Section 1957 (Engine Mechanical - 3.5L): Installation: Camshaft: Material

All camshafts 

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.
Fig 1: Locating Crankshaft Dowel Pin
Courtesy of FORD MOTOR CO.
1. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.

   LH camshafts 

NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur.
NOTE: Coat the camshafts with clean engine oil prior to installation.
Fig 2: Identifying LH Camshafts Neutral Position
Courtesy of FORD MOTOR CO.
2. Position the camshafts onto the LH cylinder head in the neutral position as shown in illustration.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
3. Install the 8 camshaft caps and the 16 bolts.
   • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
     Fig 3: Identifying Camshaft Caps Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.

   RH camshafts 

NOTE: The camshafts must remain in the neutral position during installation or engine damage may occur.
NOTE: Coat the camshafts with clean engine oil prior to installation.
Fig 4: Identifying Camshafts Neutral Position
Courtesy of FORD MOTOR CO.
4. Position the camshafts onto the RH cylinder head in the neutral position as shown in illustration.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
5. Install the 8 camshaft caps and the 16 bolts.
   • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
     Fig 5: Identifying Camshaft Caps Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.

   All camshafts 

NOTE: 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.
Fig 6: Checking Valve Tappet Clearances
Courtesy of FORD MOTOR CO.
6. 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. For additional information, refer to VALVE CLEARANCE CHECK .

   LH camshafts 

NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Fig 7: Installing Camshaft Holding Tool On Flats Of Camshafts
Courtesy of FORD MOTOR CO.
7. Rotate the LH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding 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.
     Fig 8: Aligning Colored Links With Timing Marks

     Courtesy of FORD MOTOR CO.
9. Position the LH secondary timing assembly onto the camshafts.
   Fig 9: Locating LH Secondary Timing Assembly

   Courtesy of FORD MOTOR CO.
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.
      Fig 10: Locating Secondary Timing Chain And LH Exhaust Camshaft Sprocket

      Courtesy of FORD MOTOR CO.
11. Remove the lockpin from the LH secondary timing chain tensioner.
    Fig 11: Locating Lockpin

    Courtesy of FORD MOTOR CO.

    RH camshafts 

NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Fig 12: Installing Camshaft Holding Tool On Flats Of Camshafts
Courtesy of FORD MOTOR CO.
12. Rotate the RH camshafts to the TDC  position and install the Camshaft Holding 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.
      Fig 13: Aligning Colored Links With Timing Marks

      Courtesy of FORD MOTOR CO.
14. Position the RH secondary timing assembly onto the camshafts.
    Fig 14: Positioning RH Secondary Timing Assembly Onto Camshafts

    Courtesy of FORD MOTOR CO.
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.
      Fig 15: Locating Secondary Timing Chain And RH Exhaust Camshaft Sprocket

      Courtesy of FORD MOTOR CO.
16. Remove the lockpin from the RH secondary timing chain tensioner.
    Fig 16: Locating Lockpin

    Courtesy of FORD MOTOR CO.

    All camshafts 

17. Rotate the crankshaft clockwise 60 degrees to the TDC  position (crankshaft dowel pin at 11 o'clock).
    Fig 17: Locating Crankshaft Position

    Courtesy of FORD MOTOR CO.
18. Install the primary timing chain with the colored links aligned with the timing marks on the VCT  assemblies and the crankshaft sprocket.
    Fig 18: Aligning Timing Marks On VCT Assemblies And Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
19. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 19: Locating Primary Timing Chain Tensioner Arm

      Courtesy of FORD MOTOR CO.
20. Install the primary timing chain tensioner arm.
    Fig 20: Locating Primary Timing Chain Tensioner Arm

    Courtesy of FORD MOTOR CO.
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.
      Fig 21: Aligning Hole In Lever With Hole In Tensioner Housing

      Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
22. Install the primary tensioner and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    • Remove the lockpin.
      Fig 22: Locating Primary Tensioner Bolts

      Courtesy of FORD MOTOR CO.
23. As a post-check, verify correct alignment of all timing marks.
    Fig 23: Identifying Timing Marks Location

    Courtesy of FORD MOTOR CO.
24. Inspect the VCT  housing seals for damage and replace as necessary.
    Fig 24: Locating VCT Housing Seals

    Courtesy of FORD MOTOR CO.
NOTE: 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.
25. Install the LH VCT  housing and the 3 bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 25: Identifying LH VCT Housing Bolts

      Courtesy of FORD MOTOR CO.
NOTE: 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.
26. Install the RH VCT  housing and the 3 bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 26: Identifying RH VCT Housing Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
27. Install the Alignment Pins.
    Fig 27: Identifying Alignment Pins

    Courtesy of FORD MOTOR CO.
NOTE: 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 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 silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
28. 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.
      Fig 28: Identifying RTV Silicone Applying Area

      Courtesy of FORD MOTOR CO.
NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
29. Install the engine front cover and bolts 17, 18, 19 and 20.
    • Tighten in sequence to 3 Nm (27 lb-in).
      Fig 29: Identifying Engine Front Cover Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
30. Remove the Alignment Pins.
    Fig 30: Identifying Alignment Pins

    Courtesy of FORD MOTOR CO.
NOTE: Do not tighten the bolts at this time.
Fig 31: Locating Engine Mount Bracket Bolts
Courtesy of FORD MOTOR CO.
31. Install the engine mount bracket and the 3 bolts.
NOTE: 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.
32. 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 illustration 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 (133 lb-in).
    • 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).
      Fig 32: Identifying Engine Front Cover Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new Threadlock and Sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.
33. Install the engine mount studs in the following sequence.
    1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.
    2. Clean all the thread sealer from the engine mount studs (old and new studs).
    3. Apply new Threadlock and Sealer to the engine mount stud threads.
    4. Install the 2 engine mount studs.
       • Tighten to 20 Nm (177 lb-in).
         Fig 33: Locating Engine Mount Studs

         Courtesy of FORD MOTOR CO.
34. Install the engine mount bracket and the 2 bolts.
    • Tighten to 30 Nm (22 lb-ft).
      Fig 34: Locating Engine Mount Bracket Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
Fig 35: Identifying Crankshaft Vibration Damper Installer And Front Crankshaft Installer
Courtesy of FORD MOTOR CO.
35. Using the Crankshaft Vibration Damper Installer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
Fig 36: Identifying Crankshaft Vibration Damper Installer And Front Cover Oil Seal Installer
Courtesy of FORD MOTOR CO.
36. Using the Crankshaft Vibration Damper Installer and Front Cover Oil Seal Installer, install the crankshaft pulley.
37. 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.
      Fig 37: Locating Crankshaft Pulley Washer And Bolt

      Courtesy of FORD MOTOR CO.
38. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 11 Nm (97 lb-in).
      Fig 38: Locating Accessory Drive Belt Tensioner Bolts

      Courtesy of FORD MOTOR CO.
39. Install the power steering pump and the 3 bolts.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 39: Locating Power Steering Pump And Bolts

      Courtesy of FORD MOTOR CO.
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 in illustration, VCT  seal installation similar.
Fig 40: Identifying VCT Spark Plug Tube Seal Installer And Handle
Courtesy of FORD MOTOR CO.
40. Using the VCT  Spark Plug Tube Seal Installer and Handle, install new VCT  solenoid and/or spark plug tube seals.
NOTE: 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Fig 41: Applying RTV Silicone To Engine Front Cover-To-RH Cylinder Head Joints
Courtesy of FORD MOTOR CO.
41. Apply a 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.

    Early build vehicles 

42. Using a new gasket, install the RH valve cover and tighten the bolt and 10 stud bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 42: Identifying RH Valve Cover Stud Bolts Tightening Sequence (Early Build Vehicles)

      Courtesy of FORD MOTOR CO.

    Late build vehicles 

43. Using a new gasket, install the RH valve cover and tighten the 9 stud bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 43: Identifying RH Valve Cover Stud Bolts Tightening Sequence (Late Build Vehicles)

      Courtesy of FORD MOTOR CO.

    All vehicles 

NOTE: 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
Fig 44: Applying RTV Silicone To Engine Front Cover
Courtesy of FORD MOTOR CO.
44. Apply a 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.

    Early build vehicles 

45. Using a new gasket, install the LH valve cover and tighten the 11 stud bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 45: Identifying LH Valve Cover Stud Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.

    Late build vehicles 

46. Using a new gasket, install the LH valve cover and tighten the 9 stud bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 46: Identifying LH Valve Cover Stud Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.

    All vehicles 

NOTE: LH shown in illustration, RH similar.
47. Install the 6 coil-on-plug assemblies and the 6 bolts.
    • Tighten to 7 Nm (62 lb-in).
      Fig 47: Locating Coil-On-Plugs Bolts

      Courtesy of FORD MOTOR CO.
48. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
49. Connect the 3 LH coil-on-plug electrical connectors.
    Fig 48: Locating LH Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
50. Connect the LH camshaft VCT  solenoid electrical connector.
    Fig 49: Locating LH VCT Solenoid Electrical Connector

    Courtesy of FORD MOTOR CO.
51. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
52. Connect the 3 RH coil-on-plug electrical connectors.
    Fig 50: Locating RH Coil-On-Plug Electrical Connectors

    Courtesy of FORD MOTOR CO.
53. Connect the RH VCT  solenoid electrical connector.
    Fig 51: Locating RH Variable Camshaft Timing Solenoid Electrical Connector

    Courtesy of FORD MOTOR CO.
54. Connect the Power Steering Pressure (PSP) switch electrical connector.
    Fig 52: Locating PSP Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
55. Connect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector.
    Fig 53: Locating RH Catalyst Monitor Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
NOTE: 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.
56. Using new gaskets, install the upper intake manifold and the 6 bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 54: Identifying Upper Intake Manifold Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
57. Install the upper intake manifold support bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 55: Locating Upper Intake Manifold Support Bracket Bolt

      Courtesy of FORD MOTOR CO.
58. Attach the wiring harness retainers to the upper intake manifold.
    Fig 56: Locating Wiring Harness Retainers

    Courtesy of FORD MOTOR CO.
59. Connect the Throttle Body (TB) electrical connector.
    Fig 57: Locating Throttle Body Electrical Connector

    Courtesy of FORD MOTOR CO.
60. Connect the PCV hose to the PCV valve.
    Fig 58: Locating PCV Hose

    Courtesy of FORD MOTOR CO.
61. If equipped, attach the engine block heater wiring harness retainers.
62. Raise the engine and transaxle assembly into the vehicle.
63. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 59: Locating Engine Mount Bolts

      Courtesy of FORD MOTOR CO.
64. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
      Fig 60: Locating Engine Mount Nuts

      Courtesy of FORD MOTOR CO.
65. Install the engine mount brace, the nut and the bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 61: Locating Engine Mount Brace Nut And Bolt

      Courtesy of FORD MOTOR CO.
66. Install the transaxle support insulator bracket, the 3 nuts and the bolt.
    • Tighten the 3 nuts to 63 Nm (46 lb-ft).
    • Tighten the bolt to 80 Nm (59 lb-ft).
      Fig 62: Identifying Transaxle Support Insulator Bracket Nuts

      Courtesy of FORD MOTOR CO.
67. Install the transaxle support insulator through bolt and nut.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 63: Locating Transaxle Support Insulator Through Bolt And Nut

      Courtesy of FORD MOTOR CO.
68. Using the Powertrain Lift, raise the subframe into the installed position.
    Fig 64: Positioning Powertrain Lift Under Subframe Assembly

    Courtesy of FORD MOTOR CO.
69. Install the 2 middle subframe nuts.
    • Tighten to 133 Nm (98 lb-ft).
      Fig 65: Locating Middle Subframe Nuts

      Courtesy of FORD MOTOR CO.
70. Install the 2 front subframe nuts.
    • Tighten to 133 Nm (98 lb-ft).
      Fig 66: Locating Front Subframe Nuts

      Courtesy of FORD MOTOR CO.
71. Position the subframe support brackets in place and loosely install the 4 bolts.
    Fig 67: Locating Subframe Support Bracket Bolts

    Courtesy of FORD MOTOR CO.
72. Install the 2 rear subframe bracket nuts.
    • Tighten to 133 Nm (98 lb-ft).
      Fig 68: Locating Rear Subframe Bracket Nuts

      Courtesy of FORD MOTOR CO.
73. Tighten the 4 subframe support bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).
      Fig 69: Locating Subframe Support Bracket Bolts

      Courtesy of FORD MOTOR CO.
74. Position the lower bumper on the subframe and install the 3 LH nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 70: Locating LH Subframe-To-Lower Bumper Nuts

      Courtesy of FORD MOTOR CO.
75. Install the 3 RH lower bumper-to-subframe nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 71: Locating RH Subframe-To-Lower Bumper Nuts

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
76. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install new cotter pins.
      Fig 72: Locating Tie-Rod Ends And Nuts

      Courtesy of FORD MOTOR CO.
NOTE: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to CLOCKSPRING .
77. Install the intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 73: Locating Steering Intermediate Shaft Bolt

      Courtesy of FORD MOTOR CO.
78. Using a new banjo bolt and 2 new seals, install the PSP  tube.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 74: Locating Power Steering Pressure Tube-To-Pump Banjo Bolt

      Courtesy of FORD MOTOR CO.
79. Install the engine roll restrictor-to-subframe through bolt.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 75: Locating Engine Roll Restrictor-To-Subframe Through Bolt

      Courtesy of FORD MOTOR CO.
80. Install the roll restrictor heat shield and the 2 nuts.
    • Tighten to 11 Nm (97 lb-in).
      Fig 76: Locating Roll Restrictor Heat Shield Nuts

      Courtesy of FORD MOTOR CO.

    AWD vehicles 

81. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts.
    • Tighten to 70 Nm (52 lb-ft).
      Fig 77: Locating Driveshaft Bolts

      Courtesy of FORD MOTOR CO.

    All vehicles 

82. Install the power steering cooler bracket bolt to the RH side of the subframe.
    • Tighten to 9 Nm (80 lb-in).
      Fig 78: Locating Power Steering Cooler Bracket Bolt

      Courtesy of FORD MOTOR CO.
83. Connect the power steering cooler hose.
    Fig 79: Locating Power Steering Cooler Hose

    Courtesy of FORD MOTOR CO.
NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
84. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
      Fig 80: Locating Engine Oil Filter

      Courtesy of FORD MOTOR CO.
85. Connect the 2 transmission fluid cooler tubes.
    Fig 81: Locating Transmission Fluid Cooler Tubes

    Courtesy of FORD MOTOR CO.
86. Install the 2 secondary latches onto the transmission fluid cooler tubes.
    Fig 82: Locating Secondary Latches

    Courtesy of FORD MOTOR CO.
87. Install the LH inner splash shield. For additional information, refer to FRONT END BODY PANELS .
88. Install the radiator splash shield, the 3 pin-type retainers and the 7 screws.
    Fig 83: Locating Pin-Type Retainers

    Courtesy of FORD MOTOR CO.
89. Using a new gasket, install the Y-pipe and exhaust flexible pipe assembly and 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 84: Locating Exhaust Flexible Pipe Nuts

      Courtesy of FORD MOTOR CO.
90. Install the 2 exhaust hangers and tighten the exhaust clamp.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 85: Locating Exhaust Flexible Pipe Clamp

      Courtesy of FORD MOTOR CO.
91. Install the ground wire, the radio interference capacitor wire and the nut to the engine front cover stud.
    • Tighten to 10 Nm (89 lb-in).
      Fig 86: Locating Ground Wire Nut

      Courtesy of FORD MOTOR CO.
92. Install the ground wire and bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).
      Fig 87: Locating Ground Wire Bolt

      Courtesy of FORD MOTOR CO.
93. Attach the wiring harness retainer to the RH valve cover stud bolt.
    Fig 88: Locating Wiring Harness Retainer

    Courtesy of FORD MOTOR CO.
94. Install the oil level indicator.
    Fig 89: Locating Oil Level Indicator

    Courtesy of FORD MOTOR CO.
95. Connect the 2 engine wiring harness electrical connectors.
    • Attach the electrical connector to the LH valve cover.
      Fig 90: Locating Engine Wiring Harness Electrical Connectors

      Courtesy of FORD MOTOR CO.
96. Connect the fuel hose routing clip to the transaxle stud.
    Fig 91: Locating Fuel Hose Routing Clip

    Courtesy of FORD MOTOR CO.
97. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    Fig 92: Locating Fuel Supply Tube

    Courtesy of FORD MOTOR CO.
98. Connect the hose to the power steering reservoir.
    Fig 93: Locating Hose

    Courtesy of FORD MOTOR CO.
99. Connect the A/C suction tube fitting.
    • Install the safety clip onto the A/C fitting.
      Fig 94: Locating A/C Suction Tube Safety Clip

      Courtesy of FORD MOTOR CO.
100. Using a new O-ring seal, connect the A/C pressure tube fitting and install the nut.
     • Tighten to 8 Nm (71 lb-in).
       Fig 95: Locating A/C Pressure Tube Fitting And Nut

       Courtesy of FORD MOTOR CO.
101. If equipped, attach the engine block heater harness retainers from to the radiator support and the A/C suction tube.
     Fig 96: Locating Engine Block Heater Harness And A/C Suction Tube

     Courtesy of FORD MOTOR CO.
102. Connect the transaxle control electrical connector.
     Fig 97: Locating Transaxle Control Electrical Connector

     Courtesy of FORD MOTOR CO.
103. Attach the control cable to the bracket.
     • Connect the transaxle control cable to the control lever.
       Fig 98: Locating Transaxle Control Cable

       Courtesy of FORD MOTOR CO.
104. Attach the wiring harness retainer to the transaxle control cable bracket.
     Fig 99: Locating Wiring Harness Retainer

     Courtesy of FORD MOTOR CO.
105. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
     Fig 100: Locating Upper And Lower Radiator Hose

     Courtesy of FORD MOTOR CO.
106. Connect the upper Evaporative Emission (EVAP) tube quick connect coupling to the purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
     Fig 101: Locating Upper Evaporative Emission Tube

     Courtesy of FORD MOTOR CO.
107. Connect the vacuum hose to the upper intake manifold.
     Fig 102: Locating Vacuum Hose

     Courtesy of FORD MOTOR CO.
108. Install the ground wire and the bolt.
     • Tighten to 10 Nm (89 lb-in).
     • Attach the 2 wiring harness retainers to the cowl.
       Fig 103: Locating Wiring Harness Retainers

       Courtesy of FORD MOTOR CO.
109. Connect the power feed to the battery terminal and install the nut.
     • Tighten to 8 Nm (71 lb-in).
       Fig 104: Locating Battery Terminal Nut

       Courtesy of FORD MOTOR CO.
110. Connect the battery harness electrical connector.
     Fig 105: Locating Battery Harness Electrical Connector

     Courtesy of FORD MOTOR CO.
111. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
112. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
113. Install the degas bottle. For additional information, refer to ENGINE COOLING .
114. Install the LH halfshaft and intermediate shaft. For additional information, refer to FRONT DRIVE HALFSHAFTS .
115. Install the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
NOTE: 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.
116. Fill the engine with clean engine oil.
117. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
118. Fill the power steering system. For additional information, refer to STEERING SYSTEM .
119. Recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .