Section 10 (Engine Mechanical - 3.5L): Installation: Camshaft

Tool, Camshaft Holding 303-1248

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: Location of Crankshaft Dowel Pin 9 O'Clock Position
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: Location of Camshafts In 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.
3. Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown in illustration in the following stages:
   • Stage 1: Tighten bolts 1, 2, 3 and 4 to 8 Nm (71 lb-in) then an additional 45 degrees.
   • Stage 2: Tighten bolts 5 and 6 to 8 Nm (71 lb-in).
   • Stage 3: Tighten bolts 7 and 8 to 8 Nm (71 lb-in) then an additional 45 degrees.
   • Stage 4: Loosen bolts 5 and 6.
     • Tighten bolts 5 and 6 to 8 Nm (71 lb-in) then an additional 45 degrees.
   • Stage 5: Tighten bolts 9, 10, 11 and 12 to 8 Nm (71 lb-in) then an additional 45 degrees.
   • Stage 6: Tighten bolts 13 and 14 to 8 Nm (71 lb-in).
   • Stage 7: Tighten bolts 15 and 16 to 8 Nm (71 lb-in) then an additional 45 degrees.
   • Stage 8: Loosen bolts 13 and 14.
     • Tighten bolts 13 and 14 to 8 Nm (71 lb-in) then an additional 45 degrees.
       Fig 3: 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: Location of Camshafts In 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.
5. Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown in illustration in the following stages:
   • Stage 1: Tighten bolts 1, 2, 3 and 4 to 8 Nm (71 lb-in) then an additional 45 degrees.
   • Stage 2: Tighten bolts 5 and 6 to 8 Nm (71 lb-in).
   • Stage 3: Tighten bolts 7 and 8 to 8 Nm (71 lb-in) then an additional 45 degrees.
   • Stage 4: Loosen bolts 5 and 6.
     • Tighten bolts 5 and 6 to 8 Nm (71 lb-in) then an additional 45 degrees.
   • Stage 5: Tighten bolts 9, 10, 11 and 12 to 8 Nm (71 lb-in) then an additional 45 degrees.
   • Stage 6: Tighten bolts 13 and 14 to 8 Nm (71 lb-in).
   • Stage 7: Tighten bolts 15 and 16 to 8 Nm (71 lb-in) then an additional 45 degrees.
   • Stage 8: Loosen bolts 13 and 14.
     • Tighten bolts 13 and 14 to 8 Nm (71 lb-in) then an additional 45 degrees.
       Fig 5: 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 can occur.
NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Fig 6: Measuring Valve Clearance Using Feeler Gauge
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: Location of Colored Links And Timing Chain Routing and Marks

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

   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: Location of Bolts And Original Washer

      Courtesy of FORD MOTOR CO.
11. Remove the lockpin from the LH secondary timing chain tensioner.
    Fig 11: Location of LH Secondary Timing Chain Tensioner 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 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: Location of Colored Links And Timing Chain Routing and Marks

      Courtesy of FORD MOTOR CO.
14. Position the RH secondary timing assembly onto the camshafts.
    Fig 14: Location of RH Secondary Timing Assembly And 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: Location of Exhaust Camshaft Washer

      Courtesy of FORD MOTOR CO.
16. Remove the lockpin from the RH secondary timing chain tensioner.
    Fig 16: Location of RH Secondary Timing Chain Tensioner 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: Location of Crankshaft Dowel Pin Position

    Courtesy of FORD MOTOR CO.
NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Fig 18: Aligning Primary Timing Chain & Routing Colored Links With Timing Marks
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.
19. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 19: Location of Bolts And Lower LH Primary Timing Chain Guide

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

    Courtesy of FORD MOTOR CO.
21. 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 and install a suitable lockpin.
       Fig 21: Compressing Ratchet Plunger Using Soft-Jawed Vise

       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: Location of Primary Tensioner And Bolts

      Courtesy of FORD MOTOR CO.
23. As a post-check, verify correct alignment of all timing marks.
    • There are 48 links between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
    • There are 35 links between the LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket colored links (3).
      Fig 23: Aligning Primary Timing Chain & Routing Colored Links With Timing Marks

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

    Courtesy of FORD MOTOR CO.
NOTE: RH shown in illustration, LH similar.
NOTE: During removal, the O-ring seal may remain on the cylinder head. If so, remove the O-ring seal from the cylinder head, inspect the seal (replace as necessary) and install the O-ring seal on the VCT housing.
Fig 25: Location of VCT Housing-To-Cylinder Head O-Ring Seals
Courtesy of FORD MOTOR CO.
25. Inspect the VCT housing-to-cylinder head O-ring seals for damage and replace as necessary.
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 LH VCT housing and the 3 bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 26: Identifying LH VCT Housing Bolts Tightening Sequence

      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.
27. Install the RH VCT housing and the 3 bolts.
    • Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
      Fig 27: Identifying RH VCT Housing Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
28. Install the engine front cover. For additional information, refer to ENGINE FRONT COVER  .