Steps 46-90
Engine
Engine Upper
Engine Upper - LH Cylinder Head
Engine Upper - RH Cylinder Head
Engine Front
Timing Drive Components - Roller Timing Chain
NOTE: Stamped steel RH timing chain guide shown, composite guide similar.
Timing Drive Components - Inverted Tooth Timing Chain
Lower Engine Block (View 1)
Lower Engine Block (View 2)
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
NOTICE: Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.
NOTE: The engine comes equipped with either a roller primary timing chain or an inverted tooth primary timing chain. The roller timing chain engine comes equipped with either a composite RH timing chain guide requiring the timing chain to ride on the outer side of the guide or a stamped steel RH timing chain guide requiring the timing chain to ride on the inner side of the guide. All roller timing chain engine replacement RH timing chain guides will be the stamped steel design.
NOTE: Early build engine cylinder heads and fuel injectors differ in design than late build engines. Although these parts are serviced in the same way, the parts are not interchangeable between early build and late build engines. The level of cylinder heads and fuel injectors can be determined by inspecting the engine code label. Early build engines are built through 09/14/2010 (0S 490 BA) and late build engines are built on or after 09/15/2010 (1S 490 BA).
NOTE: Assembly of the engine requires various inspections/measurements of the engine components (engine block, crankshaft, connecting rods, pistons and piston rings). These inspections/measurements will aid in determining if the engine components will require replacement. For additional information, refer to Engine System - General Information Service and Repair.
All engines
46. NOTE: The valve tappets must be installed in their original positions.
NOTE: Coat the valve tappets with clean engine oil prior to installation.
NOTE: LH shown, RH similar.
Install the valve tappets.
47. NOTICE: 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.
Position the camshafts onto the RH cylinder head in the neutral position as shown.
48. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown 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.
49. NOTICE: 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.
Position the camshafts onto the LH cylinder head in the neutral position as shown.
50. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
Install the 8 camshaft caps and the 16 bolts. Tighten the bolts in the sequence shown 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.
51. 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. For additional information, refer to Valve Clearance Check Adjustments.
52. NOTE: The engine comes equipped with either a roller primary timing chain or an inverted tooth primary timing chain. The roller timing chain engine comes equipped with either a composite RH timing chain guide requiring the timing chain to ride on the outer side of the guide or a stamped steel RH timing chain guide requiring the timing chain to ride on the inner side of the guide. All roller timing chain engine replacement RH timing chain guides will be the stamped steel design.
Install the RH timing chain guide and bolt(s). Tighten to 10 Nm (89 lb-in).
1. Roller timing chain stamped steel RH guide.
2. Roller timing chain composite RH guide.
3. Inverted tooth timing chain RH guide.
53. Install the RH secondary timing chain tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
54. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Rotate the RH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.
55. Assemble the RH Variable Camshaft Timing (VCT) assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain.
- Align the colored links with the timing marks.
56. Position the RH secondary timing assembly onto the camshafts.
57. Install the new VCT bolt and the exhaust camshaft bolt 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.
58. Remove the lockpin from the RH secondary timing chain tensioner.
59. Install the LH secondary timing chain tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
60. NOTE: Use a camshaft sprocket bolt to turn the camshafts.
Rotate the LH camshafts to the TDC position and install the Camshaft Holding Tool on the flats of the camshafts.
61. Assemble the LH VCT assembly, the LH exhaust camshaft sprocket and the LH secondary timing chain.
- Align the colored links with the timing marks.
62. Position the LH secondary timing assembly onto the camshafts.
63. Install the new VCT bolt and the exhaust camshaft bolt 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.
64. Remove the lockpin from the LH secondary timing chain tensioner.
65. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
Engine equipped with an inverted tooth timing chain
66. Install the crankshaft timing chain sprocket.
67. Install the upper LH primary timing chain guide and the bolt.
- Tighten to 10 Nm (89 lb-in).
68. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
69. Install the lower LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
70. Install the primary timing chain tensioner arm.
71. 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.
72. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
Install the primary tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Remove the lockpin.
73. 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).
Engine equipped with a roller timing chain
74. Install the crankshaft timing chain sprocket.
75. Install the upper LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
76. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
77. Install the lower LH primary timing chain guide and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
78. Install the primary timing chain tensioner arm.
79. Reset the primary timing chain tensioner.
- Rotate the lever counterclockwise.
- Using a soft-jawed vise, compress the plunger.
- Align the hole in the lever with the hole in the tensioner housing.
- Install a suitable lockpin.
80. NOTE: It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
Install the primary tensioner and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Remove the lockpin.
81. As a post-check, verify correct alignment of all timing marks.
- There are 38 links between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2).
- There are 27 links between the LH intake VCT assembly colored link (2) and the crankshaft sprocket colored link (3).
All engines
82. Inspect the VCT housing seals for damage and replace as necessary.
83. NOTE: RH shown, 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.
Inspect the VCT housing-to-cylinder head O-ring seals for damage and replace as necessary.
84. NOTICE: 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.
Install the LH VCT housing and the 3 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
85. NOTICE: 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 instruction will result in severe engine damage.
Install the RH VCT housing and the 3 bolts.
- Tighten in the sequence shown to 10 Nm (89 lb-in).
86. Install the Alignment Pins.
87. 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 17, 18, 19 and 20 must be installed within 4 minutes of the initial sealant application. The remainder of the engine front cover bolts and the engine mount bracket 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 these instructions 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 3 engine mount bracket 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.
88. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and bolts 17, 18, 19 and 20.
- Tighten in sequence to 3 Nm (27 lb-in).
89. Remove the Alignment Pins.
90. NOTE: Do not tighten the bolts at this time.
Install the engine mount bracket and the 3 bolts.
