Part 4
Camshaft
Special Tool(s)
Material(s)
Installation
1. NOTE: The following steps are for the RH (Right Hand) camshafts only.
NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the RH (Right Hand) cylinder head in the neutral position as shown.
2. NOTICE: 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.
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.
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.
5. Loosen the 4 camshaft caps bolts.
6. Tighten the 4 bolts in the sequence shown.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
7. NOTICE: 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 Adjustments.
8. Remove the 3 bolts and the RH (Right Hand) valve train oil tube.
9. Rotate the RH (Right Hand) camshafts to the TDC (Top Dead Center) position as shown.
10. NOTE: The 303-1248 will hold the camshafts in the TDC (Top Dead Center) position.
Install 303-1248 onto the flats of the RH (Right Hand) camshafts.
11. Compress the RH (Right Hand) secondary timing chain tensioner and install the 303-1530 to retain the tensioner in the collapsed position.
12. Assemble the RH (Right Hand) VCT (Variable Camshaft Timing) assembly, the RH (Right Hand) exhaust camshaft sprocket and the RH (Right Hand) 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 (Right Hand) secondary timing assembly.
Position the 2 RH (Right Hand) VCT (Variable Camshaft Timing) assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT (Variable Camshaft Timing) assemblies with the dowel pins in the camshafts.
14. Install the 2 new RH (Right Hand) VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) oil control solenoids are removed for clarity.
Compress the RH (Right Hand) secondary timing chain tensioner and remove the 303-1530. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
16. NOTE: The following steps are for the LH (Left Hand) camshafts only.
NOTE: Coat the camshafts with clean engine oil prior to installation.
Position the camshafts onto the LH (Left Hand) cylinder head in the neutral position as shown.
17. NOTICE: 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.
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.
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.
20. Loosen the 4 camshaft caps bolts.
21. Tighten the 4 bolts in the sequence shown.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then an additional 45 degrees.
22. NOTICE: 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 Adjustments.
23. Remove the 3 bolts and the LH (Left Hand) valve train oil tube.
24. Rotate the LH (Left Hand) camshafts to the TDC (Top Dead Center) position as shown.
25. NOTE: The 303-1248 will hold the camshafts in the TDC (Top Dead Center) position.
Install 303-1248 onto the flats of the LH (Left Hand) camshafts.
26. Compress the LH (Left Hand) secondary timing chain tensioner and install the 303-1530 to retain the tensioner in the collapsed position.
27. Assemble the LH (Left Hand) VCT (Variable Camshaft Timing) assembly, the LH (Left Hand) exhaust camshaft sprocket and the LH (Left Hand) 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 (Left Hand) secondary timing assembly.
Position the 2 LH (Left Hand) VCT (Variable Camshaft Timing) assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT (Variable Camshaft Timing) assemblies with the dowel pins in the camshafts.
29. Install the 2 new LH (Left Hand) VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) oil control solenoids are removed for clarity.
Compress the LH (Left Hand) secondary timing chain tensioner and remove the 303-1530. Make sure the secondary timing chain is centered on the timing chain tensioner guides.
31. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the TDC (Top Dead Center) position (crankshaft dowel pin at 11 o'clock).
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 (Variable Camshaft Timing) assemblies and the crankshaft sprocket.
33. Install the 2 bolts and the lower LH (Left Hand) primary timing chain guide.
- Tighten to 10 Nm (89 lb-in).
34. Install the primary timing chain tensioner arm.
35. 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.
36. 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.
37. As a post-check, verify correct alignment of all timing marks.
1. There are 48 links in between the RH (Right Hand) intake VCT (Variable Camshaft Timing) assembly colored link (1) and the LH (Left Hand) intake VCT (Variable Camshaft Timing) assembly colored link (2).
2. There are 35 links in between LH (Left Hand) intake VCT (Variable Camshaft Timing) assembly colored link (2) and the 2 crankshaft sprocket links (3).
38. NOTICE: Do not use excessive force when installing the VCT (Variable Camshaft Timing) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT (Variable Camshaft Timing) oil control solenoid, inspect the bore and VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) oil control solenoid.
NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.
Install the LH (Left Hand) intake VCT (Variable Camshaft Timing) oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in).
39. NOTICE: Do not use excessive force when installing the VCT (Variable Camshaft Timing) oil control solenoid. Damage to the mega cap could cause the cylinder head to be inoperable. If difficult to install the VCT (Variable Camshaft Timing) oil control solenoid, inspect the bore and VCT (Variable Camshaft Timing) 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 (Variable Camshaft Timing) oil control solenoid.
NOTE: Keep the VCT (Variable Camshaft Timing) oil control solenoid clean of dirt and debris.
Install the LH (Left Hand) intake VCT (Variable Camshaft Timing) oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in).
40. Remove the RH (Right Hand)303-1248.
41. Install the RH (Right Hand) 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 (Left Hand)303-1248.
43. Install the LH (Left Hand) 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. NOTICE: Only use a 3M Roloc(R) 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(R) 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. NOTICE: 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.
NOTICE: Do not use wire brushes, power abrasive discs or 3M Roloc(R) 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(R) Silicone Gasket Remover and allow to set for several minutes.
3. Remove the Motorcraft(R) Silicone Gasket Remover. A second application of Motorcraft(R) Silicone Gasket Remover may be required if residual traces of silicone or gasket material remain.
4. Apply Motorcraft(R) 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.
46. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install 307-399
47. NOTICE: Failure to use Motorcraft(R) High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.
NOTE: 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(R) Silicone Gasket Remover and Motorcraft(R) Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.
Apply a 3 mm (0.1181 in) bead of Motorcraft(R) High Performance Engine RTV Silicone to the sealing surface of the front cover.
- Apply a 5.5 mm (0.22 in) bead of Motorcraft(R) 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 shown to 3 Nm (27 lb-in).
49. Remove 307-399.
50. Install the M6 engine front cover bolt. Do not tighten at this time.
51. Install the 2 upper M10 engine front cover bolts. Do not tighten the bolts at this time.
52. Install the lower M10 bolt. Do not tighten at this time.
53. Install the remaining engine front cover bolts. Tighten all of the engine front cover bolts in the sequence shown 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.
54. 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).
