Removal And Installation: Camshaft: Installation

NOTE: The following steps are for the RH camshafts only.

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 in illustration.

Fig 1: Locating RH Cylinder Head Camshafts Neutral Position
Courtesy of FORD MOTOR CO.
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.

Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.

Fig 2: Locating Crankshaft Dowel Pin 9 O'Clock Position
Courtesy of FORD MOTOR CO.
NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

Position the 4 camshaft seals gaps as shown in illustration.

Fig 3: Locating Camshaft Seals Gaps
Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration.

Fig 4: Identifying Camshaft Caps, Mega Cap, Valve Train Oil Tube Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Loosen the 4 camshaft caps bolts.

Fig 5: Locating Camshaft Caps Bolts
Courtesy of FORD MOTOR CO.
Tighten the 4 bolts in the sequence shown in illustration.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
Fig 6: Identifying Camshaft Caps Bolts With Tightening Sequence
Courtesy of FORD MOTOR CO.
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.

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 .

Fig 7: Measuring Valve Tappet Clearance
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the RH valve train oil tube.

Fig 8: Locating RH Valve Train Oil Tube Bolts
Courtesy of FORD MOTOR CO.
Rotate the RH camshafts to the TDC position as shown in illustration.

Fig 9: Locating TDC Position Of RH Camshafts
Courtesy of FORD MOTOR CO.
NOTE: The 303-1248 will hold the camshafts in the TDC position.

Install 303-1248 onto the flats of the RH camshafts.

Fig 10: Identifying Camshaft Holding Tool On RH Camshafts
Courtesy of FORD MOTOR CO.
Compress the RH secondary timing chain tensioner and install The 303-1530 to retain the tensioner in the collapsed position.

Fig 11: Compressing RH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
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 12: Aligning Colored Links With Timing Marks
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.

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.

Fig 13: Locating RH VCT Assemblies And Secondary Timing Chain
Courtesy of FORD MOTOR CO.
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.
Fig 14: Locating RH VCT Bolts
Courtesy of FORD MOTOR CO.
NOTE: The 2 VCT oil control solenoids are removed for clarity.

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: NOTE: The following steps are for theLeft Hand (LH) camshafts only.

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 in illustration.

Fig 15: Locating Neutral Position LH Cylinder Head Camshafts
Courtesy of FORD MOTOR CO.
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.

Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.

Fig 16: Locating Crankshaft Dowel Pin 9 O'Clock Position
Courtesy of FORD MOTOR CO.
NOTE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.

Position the 4 camshaft seals gaps as shown in illustration.

Fig 17: Locating Camshaft Seals Gaps
Courtesy of FORD MOTOR CO.
NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Install the 6 camshaft caps, mega cap, valve train oil tube and the 15 bolts in the sequence shown in illustration.

Fig 18: Identifying Camshaft Caps, Mega Cap And Valve Train Oil Tube Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
Loosen the 4 camshaft caps bolts.

Fig 19: Locating Camshaft Caps Bolts
Courtesy of FORD MOTOR CO.
Tighten the 4 bolts in the sequence shown in illustration.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
Fig 20: Identifying Camshaft Caps Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
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.

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 .

Fig 21: Measuring Valve Tappet Clearance
Courtesy of FORD MOTOR CO.
Remove the 3 bolts and the LH valve train oil tube.

Fig 22: Locating LH Valve Train Oil Tube And Mounting Bolts
Courtesy of FORD MOTOR CO.
Rotate the LH camshafts to the TDC position as shown in illustration.

Fig 23: Locating LH Camshafts To TDC Position
Courtesy of FORD MOTOR CO.
NOTE: The 303-1248 will hold the camshafts in the TDC position.

Install 303-1248 onto the flats of the LH camshafts.

Fig 24: Identifying Camshaft Holding Tool On LH Camshafts
Courtesy of FORD MOTOR CO.
Compress the LH secondary timing chain tensioner and install The 303-1530 to retain the tensioner in the collapsed position.

Fig 25: Compressing LH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain. Align the colored links with the timing marks.

Fig 26: Aligning Colored Links With Timing Marks
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.

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.

Fig 27: Locating LH VCT Assemblies And Secondary Timing Chain
Courtesy of FORD MOTOR CO.
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.
Fig 28: Locating LH VCT Assembly Bolts
Courtesy of FORD MOTOR CO.
NOTE: The 2 VCT oil control solenoids are removed for clarity.

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.

Fig 29: Compressing LH Secondary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the TDC position (crankshaft dowel pin at 11 o'clock).

Fig 30: Locating Crankshaft Dowel Pin Position
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.

Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.

Fig 31: Aligning Primary Timing Chain Colored Links With Timing Marks On VCT Assemblies And Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
Install the 2 bolts and the lower LH primary timing chain guide.

Fig 32: Locating Lower LH Primary Timing Chain Guide And Mounting Bolts
Courtesy of FORD MOTOR CO.
- Tighten to 10 Nm (89 lb-in).
Install the primary timing chain tensioner arm.

Fig 33: Locating Primary Timing Chain Tensioner Arm
Courtesy of FORD MOTOR CO.
Reset the primary timing chain tensioner.
1. Release the ratchet detent.
2. Using a soft-jawed vise, compress the ratchet plunger.
3. Align the hole in the ratchet plunger with the hole in the tensioner housing.
4. Install a suitable lockpin.
Fig 34: Resetting Primary Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.

Install the 2 bolts and the primary timing chain tensioner.
- Tighten to 10 Nm (89 lb-in) and remove the lock pin.
Fig 35: Locating Primary Tensioner, Bolts And Lockpin
Courtesy of FORD MOTOR CO.
As a post-check, verify correct alignment of all timing marks.
1. There are 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
2. There are 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
Fig 36: Verifying Correct Alignment Of All Timing Chains Colored Links And Timing Marks
Courtesy of FORD MOTOR CO.
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.

NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.

NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

Install the LH intake VCT oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in).
Fig 37: Locating LH Intake VCT Oil Control Solenoid And Mounting Bolt
Courtesy of FORD MOTOR CO.
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.

NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.

NOTE: Keep the VCT oil control solenoid clean of dirt and debris.

Install the LH intake VCT oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in).
Fig 38: Locating RH Intake VCT Oil Control Solenoid And Mounting Bolt
Courtesy of FORD MOTOR CO.
Remove the RH 303-1248 .

Fig 39: Installing Camshaft Holding Tool Onto Flats Of RH Camshafts
Courtesy of FORD MOTOR CO.
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.
Fig 40: Locating RH Valve Train Oil Tube Bolts
Courtesy of FORD MOTOR CO.
Remove the LH 303-1248 .

Fig 41: Installing Camshaft Holding Tool Onto Flats Of LH Camshafts
Courtesy of FORD MOTOR CO.
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.
Fig 42: Locating LH Valve Train Oil Tube And Mounting Bolts
Courtesy of FORD MOTOR CO.
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.

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: 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.

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.

Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence.
1. Remove any large deposits of silicone or gasket material.
2. Apply Motorcraft® Silicone Gasket Remover and allow to set for several minutes.
3. 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.
4. 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.

Install 307-399

Fig 43: Identifying Cylinder Block Dowel 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 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.

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.
Fig 44: Locating RTV Silicone Applying Area On Engine Front Cover Sealing Surfaces
Courtesy of FORD MOTOR CO.
NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.

Install the engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22.
- Tighten in sequence shown in illustration to 3 Nm (27 lb-in).
Fig 45: Identifying Tightening Sequence Of Engine Front Cover Mounting Bolts
Courtesy of FORD MOTOR CO.
Remove 307-399 .

Fig 46: Identifying Cylinder Block Dowel Pins
Courtesy of FORD MOTOR CO.
Install the M6 engine front cover bolt. Do not tighten at this time.

Fig 47: Locating M6 Engine Front Cover Bolt
Courtesy of FORD MOTOR CO.
Install the 2 upper M10 engine front cover bolts. Do not tighten the bolts at this time.

Fig 48: Locating Engine Front Cover Bolt (M10)
Courtesy of FORD MOTOR CO.
Install the lower M10 bolt. Do not tighten at this time.

Fig 49: Locating Lower M10 Engine Front Cover Bolt
Courtesy of FORD MOTOR CO.
Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts in the sequence shown in illustration 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 50: Identifying Tightening Sequence Of Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: Installation of new seals is only required if damaged seals were removed.

Using 303-1247/2 and 205-153 (T80T-4000-W) install the new spark plug tube seal(s).

Fig 51: Installing Spark Plug Tube Seals
Courtesy of FORD MOTOR CO.
NOTE: Installation of new seals is only required if damaged seals were removed.

Using 205-142 (T80T-4000-J) and 205-153 (T80T-4000-W) install the new VCT seal(s).

Fig 52: Installing VCT Solenoid Seals
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: 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.

Apply an 8 mm (0.315 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.

Fig 53: Locating Bead Of Motorcraft® High Performance Engine RTV Silicone
Courtesy of FORD MOTOR CO.
Using a new gasket, install the RH valve cover and tighten the 3 bolts and 8 stud bolts.
- Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
Fig 54: Identifying RH Valve Cover Bolts And Stud Bolts With Tightening Sequence
Courtesy of FORD MOTOR CO.
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.

Fig 55: Identifying VCT Seal Position
Courtesy of FORD MOTOR CO.
Attach the wiring harness retainer.

Fig 56: View Of Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Connect the 3 fuel injector electrical connectors and attach the 2 wiring harness retainers to the RH valve cover stud bolts.

Fig 57: Locating Fuel Injector Electrical Connectors And Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
Connect the 2 VCT oil control solenoid electrical connectors and attach the 2 oil control solenoid wiring harness retainers.

Fig 58: Locating VCT Oil Control Solenoid Electrical Connectors
Courtesy of FORD MOTOR CO.
Attach the 3 wire harness retainers from the main engine wiring harness to the RH valve cover.

Fig 59: Locating RH Valve Cover Wire Harness Retainers
Courtesy of FORD MOTOR CO.
Connect the HO2S electrical connector and attach the wiring harness retainer to the RH valve cover.

Fig 60: Locating HO2S Electrical Connector
Courtesy of FORD MOTOR CO.
Install the RH ignition coils.
- Tighten to 7 Nm (62 lb-in).
Fig 61: Locating RH Ignition Coil-On-Plugs And Bolts
Courtesy of FORD MOTOR CO.
Connect the 3 RH coil-on-plug electrical connectors.

Fig 62: Locating RH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
Using a new gasket, install the intake manifold and the 7 bolts.
1. Tighten in the sequence shown in illustration in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Fig 63: Install The Intake Manifold And Bolts With Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the upper intake manifold support bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 64: Locating Upper Intake Manifold Support Bracket Bolt
Courtesy of FORD MOTOR CO.
Connect the crankcase ventilation hose to the PCV valve. REFER to QUICK CONNECT COUPLING .

Fig 65: Locating Crankcase Ventilation Hose
Courtesy of FORD MOTOR CO.
Attach the 2 wiring harness/coolant tube retainers to the upper intake manifold.

Fig 66: Locating Wiring Harness/Coolant Tube Retainers
Courtesy of FORD MOTOR CO.
Connect the EVAP vapor tube to the EVAP canister vent solenoid.

Fig 67: Locating Evaporative Emission Canister Vent Solenoid
Courtesy of FORD MOTOR CO.
Connect the EVAP canister vent solenoid and throttle body electrical connectors.
1. Attach the 2 wiring harness pin-type retainers (1 shown in illustration).
Fig 68: Locating EVAP Canister Vent Solenoid And Throttle Body Electrical Connectors
Courtesy of FORD MOTOR CO.
NOTE: Installation of new seals is only required if damaged seals were removed.

Using 303-1247/2 and 205-153 (T80T-4000-W) install the new spark plug tube seal(s).

Fig 69: Installing Spark Plug Tube Seals
Courtesy of FORD MOTOR CO.
NOTE: Installation of new seals is only required if damaged seals were removed.

Using 205-142 (T80T-4000-J) and 205-153 (T80T-4000-W) install the new VCT seal(s).

Fig 70: Installing VCT Seals
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: 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.

Apply an 8 mm (0.315 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.

Fig 71: Locating Bead Of Motorcraft High Performance Engine RTV Silicone Applying Areas
Courtesy of FORD MOTOR CO.
Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts.
- Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
Fig 72: Identifying LH Valve Cover Bolts With Tightening Sequence
Courtesy of FORD MOTOR CO.
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.

Fig 73: Identifying VCT Seal Position
Courtesy of FORD MOTOR CO.
NOTE: Coolant hose removed from graphic for clarity.

Attach the wiring harness retainer.

Fig 74: Locating Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Connect the 3 fuel injector electrical connectors and attach the 2 wiring harness retainers to the LH valve cover stud bolts.

Fig 75: Locating Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the LH HO2S electrical connector and attach the wiring harness connector pin-type retainer to the LH valve cover.

Fig 76: Locating HO2S Electrical Connector
Courtesy of FORD MOTOR CO.
Attach the 2 wiring harness pin-type retainers.

Fig 77: Locating Wiring Harness Pin-Type Retainers
Courtesy of FORD MOTOR CO.
Connect the 2 VCT oil control solenoid electrical connectors and attach the 2 oil control solenoid wiring harness pin-type retainers (1 shown in illustration).

Fig 78: View Of VCT Oil Control Solenoid Electrical Connectors And Harness Retainer
Courtesy of FORD MOTOR CO.
Attach the 3 wiring harness retainers to the LH valve cover stud bolts.

Fig 79: View Of Wiring Harness Retainers To The LH Valve Cover Stud Bolts
Courtesy of FORD MOTOR CO.
Install the oil level indicator.

Fig 80: Locating Oil Level Indicator
Courtesy of FORD MOTOR CO.
Install the LH ignition coils.
- Tighten to 7 Nm (62 lb-in).
Fig 81: Locating LH Ignition Coil-On-Plugs And Bolts
Courtesy of FORD MOTOR CO.
Connect the 3 LH coil-on-plug electrical connectors.

Fig 82: Locating LH Coil-On-Plug Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the crankcase vent tube to the LH valve cover.

Fig 83: Locating Crankcase Vent Tube
Courtesy of FORD MOTOR CO.
Install a new crankshaft seal. REFER to Installation .
Install the accessory drive belt tensioner. REFER to Exploded View .
Raise the subframe and powertrain assembly into the vehicle.
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).
Fig 84: View Of Engine Mount And Fasteners
Courtesy of FORD MOTOR CO.
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).
Fig 85: Locating Transaxle Support Insulator Bracket, Nuts And Bolt
Courtesy of FORD MOTOR CO.
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).
Fig 86: Locating Transaxle Support Insulator Bolt And Nut
Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.

Install the 2 front subframe bolts.
- Tighten to 200 Nm (148 lb-ft).
Fig 87: Locating Front Subframe Bolt
Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.

Position the subframe brackets and install the 4 bolts finger-tight.

Fig 88: Locating Subframe Brackets Bolts
Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.

Install the 2 rear subframe bolts.
- Tighten to 150 Nm (111 lb-ft).
Fig 89: Locating Rear Subframe And Bolts
Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.

Finish tightening the subframe bracket-to-body bolts.
- Tighten the 4 subframe bracket-to-body bolts to 55 Nm (41 lb-ft).
Fig 90: Locating Subframe Bracket-To-Body Bolts
Courtesy of FORD MOTOR CO.
Remove the ratchet strap from the front of the subframe to the rear of the subframe.
Remove the Adjustable Grip Arm and the powertrain lift table.

Fig 91: Removing the Adjustable Grip Arm
NOTE: LH shown in illustration, RH similar.

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 in illustration, RH similar.

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: 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.

NOTE: LH shown in illustration, RH similar.

NOTE: Apply the brake to keep the halfshaft from rotating.

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: 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.

NOTE: LH shown in illustration, RH similar.

NOTE: Apply the brake to keep the halfshaft from rotating.

Install a new wheel hub nuts.
- Tighten to 350 Nm (258 lb-ft).
NOTE: RH shown in illustration, LH similar.

Install new upper stabilizer bar link nuts.
- Tighten to 150 Nm (111 lb-ft).
Fig 92: Locating Upper Stabilizer Bar Link Nut
Courtesy of FORD MOTOR CO.
NOTE: LH shown in illustration, RH similar.

Install the wheel speed sensor and the bolt.
- Tighten to 15 Nm (133 lb-in).
Connect the transaxle cooler tubes and install the 2 secondary latches.

Fig 93: Locating Transaxle Cooler Tubes Secondary Latches
Courtesy of FORD MOTOR CO.
If equipped, attach the oil cooler hose support clip to the subframe.

Fig 94: Locating Oil Cooler Coolant Hose Retainer
Courtesy of FORD MOTOR CO.
If equipped, connect the oil cooler coolant hoses.

Fig 95: Locating Oil Cooler Coolant Hoses Clamps
Courtesy of FORD MOTOR CO.
NOTE: Do not lubricate the engine oil filter gasket.

Install a new engine oil filter.
- Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
Fig 96: Locating Engine Oil Filter
Courtesy of FORD MOTOR CO.
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).
Fig 97: Locating Driveshaft Bolts
Courtesy of FORD MOTOR CO.
Install the exhaust Y-pipe. REFER to EXHAUST Y-PIPE .
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. REFER to CLOCKSPRING .

Install the steering intermediate shaft onto the steering gear and install a new bolt.
- Tighten to 20 Nm (177 lb-in).
Fig 98: Identifying Steering Intermediate Shaft, Steering Gear And Fastener
Courtesy of FORD MOTOR CO.
Install the underbody air duct and the 3 twist lock retainers.

Fig 99: Locating Underbody Air Duct And Twist Lock Retainers
Courtesy of FORD MOTOR CO.
If equipped, attach the engine block heater harness to the radiator support.
Attach the wiring harness pin-type retainer and connect the transaxle control cable to the shift cable bracket.

Fig 100: Locating Shift Cable Bracket And Wiring Harness
Courtesy of FORD MOTOR CO.
Connect the transaxle control cable to the control lever.

Fig 101: View Of Transaxle Control Cable And Transmission Control Lever
Courtesy of FORD MOTOR CO.
Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.

Fig 102: Locating Upper Radiator Hose, Lower Radiator Hose And Heater Hoses
Courtesy of FORD MOTOR CO.
Install the ground wire to the RH shock tower and install the bolt.
- Tighten to 10 Nm (89 lb-in).
Install the engine wiring harness retainer to the bulkhead.
1. Slide the wiring harness in the bulkhead.
2. Make sure the wiring harness retainer tab is below the bulkhead lip.
Fig 103: Locating Engine Wiring Harness Retainer At Bulkhead
Courtesy of FORD MOTOR CO.
Connect the engine harness electrical connector.

Fig 104: Identifying Engine Harness Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 2 PCM electrical connectors.

Fig 105: Locating PCM Electrical Connectors
Courtesy of FORD MOTOR CO.
Attach the PCM and engine harness retainer.

Fig 106: View Of PCM And Engine Harness Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the EVAP tube and the fuel supply tube quick connect coupling. REFER to QUICK CONNECT COUPLING .

Fig 107: Locating Evaporative Emission Canister Vent Solenoid
Courtesy of FORD MOTOR CO.
Connect the brake booster vacuum hose to the upper intake manifold.

Fig 108: Locating Power Brake Booster Vacuum Supply Hose
Courtesy of FORD MOTOR CO.
If equipped, disconnect the degas bottle coolant hose from the engine coolant tube.

Fig 109: View Of Degas Bottle Coolant Hose Connected -To- Engine Coolant Tube
Courtesy of FORD MOTOR CO.
Install the degas bottle. REFER to DEGAS BOTTLE .
Using a new O-ring seal and gasket seal, install the A/C tube and the nut.
- Tighten to 15 Nm (133 lb-in).
Fig 110: Locating A/C Tube And Mounting Nut
Courtesy of FORD MOTOR CO.
Connect the A/C pressure switch electrical connector.

Fig 111: Locating A/C Pressure Switch Electrical Connector
Courtesy of FORD MOTOR CO.
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).
Fig 112: Locating A/C Tube And Mounting Nut
Courtesy of FORD MOTOR CO.
Install the accessory drive belt. REFER to ACCESSORY DRIVE BELT - 3.5L TI-VCT .
Install the 2 lower scrivets in the LF fender splash shield.

Fig 113: Locating RF Fender Splash Shield Lower Scrivets
Courtesy of FORD MOTOR CO.
Install the 2 lower scrivets in the RF fender splash shield.

Fig 114: Locating LF Fender Splash Shield Lower Scrivets
Courtesy of FORD MOTOR CO.
Install the front wheels and tires. REFER to WHEEL AND TIRE .
Connect the 2 battery feed cables to the positive battery terminal and install the nut.
- Tighten to 5 Nm (44 lb-in).
Install the ground wire and the stud bolt.
- Tighten to 10 Nm (89 lb-in).
Fig 115: Locating Ground Wire Attached To Body Stud Bolt
Courtesy of FORD MOTOR CO.
Connect the nut to the ground wire attached to the body.
- Tighten to 10 Nm (89 lb-in).
Fig 116: Locating Ground Wire To Body Attached Nut
Courtesy of FORD MOTOR CO.
Connect the engine wiring harness electrical connector.

Fig 117: Identifying Engine Wiring Harness Electrical Connector
Courtesy of FORD MOTOR CO.
Install the battery tray. REFER to BATTERY AND BATTERY TRAY - EXPLODED VIEW .
Install the engine ACL and ACL outlet pipe. REFER to INTAKE AIR SYSTEM COMPONENTS - EXPLODED VIEW .
Install the cowl panel. REFER to COWL PANEL .
Fill the engine with clean engine oil.
Fill and bleed the cooling system. REFER to COOLING SYSTEM DRAINING, FILLING AND BLEEDING - 3.5L TI-VCT .
Recharge the A/C system. REFER to AIR CONDITIONING (AC) SYSTEM RECOVERY, EVACUATION, AND CHARGING .