Part 2

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.

All camshafts

36. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Using the Crankshaft Vibration Damper Installer and Front Crankshaft Seal Installer, install a new crankshaft front seal.






37. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Using the Crankshaft Vibration Damper Installer and Front Cover Oil Seal Installer, install the crankshaft pulley.






38. Using the Strap Wrench, 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.






39. Install the accessory drive belt tensioner and the 3 bolts.
- Tighten to 11 Nm (97 lb-in).






40. Install the power steering pump and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






41. 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 (Variable Camshaft Timing) seal solenoid installation similar.

Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Installer and Handle, install new VCT (Variable Camshaft Timing) solenoid and/or spark plug tube seals.





42. 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: 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(R) High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.






43. Using a new gasket, install the RH valve cover and tighten the bolt and 8 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






44. 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: 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(R) High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.






45. Using a new gasket, install the LH valve cover and tighten the 9 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






46. Install the engine cover stud to the LH valve cover stud bolt.
- Tighten to 6 Nm (53 lb-in).






47. Install the PSP (Power Steering Pressure) tube bracket and nut to the RH valve cover stud bolt.
- Tighten to 7 Nm (62 lb-in).






48. Install the PSP (Power Steering Pressure) tube bracket bolt.
- Tighten to 10 Nm (89 lb-in).






49. Connect the PSP (Power Steering Pressure) switch electrical connector.





50. NOTE: LH shown, RH similar.
Install the 6 coil-on-plug assemblies and the 6 bolts.

- Tighten to 7 Nm (62 lb-in).






51. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.

52. Connect the 3 LH coil-on-plug electrical connectors.





53. Connect the LH VCT (Variable Camshaft Timing) solenoid electrical connector.





54. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.

55. Connect the 3 RH coil-on-plug electrical connectors.





56. Connect the RH VCT (Variable Camshaft Timing) solenoid electrical connector.





57. Connect the RH CMS (Catalyst Monitor Sensor) electrical connector.





58. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

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 support bracket bolt.
- Tighten to 10 Nm (89 lb-in).






61. Attach the wiring harness retainers to the upper intake manifold.





62. Connect the Throttle Body (TB) electrical connector.





63. Connect the PCV hose to the PCV valve.





64. Raise the engine and transaxle assembly into the vehicle.

65. Install the engine mount and the 3 bolts.
- Tighten to 90 Nm (66 lb-ft).






66. Install the 4 engine mount nuts.
- Tighten to 63 Nm (46 lb-ft).






67. Install the engine mount brace, the nut and the bolt.
- Tighten to 20 Nm (177 lb-in).






68. Install the transaxle support insulator bracket, 3 nuts and the bolt.
- Tighten the transaxle support insulator bracket nuts to 63 Nm (46 lb-ft).

- Tighten the transaxle support insulator bolt to 55 Nm (41 lb-ft).






69. Install the transaxle support insulator through bolt and nut.
- Tighten to 175 Nm (129 lb-ft).






All-Wheel Drive (AWD) vehicles

70. NOTE: A new Power Transfer Unit (PTU) seal must be installed whenever the intermediate shaft is removed.

Install a new PTU (Power Transfer Unit) seal.