Removal And Installation: Camshaft: Installation
- 1.
Position the camshafts onto the RH cylinder head in the neutral position as shown.
NOTE:
Coat the camshafts with clean engine oil prior to installation.
NOTE:
The following steps are for the RH camshafts only.
- 2.
Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
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.
- 3.
Position the 4 camshaft seals gaps as shown.
NOTE:
The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
- 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.
NOTE:
Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
- 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.
- 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 .
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.
- 10.
Install 303-1248 onto the flats of the RH camshafts.
NOTE:
The 303-1248 will hold the camshafts in the TDC position.
- 11.
Compress the RH secondary timing chain tensioner and install the 303-1530 to retain the tensioner in the collapsed position.
- 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.
- 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.
NOTE:
It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.
- 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.
- 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.
NOTE:
The 2 VCT oil control solenoids are removed for clarity.
- 16.
Position the camshafts onto the LH cylinder head in the neutral position as shown.
NOTE:
Coat the camshafts with clean engine oil prior to installation.
NOTE:
The following steps are for the Left Hand (LH) camshafts only.
- 17.
Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
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.
- 18.
Position the 4 camshaft seals gaps as shown.
NOTE:
The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
- 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.
NOTE:
Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
- 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.
- 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 .
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.
- 25.
Install 303-1248 onto the flats of the LH camshafts.
NOTE:
The 303-1248 will hold the camshafts in the TDC position.
- 26.
Compress the LH secondary timing chain tensioner and install the 303-1530 to retain the tensioner in the collapsed position.
- 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.
- 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.
NOTE:
It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.
- 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.
- 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.
NOTE:
The 2 VCT oil control solenoids are removed for clarity.
- 31.
Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the TDC position (crankshaft dowel pin at 11 o'clock).
- 32.
Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
NOTE:
It may be necessary to rotate the camshafts slightly, to align the timing marks.
- 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.
- 36.
Install the 2 bolts and the primary timing chain tensioner.- Tighten to 10 Nm (89 lb-in) and remove the lock pin.
NOTE:
It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.
- 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).
- 38.
Install the LH intake VCT oil control solenoid and the bolt.- Tighten to 8 Nm (71 lb-in).
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.
- 39.
Install the LH intake VCT oil control solenoid and the bolt.- Tighten to 8 Nm (71 lb-in).
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.
- 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.
- 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.
- 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:
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.
- 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:
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.
- 46.
Install 307-399
NOTE:
Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
- 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.
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.
- 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).
NOTE:
Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
- 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.
- 53.
Using 303-1247/2 and 205-153 T80T-4000-W install the new spark plug tube seal(s).
NOTE:
Installation of new seals is only required if damaged seals were removed.
- 54.
Using 205-142 T80T-4000-J and 205-153 T80T-4000-W install the new VCT seal(s).
NOTE:
Installation of new seals is only required if damaged seals were removed.
- 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.
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.
- 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).
- 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.
- 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.
- 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.
NOTE:
Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before attaching to the spark plugs.
- 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.
- 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.
- 66.
Connect the EVAP canister purge valve and throttle body electrical connectors.- Attach the wiring harness pin-type retainer to the upper intake manifold.
- 67.
Using 303-1247/2 and 205-153 T80T-4000-W install the new spark plug tube seal(s).
NOTE:
Installation of new seals is only required if damaged seals were removed.
- 68.
Using 205-142 T80T-4000-J and 205-153 T80T-4000-W install the new VCT seal(s).
NOTE:
Installation of new seals is only required if damaged seals were removed.
- 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.
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.
- 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).
- 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.
- 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.
- 74.
Install the LH ignition coils.- Tighten to 7 Nm (62 lb-in).
- Connect the 3 coil-on-plug electrical connectors.
- 77.
Install a new crankshaft front seal. Refer to CRANKSHAFT FRONT SEAL .
- 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).
- 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).
- 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).
- 83.
Align the subframe and install the new front subframe bolts.- Tighten to 200 Nm (148 lb-ft).
NOTE:
RH shown, LH similar.
- 84.
Install the rear subframe brackets and the new subframe bracket-to-body bolts.- Finger tight at this stage.
NOTE:
RH shown, LH similar.
- 85.
Install the new subframe bracket bolts.- Tighten to 150 Nm (111 lb-ft).
NOTE:
RH shown, LH similar.
- 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).
NOTE:
LH shown, RH similar.
- 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).
NOTE:
LH shown, RH similar.
- 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.
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.
- 92.
Install a new wheel hub nuts.- Tighten to 350 Nm (258 lb-ft).
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.
- 93.
Install the new upper stabilizer link nut.- Tighten to 150 Nm (111 lb-ft).
NOTE:
LH shown, RH similar.
- 94.
Install the wheel speed sensor and the bolt.- Tighten to 15 Nm (133 lb-in).
NOTE:
LH shown, RH similar.
- 98.
If equipped, connect the 2 PTU cooler hoses. For additional information, REFER TO FUEL SYSTEM GENERAL INFORMATION .
- 99.
Install a new engine oil filter.- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
NOTE:
Do not lubricate the engine oil filter gasket.
- 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).
- 101.
Install the exhaust Y-pipe. For additional information, REFER to Exhaust System .
- 102.
Align and connect the steering column shaft to the steering gear and install the bolt.- Tighten to 20 Nm (177 lb-in).
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
.
- 107.
Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
- 108.
Install the ground wire to the RH shock tower and install the bolt.- Tighten to 10 Nm (89 lb-in).
- 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.
- 112.
Connect the EVAP tube and the fuel supply tube quick connect coupling. REFER to Fuel System General Information .
- 115.
Install the degas bottle. REFER to Engine Cooling .
- 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).
- 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).
- 119.
Install the accessory drive belt. REFER to Accessory Drive .
- 120.
Install the 2 RH and 2 LH lower pin-type retainers for the engine splash shields.
NOTE:
RH shown, LH similar.
- 121.
Install the front wheels and tires. REFER to Wheels and Tires .
- 125.
Connect the 2 battery feed cables to the positive battery terminal and install the nut.- Tighten to 5 Nm (44 lb-in).
- 126.
Install the battery tray. REFER to Battery, Mounting and Cables .
- 127.
Install the engine ACL and ACL outlet pipe. REFER to Intake Air Distribution and Filtering .
- 128.
Install the cowl panel. REFER to Front End Body Panels .
- 130.
Fill and bleed the cooling system. REFER to Engine Cooling .
- 131.
Recharge the A/C system. REFER to Climate Control DATC .











































































































