Section 9 (Engine Mechanical - 3.5L): Installation: Camshaft

	Adjustable Grip Arm, 1735A 014-00001
	Alignment Pins 307-399
	Handle 205-153 (T80T-4000-W)
	Hold Down, Secondary Chain 303-1530
	Installer, Differential Bearing Cone 205-142 (T80T-4000-J)
	Installer, Front Cover Oil Seal 303-335 (T88T-6701-A)
	Installer, Front Crankshaft Seal 303-1251
	Installer, VCT Spark Plug Tube Seal 303-1247/2
	Powertrain Lift 300-OTC1585AE
	Replacer, Crankshaft Vibration Damper 303-102 (T74P-6312-B)
	Strap Wrench 303-D055 (D85L-6000-A) or equivalent
	Tool, Camshaft Holding 303-1248

RH camshafts 

1. 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 below.

2. 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 1: Locating Crankshaft Dowel Pin

   Courtesy of FORD MOTOR CO.
3. 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 below.

   Fig 2: Locating Camshaft Seals Gaps

   Courtesy of FORD MOTOR CO.
4. 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 below.

   • Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
     Fig 3: Camshaft Caps, Mega Cap, Valve Train Oil Tube Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
5. Loosen the 4 camshaft caps bolts.
   Fig 4: Locating Camshaft Caps Bolts

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

     Courtesy of FORD MOTOR CO.
7. 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. For additional information, refer to VALVE CLEARANCE CHECK .

   Fig 6: Checking Valve Tappet Clearances

   Courtesy of FORD MOTOR CO.
8. Remove the 3 bolts and the RH valve train oil tube.
9. Rotate the RH camshafts to the TDC position as shown below.
10. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.

    Install the Camshaft Holding Tool onto the flats of the RH camshafts.

11. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down 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. 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.

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. NOTE: The 2 VCT oil control solenoids are removed for clarity.

    Compress the RH secondary timing chain tensioner and remove the Secondary Chain Hold Down.

    • Make sure the secondary timing chain is centered on the timing chain tensioner guides.

    LH camshafts 

16. 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 below.

17. 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 7: Locating Crankshaft Dowel Pin

    Courtesy of FORD MOTOR CO.
18. 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 below.

    Fig 8: Locating Camshaft Seals Gaps

    Courtesy of FORD MOTOR CO.
19. 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 below.

    • Tighten to 8 Nm (71 lb-in) then additional 45 degrees.
      Fig 9: Locating Cylinder Head Camshaft Tightening Sequence

      Courtesy of FORD MOTOR CO.
20. Loosen the 4 camshaft caps bolts.
    Fig 10: Locating Camshaft Caps Bolts

    Courtesy of FORD MOTOR CO.
21. Tighten the 4 camshaft caps bolts in the sequence shown below.
    • Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then additional 45 degrees.
      Fig 11: Locating Camshaft Caps Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
22. 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. For additional information, refer to VALVE CLEARANCE CHECK .

    Fig 12: Checking Valve Tappet Clearances

    Courtesy of FORD MOTOR CO.
23. Remove the 3 bolts and the LH valve train oil tube.
24. Rotate the LH camshafts to the TDC position as shown below.
25. NOTE: The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.

    Install the Camshaft Holding Tool onto the flats of the LH camshafts.

26. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
27. Assemble the 2 LH VCT assemblies and the LH secondary timing chain.
    • Align the colored links with the timing marks.
28. 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.

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. NOTE: The 2 VCT oil control solenoids are removed for clarity.

    Compress the LH secondary timing chain tensioner and remove the Secondary Chain Hold Down.

    • Make sure the secondary timing chain is centered on the timing chain tensioner guides.

      All camshafts 

31. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
    Fig 13: Locating Crankshaft Dowel Pin Position

    Courtesy of FORD MOTOR CO.
32. 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 14: Aligning With Timing Marks On VCT Assemblies And Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
33. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
34. Install the primary timing chain tensioner arm.
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. NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the tensioner.

    Install the primary tensioner and the 2 bolts.

    • Tighten to 10 Nm (89 lb-in).
    • Remove the lockpin.
37. As a post-check, verify correct alignment of all timing marks.
    • There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
    • There is 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
38. NOTE: Do not use excessive force when installing the Variable Camshaft Timing (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) then an additional 20 degrees.
39. NOTE: Do not use excessive force when installing the Variable Camshaft Timing (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 RH intake VCT oil control solenoid and the bolt.

    • Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
40. Remove the RH Camshaft Holding Tool.
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.
42. Remove the LH Camshaft Holding Tool.
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. 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.
45. 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 silicone gasket remover and allow to set for several minutes.
    3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply 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.
    5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
46. Install the Alignment Pins.
47. 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 silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

    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 4 inner bolt 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.
48. 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 to 3 Nm (27 lb-in).
49. Remove the Alignment Pins.
50. NOTE: Do not tighten the bolt at this time.

    Install the M6 engine front cover bolt.

51. NOTE: Do not tighten the bolts at this time.

    Install the 3 M10 engine front cover bolts.

52. 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.

    Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts and engine mount bracket bolts in the sequence shown below in 7 stages:

    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in).
    • Stage 2: Tighten bolts 23, 24 and 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, 24 and 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. NOTE: Power steering hoses removed from graphic for clarity.

    Install the power steering pump and the 3 bolts.

    • Tighten to 25 Nm (18 lb-ft).
54. NOTE: Installation of new seals is only required if damaged seals were removed.
    NOTE: RH shown, LH similar.

    Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.

55. NOTE: Installation of new seals is only required if damaged seals were removed.
    NOTE: RH shown, LH similar.

    Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).

56. NOTE: Failure to use the correct 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. Failure to follow this procedure can cause future oil leakage.

    Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.

57. Using a new gasket, install the RH valve cover and tighten the 3 bolts and 8 stud bolts.
    • Tighten in the sequence shown below to 10 Nm (89 lb-in).
58. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
59. Position the power steering hose and install the 2 nuts.
    • Tighten to 9 Nm (80 lb-in).
60. Attach the wiring harness retainer.
61. Connect the 3 fuel injector electrical connectors.
    • Attach the 2 wiring harness retainers.
62. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
    • Attach the 2 wiring harness retainers.
63. Connect the HO2S and CMS electrical connectors.
    • Attach the 2 wiring harness retainers to the RH valve cover.
64. Install the PCV crankcase vent tube.
65. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before attaching to the spark plugs.

    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.
66. Using a new gasket, install the intake manifold and the 7 bolts.
    • Tighten in the sequence shown below in 2 stages.
      • Stage 1: Tighten to 10 Nm (89 lb-in).
      • Stage 2: Tighten an additional 45 degrees.
        Fig 15: Identifying Upper Intake Manifold Bolts Tightening Sequence

        Courtesy of FORD MOTOR CO.
67. Install the upper intake manifold support bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
68. Connect the crankcase ventilation hose to the upper intake manifold.
69. Attach the 2 wiring harness/coolant tube retainers to the upper intake manifold.
70. Connect the EVAP vapor tube to the EVAP canister vent solenoid. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    • Attach the pin-type retainer.
71. Connect the Evaporative Emission (EVAP) canister vent solenoid and throttle body electrical connectors.
    • Attach the wiring harness pin-type retainer.
72. 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. Failure to follow this procedure can cause future oil leakage.

    Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.

73. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts.
    • Tighten in the sequence shown below to 10 Nm (89 lb-in).
74. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
75. NOTE: Coolant hose removed from graphic for clarity.

    Attach the 2 wiring harness retainers.

76. Connect the 3 fuel injector electrical connectors.
    • Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
77. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector.
    • Attach the wiring harness connector pin-type retainer to the LH valve cover.
78. Attach the 2 wiring harness pin-type retainers.
79. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors.
    • Attach the wiring harness pin-type retainer.
80. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
81. Attach the wiring harness connector pin-type retainer to the LH valve cover.
82. Install the 3 LH-coil-on-plugs and the 3 bolts.
    • Tighten to 7 Nm (62 lb-in).
83. Connect the 3 LH coil-on-plug electrical connectors.
84. Install the crankcase vent tube. For additional information, refer to the QUICK CONNECT COUPLING procedure.
85. NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.

    Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.

    Fig 16: Locating Crankshaft Front Seal Installer

    Courtesy of FORD MOTOR CO.
86. NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.

    Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.

    Fig 17: Installing Crankshaft Pulley

    Courtesy of FORD MOTOR CO.
87. 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 18: Installing Crankshaft Pulley Washer And Bolt Using Strap Wrench

      Courtesy of FORD MOTOR CO.
88. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 11 Nm (97 lb-in).
89. Using the Powertrain Lift, raise the powertrain/subframe assembly into the vehicle.
90. Install the transaxle support insulator bracket, the 3 nuts and the bolt.
    • Do not torque at this time.
      Fig 19: Identifying Transaxle Support Insulator Bracket, Nuts And Bolt

      Courtesy of FORD MOTOR CO.
91. Install the transaxle support insulator through bolt and nut.
    • Do not torque at this time.
      Fig 20: Locating Transaxle Support Insulator Through Bolt And Nut

      Courtesy of FORD MOTOR CO.
92. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
93. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
94. Install the engine mount brace, the nut and the bolt.
    • Tighten to 20 Nm (177 lb-in).
      Fig 21: Locating Engine Mount Brace Nut And Bolt

      Courtesy of FORD MOTOR CO.
95. Tighten the transaxle support insulator bracket nuts and bolt.
    1. Tighten the bolt to 80 Nm (59 lb-ft).
    2. Tighten the 3 nuts to 63 Nm (46 lb-ft).
       Fig 22: Identifying Transaxle Support Insulator Bracket, Nuts And Bolt

       Courtesy of FORD MOTOR CO.
96. Tighten the transaxle support insulator through bolt and nut.
    • Tighten to 175 Nm (129 lb-ft).
      Fig 23: Locating Transaxle Support Insulator Through Bolt And Nut

      Courtesy of FORD MOTOR CO.
97. Install the 2 middle subframe nuts.
    • Tighten to 133 Nm (98 lb-ft).
      Fig 24: Locating Middle Subframe Nuts

      Courtesy of FORD MOTOR CO.
98. NOTE: Align the reference marks on the subframe and underbody that were made during the removal of the subframe.

    Install the 2 front subframe nuts.

    • Tighten to 133 Nm (98 lb-ft).
      Fig 25: Locating Front Subframe Nuts

      Courtesy of FORD MOTOR CO.
99. Position the subframe support brackets in place and loosely install the 2 bolts and 2 nuts.
100. Position the subframe brace and loosely install the 2 bolts.
101. Tighten the 2 rear subframe bracket nuts to 133 Nm (98 lb-ft).
102. Tighten the 4 bolts to 90 Nm (66 lb-ft).
103. Remove the Adjustable Grip Arm and Powertrain Lift.
104. NOTE: The fuel and vapor tube assembly clip must remain attached to the transaxle case stud during engine removal. Failure to follow these instructions can result in damage to the fuel and vapor tube assembly.

     Connect the fuel supply tube and Evaporative Emission (EVAP) tube quick connect couplings. For additional information, refer to the QUICK CONNECT COUPLING procedure.

105. Position the lower bumper on the subframe and install the 3 LH nuts.
     • Tighten to 9 Nm (80 lb-in).
       Fig 26: Locating LH Subframe-To-Lower Bumper Nuts

       Courtesy of FORD MOTOR CO.
106. Install the 3 RH lower bumper-to-subframe nuts.
     • Tighten to 9 Nm (80 lb-in).
       Fig 27: Locating RH Subframe-To-Lower Bumper Nuts

       Courtesy of FORD MOTOR CO.
107. 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 SUPPLEMENTAL RESTRAINT SYSTEM .

     Install the intermediate shaft onto the steering gear and install a new bolt.

     • Tighten to 23 Nm (17 lb-ft).
108. Install the roll restrictor heat shield and the 2 nuts.
     • Tighten to 9 Nm (80 lb-in).

     AWD vehicles 

109. 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 28: Locating Driveshaft Bolts

       Courtesy of FORD MOTOR CO.

       All vehicles 

110. Install the exhaust Y-pipe. For additional information, refer to EXHAUST SYSTEM .
111. NOTE: Do not lubricate the oil filter gasket.

     Install a new engine oil filter.

     • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
112. NOTE: RH shown, LH similar.

     Install the 2 RH and 2 LH front shock absorber lower flag bolts and nuts.

     • Tighten to 225 Nm (166 lb-ft).
113. NOTE: RH shown, LH similar.

     Position the RH and LH front wheel speed sensors and install the 2 bolts.

     • Tighten to 7 Nm (62 lb-in).
114. NOTE: RH shown, LH similar.
     NOTE: The guide pin bolts are different sizes. The longer/bigger bolt is the upper guide pin bolt.

     Install the RH and LH brake caliper and install the guide pin bolts.

     • Tighten to 88 Nm (63 lb-ft).
115. Connect the 2 transmission fluid cooler tubes.
     Fig 29: Locating Transmission Fluid Cooler Tubes

     Courtesy of FORD MOTOR CO.
116. Install the 2 secondary latches onto the transmission fluid cooler tubes.
     Fig 30: Locating Transmission Fluid Cooler Tubes Secondary Latches

     Courtesy of FORD MOTOR CO.
117. Install the radio interference capacitor wire and the nut to the engine front cover stud.
     • Tighten to 10 Nm (89 lb-in).
118. Install the ground wire and bolt to the engine front cover.
     • Tighten to 10 Nm (89 lb-in).
119. Connect the wiring harness electrical connector.
     • Attach the wiring harness retainer to the RH valve cover stud bolt.
120. Connect the 2 PCM electrical connectors.
     • Attach the 2 wiring harness retainers to the stud bolts.
121. Connect the A/C suction tube fitting.
     • Install the safety clip onto the A/C fitting.
       Fig 31: Locating A/C Suction Tube Fitting Safety Clip

       Courtesy of FORD MOTOR CO.
122. Using a new O-ring seal, connect the A/C tube fitting and install the nut.
     • Tighten to 8 Nm (71 lb-in).
       Fig 32: Locating A/C Pressure Tube Fitting Bolt

       Courtesy of FORD MOTOR CO.
123. Install the A/C tube bracket bolt.
     • Tighten to 12 Nm (106 lb-in).
124. If equipped, attach the engine block heater harness retainers to the radiator support and the A/C suction tube.
     Fig 33: Locating Engine Block Heater Harness Retainers

     Courtesy of FORD MOTOR CO.
125. Attach the control cable to the bracket.
     • Connect the transaxle control cable to the control lever.
       Fig 34: Locating Control Cable Bracket

       Courtesy of FORD MOTOR CO.
126. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
127. Connect the vacuum hose to the upper intake manifold.
128. Attach the 3 wiring harness retainers to the bracket and inner fender.
129. Connect the wiring harness electrical connector.
130. Attach the 2 wiring harness retainers to the stud bolt and bracket.
131. Install the ground wire and bolt.
     • Tighten to 10 Nm (89 lb-in).
     • Connect the wiring harness electrical connector.
132. Connect the power feed to the battery terminal and install the 2 nuts.
     • Tighten to 8 Nm (71 lb-in).
     • Connect the wiring harness electrical connector.
133. Install the battery tray. For additional information, refer to BATTERY, BATTERY MOUNTING & BATTERY CABLES .
134. Install the engine Air Cleaner (ACL) and the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION SYSTEM & INTAKE AIR FILTERING SYSTEM .
135. Connect the hose to the power steering reservoir.
     Fig 35: Locating ACL Outlet Pipe Clamp

     Courtesy of FORD MOTOR CO.
136. Install the degas bottle. Refer to ENGINE COOLING .
137. Install the power steering cooler bracket bolt to the RH side of the subframe.
     • Tighten to 9 Nm (80 lb-in).
       Fig 36: Locating Power Steering Cooler Bracket Bolt

       Courtesy of FORD MOTOR CO.
138. Connect the power steering cooler hose.
139. Install the accessory drive belt and the power steering belt. Refer to ACCESSORY DRIVE BELT .
140. Install the LH and RH inner splash shields. Refer to BODY PANEL SYSTEM - FRONT END BODY PANELS .
141. Install the LH and RH front wheels and tires. Refer to WHEELS & TIRES .
142. Fill the engine with clean engine oil.
143. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
144. Fill the power steering system. For additional information, refer to STEERING SYSTEM .
145. Recharge the A/C system. For additional information, refer to HVAC - CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
146. Install the engine appearance cover. For additional information, refer to ENGINE APPEARANCE COVER - EXPLODED VIEW .
147. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.