Part 1

Camshaft














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.






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. NOTICE: 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.

- Tighten to 8 Nm (71 lb-in) then additional 45 degrees.






5. Loosen the 4 camshaft caps bolts.





6. Tighten the 4 camshaft caps bolts in the sequence shown.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then 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. For additional information, refer to Valve Clearance Check Adjustments.





8. Remove the 3 bolts and the RH valve train oil tube.





9. Rotate the RH camshafts to the TDC (Top Dead Center) position as shown.





10. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC (Top Dead Center) 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 (Variable Camshaft Timing) 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 (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 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 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.






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. NOTICE: 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.

- Tighten to 8 Nm (71 lb-in) then additional 45 degrees.






20. Loosen the 4 camshaft caps bolts.





21. Tighten the 4 camshaft caps bolts in the sequence shown.
- Tighten bolts 8, 9, 10 and 11 to 8 Nm (71 lb-in) then 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. For additional information, refer to Valve Clearance Check Adjustments.





23. Remove the 3 bolts and the LH valve train oil tube.





24. Rotate the LH camshafts to the TDC (Top Dead Center) position as shown.





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 (Variable Camshaft Timing) 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 (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 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 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 (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 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 (Variable Camshaft Timing) assembly colored link (1) and the LH intake VCT (Variable Camshaft Timing) assembly colored link (2).

- There is 35 links in between LH 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 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 (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 intake VCT (Variable Camshaft Timing) oil control solenoid and the bolt.
- Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.






39. NOTICE: 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 (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 RH intake VCT (Variable Camshaft Timing) 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. NOTICE: Only use a 3M(TM) 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(TM) 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(TM) 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 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. 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 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(R) 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(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 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. NOTICE: Do not expose the Motorcraft(R) 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 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 (Variable Camshaft Timing) 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 (Variable Camshaft Timing) solenoid seal(s).






56. NOTICE: Failure to use the correct 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 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(R) 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 4 bolts and 7 stud bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).






58. Make sure the VCT (Variable Camshaft Timing) seals in the valve cover are below the top of the VCT (Variable Camshaft Timing) oil control solenoid electrical connector or the VCT (Variable Camshaft Timing) seal may leak oil.





59. Position the 2 power steering hose brackets 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 (Heated Oxygen Sensor) and CMS (Catalyst Monitor Sensor) electrical connectors.
- Attach the 2 wiring harness retainers to the RH valve cover.






64. Install the 3 RH -coil-on-plugs and the 3 bolts.
- Tighten to 7 Nm (62 lb-in).






65. Connect the 3 RH coil-on-plug electrical connectors.