COMPANY

  1. 100.

    If equipped with AWD, line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 new bolts.
    • Tighten to 70 Nm (52 lb-ft).
GFD34563Courtesy of FORD MOTOR COMPANY

  1. 101.

    Install the exhaust Y-pipe. For additional information, REFER to Exhaust System .
    NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring may occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, REFER to Supplemental Restraint System .

  1. 102.
    Align and connect the steering column shaft to the steering gear and install the bolt.
    • Tighten to 20 Nm (177 lb-in).
GFD34564Courtesy of FORD MOTOR COMPANY

  1. 103.

    Install the underbody air duct and the 3 twist lock retainers.
GFD34445Courtesy of FORD MOTOR COMPANY

  1. 104.

    If equipped, attach the engine block heater harness to the radiator support.

  1. 105.

    Connect the transaxle control cable to the shift cable bracket.
GFD34443Courtesy of FORD MOTOR COMPANY

  1. 106.

    Connect the transaxle control cable to the control lever.
GFD34442Courtesy of FORD MOTOR COMPANY

  1. 107.

    Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
GFD34441Courtesy of FORD MOTOR COMPANY

  1. 108.

    Install the ground wire to the RH shock tower and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
GFD34440Courtesy of FORD MOTOR COMPANY

  1. 109.

    Install the engine wiring harness retainer to the bulkhead.
    • Slide the wiring harness in the bulkhead.
    • Make sure the wiring harness retainer tab is below the bulkhead lip.
GFD34565Courtesy of FORD MOTOR COMPANY

  1. 110.

    Connect the engine harness electrical connector.
    • Attach the wiring harness retainer.
GFD34438Courtesy of FORD MOTOR COMPANY

  1. 111.

    Connect the 2 PCM electrical connectors.
GFD34437Courtesy of FORD MOTOR COMPANY

  1. 112.

    Connect the EVAP tube and the fuel supply tube quick connect coupling. REFER to Fuel System General Information .
GFD34436Courtesy of FORD MOTOR COMPANY

  1. 113.

    Connect the brake booster vacuum hose to the upper intake manifold.
GFD34435Courtesy of FORD MOTOR COMPANY

  1. 114.

    Connect the degas bottle coolant hose to the engine coolant tube.
GFD34434Courtesy of FORD MOTOR COMPANY

  1. 115.

    Install the degas bottle. REFER to Engine Cooling .

  1. 116.

    Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
    • Tighten to 15 Nm (133 lb-in).
GFD34433Courtesy of FORD MOTOR COMPANY

  1. 117.

    Connect the A/C pressure switch electrical connector.
GFD34432Courtesy of FORD MOTOR COMPANY

  1. 118.

    Using a new O-ring seal and gasket seal, connect the A/C tube and install the nut.
    • Tighten to 15 Nm (133 lb-in).
GFD34431Courtesy of FORD MOTOR COMPANY

  1. 119.

    Install the accessory drive belt. REFER to Accessory Drive .
    NOTE: RH shown, LH similar.

  1. 120.
    Install the 2 RH and 2 LH lower pin-type retainers for the engine splash shields.
GFD34430Courtesy of FORD MOTOR COMPANY

  1. 121.

    Install the front wheels and tires. REFER to Wheels and Tires .

  1. 122.

    Connect the engine wiring harness electrical connector.
GFD34429Courtesy of FORD MOTOR COMPANY

  1. 123.

    Install the ground wire and install the retainer.
    • Tighten to 10 Nm (89 lb-in).
GFD34428Courtesy of FORD MOTOR COMPANY

  1. 124.

    Install the ground wire and the retainer.
    • Tighten to 10 Nm (89 lb-in).
GFD34427Courtesy of FORD MOTOR COMPANY

  1. 125.

    Connect the 2 battery feed cables to the positive battery terminal and install the nut.
    • Tighten to 5 Nm (44 lb-in).
GFD34426Courtesy of FORD MOTOR COMPANY

  1. 126.

    Install the battery tray. REFER to Battery, Mounting and Cables .

  1. 127.

    Install the engine ACL and ACL outlet pipe. REFER to Intake Air Distribution and Filtering .

  1. 128.

    Install the cowl panel. REFER to Front End Body Panels .

  1. 129.

    Fill the engine with clean engine oil.

  1. 130.

    Fill and bleed the cooling system. REFER to Engine Cooling .

  1. 131.

    Recharge the A/C system. REFER to Climate Control DATC .

  1. 132.

    Perform the Misfire Monitor Neutral Profile Correction procedure, following the on-screen instructions.