Part 5

Camshaft

Special Tool(s)










Material(s)






55. 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 (Variable Camshaft Timing) seal(s).





56. 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: 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(R) Silicone Gasket Remover and Motorcraft(R) Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.

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





57. Using a new gasket, install the RH (Right Hand) valve cover and tighten the 3 bolts and 8 stud bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





58. Ensure the VCT (Variable Camshaft Timing) seals in the valve cover are below the top of the connector (flat portion) on the VCT (Variable Camshaft Timing) oil control valve otherwise the interface may leak.





59. Attach the wiring harness retainer.





60. Connect the 3 fuel injector electrical connectors and attach the 2 wiring harness retainers to the RH (Right Hand) valve cover stud bolts.





61. Connect the 2 VCT (Variable Camshaft Timing) oil control solenoid electrical connectors and attach the 2 oil control solenoid wiring harness retainers.





62. Attach the 3 wire harness retainers from the main engine wiring harness to the RH (Right Hand) valve cover.





63. Connect the HO2S (Heated Oxygen Sensor) electrical connector and attach the wiring harness retainer to the RH (Right Hand) valve cover.





64. Install the RH (Right Hand) ignition coils.

- Tighten to 7 Nm (62 lb-in).





65. Connect the 3 RH (Right Hand) coil-on-plug electrical connectors.





66. Using a new gasket, install the intake manifold and the 7 bolts.

1. Tighten in the sequence shown in 2 stages.

- Stage 1: Tighten to 10 Nm (89 lb-in).

- Stage 2: Tighten an additional 45 degrees.





67. Install the upper intake manifold support bolt.

- Tighten to 10 Nm (89 lb-in).





68. Connect the crankcase ventilation hose to the PCV (Positive Crankcase Ventilation) valve. REFER to Quick Connect Coupling Quick Connect Coupling





69. Attach the 2 wiring harness/coolant tube retainers to the upper intake manifold.





70. Connect the EVAP (Evaporative Emission) vapor tube to the EVAP (Evaporative Emission) canister vent solenoid.





71. Connect the EVAP (Evaporative Emission) canister vent solenoid and throttle body electrical connectors.

1. Attach the 2 wiring harness pin-type retainers (1 shown).





72. 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).





73. 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 (Variable Camshaft Timing) seal(s).





74. 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: 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(R) Silicone Gasket Remover and Motorcraft(R) Metal Surface Prep. Failure to follow this procedure can cause future oil leakage.

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





75. Using a new gasket, install the LH (Left Hand) valve cover and tighten the 4 bolts and 7 stud bolts.

- Tighten in the sequence shown to 10 Nm (89 lb-in).





76. Ensure the VCT (Variable Camshaft Timing) seals in the valve cover are below the top of the connector (flat portion) on the VCT (Variable Camshaft Timing) oil control valve otherwise the interface may leak.





77. NOTE: Coolant hose removed from graphic for clarity.

Attach the wiring harness retainer.





78. Connect the 3 fuel injector electrical connectors and attach the 2 wiring harness retainers to the LH (Left Hand) valve cover stud bolts.





79. Connect the LH (Left Hand) HO2S (Heated Oxygen Sensor) electrical connector and attach the wiring harness connector pin-type retainer to the LH (Left Hand) valve cover.





80. Attach the 2 wiring harness pin-type retainers.





81. Connect the 2 VCT (Variable Camshaft Timing) oil control solenoid electrical connectors and attach the 2 oil control solenoid wiring harness pin-type retainers (1 shown).





82. Attach the 3 wiring harness retainers to the LH (Left Hand) valve cover stud bolts.





83. Install the oil level indicator.





84. Install the LH (Left Hand) ignition coils.

- Tighten to 7 Nm (62 lb-in).





85. Connect the 3 LH (Left Hand) coil-on-plug electrical connectors.





86. Connect the crankcase vent tube to the LH valve cover.





87. Install a new crankshaft seal. REFER to Installation Crankshaft Front Seal.

88. Install the accessory drive belt tensioner. REFER to Exploded View [1][2]Diagrams.

89. Raise the engine and transaxle assembly into the vehicle.

90. Install the engine mount, the 3 bolts and the 4 engine mount nuts hand tight.





91. Tighten the 3 engine mount bolts.

- Tighten to 90 Nm (66 lb-ft).

92. Tighten the 4 engine mount nuts.

- Tighten to 63 Nm (46 lb-ft).

93. Install the 3 nuts and the bolt for the transaxle support insulator bracket.

- Tighten the nuts to 63 Nm (46 lb-ft).

- Tighten the bolt to 80 Nm (59 lb-ft).





94. Install the transaxle support insulator bracket through bolt and nut.

- Tighten to 175 Nm (129 lb-ft).





95. Connect the transaxle cooler tubes and install the 2 secondary latches.





96. If equipped, connect the oil cooler coolant hoses.





97. Install the RH (Right Hand) halfshaft support bracket and the bolt and stud bolt.

- Tighten to 40 Nm (30 lb-ft).





98. Install the 2 halfshaft support bracket studs.

- Tighten to 15 Nm (133 lb-in).





99. NOTE: Install a new compression seal whenever the PTU (Power Transfer Unit) is removed from the vehicle.

If equipped with AWD (All-Wheel Drive), using a small screwdriver, remove the compression seal and discard.





100. If equipped with AWD (All-Wheel Drive), using a soft face hammer, install the new compression seal.





101. If equipped with AWD (All-Wheel Drive), position the PTU (Power Transfer Unit) in place and install the 5 bolts.

- Tighten to 90 Nm (66 lb-ft).





102. If equipped with AWD (All-Wheel Drive), position the PTU (Power Transfer Unit) support bracket in place and install the 5 bolts.

- Tighten to 70 Nm (52 lb-ft).





103. Using a new gasket, install the RH (Right Hand) catalytic converter and 4 new nuts.

- Tighten to 40 Nm (30 lb-ft).





104. Connect the RH (Right Hand) CMS (Catalyst Monitor Sensor) electrical connector.





105. NOTE: A new PTU (Power Transfer Unit) shaft seal must be installed whenever the intermediate shaft is removed or damage to the components can occur.

If equipped with AWD (All-Wheel Drive), install a new intermediate shaft seal and deflector. REFER to Intermediate Shaft Seal and Deflector Intermediate Shaft Seal and Deflector.

106. NOTICE: The circlips are unique in size and shape for each shaft. Make sure to use the specified circlip for the application or vehicle damage may occur.

Install the correct new circlip on the inboard stub shaft.





107. Push the LH (Left Hand) stub shaft into the transmission so the circlip locks into the differential side gear.

- After insertion, pull the halfshaft inner end to make sure the circlip is locked.

108. Rotate the LH (Left Hand) wheel knuckle into position and insert the LH (Left Hand) halfshaft into the wheel hub.