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Engine Mechanical: Mechanical: Engine: Installation: Camshaft

Special Tools

Illustration Tool Name Tool Number
GF0000970
 Alignment Pins 307-399
GF0029191
 Camshaft Alignment Tool 303-1248
GF0000811
 Handle 205-153 (T80T-4000-W)
GF0029105
 Installer, Crankshaft Front Seal 303-1251
GF0000290
 Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B)
GF0002553
 Installer, Front Cover Oil Seal 303-335
GF0029085
 Installer, Seal 303-1247/2
GF0017081
 Powertrain Lift 014-00765
GF0000246
 Strap Wrench 303-D055 (D85L-6000-A)
Material

Item Specification
Motorcraft Metal Surface Prep
ZC-31		 -
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A
Silicone Gasket Remover
ZC-30		 -
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
CAUTION: 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, can cause engine failure.

All camshafts 

    CAUTION: 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.
  1. Rotate the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o'clock position.
    2. Fig 1: Rotating Crankshaft Counterclockwise Until Crankshaft Dowel Pin Is In 9 O'clock Position
    GF0029339Courtesy of FORD MOTOR CO.

    LH camshafts 

    CAUTION: The camshafts must remain in the neutral position during installation.
    NOTE: Coat the camshafts with clean engine oil prior to installation.
  2. Position the camshafts onto the LH cylinder head in the neutral position as shown.
    3. Fig 2: Verifying LH Camshafts Are In Neutral Position
    GF0029212Courtesy of FORD MOTOR CO.
    CAUTION: 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 in the sequence shown to 10 Nm (89 lb-in).
    4. Fig 3: Installing Camshaft Caps & Bolts In Sequence
    GF0029312Courtesy of FORD MOTOR CO.

    RH camshafts 

    CAUTION: The camshafts must remain in the neutral position during installation.
    NOTE: Coat the camshafts with clean engine oil prior to installation.
  4. Position the camshafts onto the RH cylinder head in the neutral position as shown.
    5. Fig 4: Positioning Camshafts Onto RH Cylinder Head In Neutral Position
    GF0029309Courtesy of FORD MOTOR CO.
    CAUTION: 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 in the sequence shown to 10 Nm (89 lb-in).
    6. Fig 5: Installing Camshaft Caps & Bolts In Sequence
    GF0029310Courtesy of FORD MOTOR CO.

    All camshafts 

    CAUTION: 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.
  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 .
    7. Fig 6: Measuring Valve Clearance
    GF0029313Courtesy of FORD MOTOR CO.

    LH camshafts 

    NOTE: Use a camshaft sprocket bolt to turn the camshafts.
  7. Rotate the LH camshafts to the top dead center position and install the special tool on the flats of the camshafts.
    8. Fig 7: Installing Special Tool (303-1248) On Flats Of Camshafts
    GF0029318Courtesy of FORD MOTOR CO.
  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.
    9. Fig 8: Aligning LH Exhaust Camshaft Sprocket & LH Secondary Timing Chain Colored Links With Timing Marks
    GF0029319Courtesy of FORD MOTOR CO.
  9. Position the LH secondary timing assembly onto the camshafts.
    10. Fig 9: Positioning LH Secondary Timing Assembly Onto Camshafts
    GF0029320Courtesy 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.
    11. Fig 10: Locating LH VCT Assembly Bolt & LH Exhaust Camshaft Sprocket Bolt
    GF0029205Courtesy of FORD MOTOR CO.
  11. Remove the lock pin from the LH secondary timing chain tensioner.
    12. Fig 11: Locating Lock Pin On LH Secondary Timing Chain Tensioner
    GF0029321Courtesy of FORD MOTOR CO.

    RH camshafts 

    NOTE: Use a camshaft sprocket bolt to turn the camshafts.
  12. Rotate the RH camshafts to the top dead center position and install the special tool on the flats of the camshafts.
    13. Fig 12: Installing Special Tool (303-1248) On Flats Of Camshafts
    GF0029314Courtesy of FORD MOTOR CO.
  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.
    14. Fig 13: Aligning RH Exhaust Camshaft Sprocket & RH Secondary Timing Chain Colored Links With Timing Marks
    GF0029315Courtesy of FORD MOTOR CO.
  14. Position the RH secondary timing assembly onto the camshafts.
    15. Fig 14: Positioning RH Secondary Timing Assembly Onto Camshafts
    GF0029316Courtesy 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.
    16. Fig 15: Locating RH VCT Assembly Bolt & RH Exhaust Camshaft Sprocket Bolt
    GF0029208Courtesy of FORD MOTOR CO.
  16. Remove the lock pin from the RH secondary timing chain tensioner.
    17. Fig 16: Identifying Lock Pin On RH Secondary Timing Chain Tensioner
    GF0029317Courtesy of FORD MOTOR CO.

    All camshafts 

  17. Rotate the crankshaft clockwise 60 degrees to the top dead center position (crankshaft dowel pin at 11 o'clock).
    18. Fig 17: Identifying Crankshaft Dowel Pin At 11 O'clock
    GF0029340Courtesy 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. Fig 18: Aligning Timing Marks On VCT Assemblies & Crankshaft Sprocket
    GF0029323Courtesy of FORD MOTOR CO.
  19. Install the lower LH primary timing chain guide and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    20. Fig 19: Locating Lower LH Primary Timing Chain Guide Bolts
    GF0029200Courtesy of FORD MOTOR CO.
  20. Install the primary timing chain tensioner arm.
    21. Fig 20: Locating Primary Timing Chain Tensioner Arm
    GF0029199Courtesy of FORD MOTOR CO.
  21. 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 lock pin.
    22. Fig 21: Compressing Plunger Using A Soft-Jawed Vise
    GF0029324Courtesy 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 lock pin.
    23. Fig 22: Locating Primary Tensioner Bolts
    GF0029325Courtesy of FORD MOTOR CO.
  23. As a post-check, verify correct alignment of all timing marks.
    24. Fig 23: Verifying Correct Alignment Of All Timing Marks
    GF0029326Courtesy of FORD MOTOR CO.
  24. Install new VCT housing seals.
    25. Fig 24: Locating VCT Housing Seals
    GF0029197Courtesy of FORD MOTOR CO.
    CAUTION: Make sure the dowels on the VCT housing are fully engaged in the cylinder head prior to tightening the bolts.
  25. Install the LH VCT housing and the 3 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    26. Fig 25: Identifying LH VCT Housing Bolts Tightening Sequence
    GF0029327Courtesy of FORD MOTOR CO.
    CAUTION: Make sure the dowels on the VCT housing are fully engaged in the cylinder head prior to tightening the bolts.
  26. Install the RH VCT housing and the 3 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    27. Fig 26: Identifying RH VCT Housing Bolts Tightening Sequence
    GF0029328Courtesy of FORD MOTOR CO.
  27. Install the special tools.
    28. Fig 27: Identifying Special Tool (307-399)
    GF0029329Courtesy of FORD MOTOR CO.
    CAUTION: Failure to use the correct RTV Silicone Sealant (TA-357) 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  28. Apply a 3.0 mm (0.11 in) bead of RTV Silicone Sealant (TA-357) to the engine front cover sealing surfaces including the 3 engine mount bracket bosses.
    • Apply a 5.5 mm (0.21 in) bead of RTV Silicone Sealant (TA-357) 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.
    29. Fig 28: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Engine Front Cover Sealing Surfaces
    GF0029330Courtesy of FORD MOTOR CO.
    NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  29. Install the engine front cover and bolts 17, 18, 19 and 20.
    • Tighten in sequence to 3 Nm (27 lb-in).
    30. Fig 29: Installing Engine Front Cover & Bolts In Sequence
    GF0029331Courtesy of FORD MOTOR CO.
  30. Remove the special tools (alignment pins).
    31. NOTE: Do not tighten the bolts at this time.
  31. Install the engine mount bracket and the 3 bolts.
    32. Fig 30: Locating Engine Mount Bracket & Bolts
    GF0029188Courtesy of FORD MOTOR CO.
    CAUTION: Do not expose the RTV Silicone Sealant (TA-357) to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
  32. 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 2 stages:
    • Stage 1: Tighten bolts 1 thru 22 to 10 Nm (89 lb-in) and bolts 23, 24 and 25 to 15 Nm (11 lb-ft).
    • Stage 2: Tighten bolts 1 thru 22 to 24 Nm (18 lb-ft) and bolts 23, 24 and 25 to 75 Nm (55 lb-ft).
    33. Fig 31: Identifying Tightening Of Engine Front Cover Bolts & Engine Mount Bracket Bolts In Sequence
    GF0029332Courtesy of FORD MOTOR CO.
  33. Install the engine mount bracket and the 2 bolts.
    • Tighten to 24 Nm (18 lb-ft).
    34. Fig 32: Locating Engine Mount Bracket & Bolts
    GF0029186Courtesy of FORD MOTOR CO.
  34. Install the 2 engine mount studs.
    • Tighten to 18 Nm (13 lb-ft).
    35. Fig 33: Locating Engine Mount Studs
    GF0029187Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
  35. Using the special tools, install a new crankshaft front seal.
    36. Fig 34: Installing Crankshaft Front Seal Using Special Tools (303-102) & (303-1251)
    GF0029107Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the outside diameter sealing surfaces with clean engine oil.
  36. Using the special tools, install the crankshaft pulley.
    37. Fig 35: Installing Crankshaft Pulley Using Special Tools (303-102) & (303-335)
    GF0017018Courtesy of FORD MOTOR CO.
  37. Using the special tool, install the crankshaft pulley washer and new bolt and tighten in 4 stages.
    • Stage 1: Tighten to 120 Nm (89 (lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
    38. Fig 36: Installing Crankshaft Pulley Washer & Bolt Using Special Tools (303-D055)
    GF0029104Courtesy of FORD MOTOR CO.
  38. Install the accessory drive belt tensioner and the 3 bolts.
    • Tighten to 11 Nm (8 lb-ft).
    39. Fig 37: Locating Accessory Drive Belt Tensioner Bolts
    GF0029185Courtesy of FORD MOTOR CO.
  39. Install the power steering pump and the 3 bolts.
    • Tighten to 24 Nm (18 lb-ft).
    40. Fig 38: Locating Power Steering Pump Bolts
    GF0031411Courtesy of FORD MOTOR CO.
    NOTE: Installation of new seals is only required if damaged seals were removed during disassembly of the engine.
    NOTE: Spark plug tube seal installation shown, variable camshaft timing (VCT) seal installation similar.
  40. Using the special tools, install new VCT solenoid and/or spark plug tube seals.
    41. Fig 39: Installing VCT Solenoid And/Or Spark Plug Tube Seals Using Special Tools (205-153) & (303-1247/2)
    GF0029093Courtesy of FORD MOTOR CO.
    CAUTION: Failure to use the correct RTV Silicone Sealant (TA-357) 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  41. Apply a 8 mm (0.31 in) bead of RTV Silicone Sealant (TA-357) to the engine front cover-to-RH cylinder head joints.
    42. Fig 40: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Engine Front Cover-To-RH Cylinder Head Joints
    GF0029100Courtesy of FORD MOTOR CO.
  42. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    43. Fig 41: Installing RH Valve Cover Stud Bolts In Sequence
    GF0029101Courtesy of FORD MOTOR CO.
    CAUTION: Failure to use the correct RTV Silicone Sealant (TA-357) 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  43. Apply a 8 mm (0.31 in) bead of RTV Silicone Sealant (TA-357) to the engine front cover-to-LH cylinder head joints.
    44. Fig 42: Applying Bead Of Motorcraft High Performance Engine RTV Silicone To Engine Front Cover-To-LH Cylinder Head Joints
    GF0029094Courtesy of FORD MOTOR CO.
  44. Using a new gasket, install the LH valve cover and 11 stud bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    45. Fig 43: Installing LH Valve Cover Stud Bolts In Sequence
    GF0029095Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  45. Install the 6 coil-on-plug assemblies and the 6 bolts.
    • Tighten to 7 Nm (62 lb-in).
    46. Fig 44: Locating Coil-On-Plugs & Bolts
    GF0029180Courtesy of FORD MOTOR CO.
  46. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
  47. Connect the 3 LH coil-on-plug electrical connectors.
    48. Fig 45: Locating LH Coil-On-Plug Electrical Connectors
    GF0029179Courtesy of FORD MOTOR CO.
  48. Connect the LH camshaft VCT solenoid electrical connector.
    49. Fig 46: Locating LH VCT Solenoid Electrical Connector
    GF0029178Courtesy of FORD MOTOR CO.
  49. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
  50. Connect the heated positive crankcase ventilation (PCV) valve electrical connector.
    51. Fig 47: Locating Heated PCV Valve Electrical Connector
    GF0029177Courtesy of FORD MOTOR CO.
  51. Connect the 3 RH coil-on-plug electrical connectors.
    52. Fig 48: Locating RH Coil-On-Plug Electrical Connectors
    GF0029176Courtesy of FORD MOTOR CO.
  52. Connect the RH VCT solenoid electrical connector.
    53. Fig 49: Locating RH Variable Camshaft Timing (VCT) Solenoid Electrical Connector
    GF0029175Courtesy of FORD MOTOR CO.
  53. Connect the power steering pressure (PSP) switch electrical connector.
    54. Fig 50: Locating PSP Switch Electrical Connector
    GF0029174Courtesy of FORD MOTOR CO.
  54. Connect the RH catalyst monitor sensor electrical connector.
    55. Fig 51: Locating RH Catalyst Monitor Electrical Connector
    GF0029150Courtesy of FORD MOTOR CO.
  55. Using new gaskets, install the upper intake manifold and the 6 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    56. Fig 52: Installing Upper Intake Manifold Bolts In Sequence
    GF0029082Courtesy of FORD MOTOR CO.
  56. Install the upper intake manifold support bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
    57. Fig 53: Locating Upper Intake Manifold Support Bracket Bolt
    GF0029172Courtesy of FORD MOTOR CO.
  57. Install the upper intake manifold support bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
    58. Fig 54: Locating Upper Intake Manifold Support Bracket Bolt
    GF0029171Courtesy of FORD MOTOR CO.
  58. Attach the wiring harness retainers to the upper intake manifold.
    59. Fig 55: Locating Wiring Harness Retainers From Upper Intake Manifold
    GF0029170Courtesy of FORD MOTOR CO.
  59. Connect the throttle body electrical connector.
    60. Fig 56: Locating Throttle Body Electrical Connector
    GF0029169Courtesy of FORD MOTOR CO.
  60. Connect the PCV hose to the PCV valve.
    61. Fig 57: Identifying PCV Hose From PCV Valve
    GF0029168Courtesy of FORD MOTOR CO.
  61. Connect the PCV fitting electrical connector.
    62. Fig 58: Identifying Positive Crankcase Ventilation (PCV) Fitting Electrical Connector
    GF0029167Courtesy of FORD MOTOR CO.
  62. If equipped, attach the engine block heater wiring harness retainers.
  63. Raise the engine and transaxle assembly into the vehicle.
  64. Install the engine mount and the 3 bolts.
    • Tighten to 90 Nm (66 lb-ft).
    65. Fig 59: Locating Engine Mount Bolts
    GF0031368Courtesy of FORD MOTOR CO.
  65. Install the 4 engine mount nuts.
    • Tighten to 63 Nm (46 lb-ft).
    66. Fig 60: Locating Engine Mount Nuts
    GF0031367Courtesy of FORD MOTOR CO.
  66. Install the engine mount brace, the nut and the bolt.
    • Tighten to 20 Nm (15 lb-ft).
    67. Fig 61: Locating Nut, Bolt & Engine Mount Brace
    GF0031366Courtesy of FORD MOTOR CO.
  67. Install the transaxle support insulator bracket, the 3 nuts and the bolt.
    • Tighten to 63 Nm (46 lb-ft).
    68. Fig 62: Identifying Transaxle Support Insulator Bracket, Nuts & Bolts
    GF0031406Courtesy of FORD MOTOR CO.
  68. Install the transaxle support insulator through bolt and nut.
    • Tighten to 175 Nm (129 lb-ft).
    69. Fig 63: Identifying Transaxle Support Insulator Bolt
    GF0031405Courtesy of FORD MOTOR CO.

    All wheel drive (AWD) vehicles 

    CAUTION: A new powertrain transfer unit (PTU) seal must be installed whenever the intermediate shaft is removed.
  69. Install a new powertrain transfer unit (PTU) seal. For additional information, refer to TRANSFER CASE - POWER TRANSFER UNIT (PTU) .
    70. NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.
  70. Position the RH halfshaft/intermediate shaft assembly in the PTU and in the steering knuckle and install the 2 bolts.
    • Tighten to 40 Nm (30 lb-ft).
    71. Fig 64: Locating RH Halfshaft Bearing Support Bracket Bolts
    GF0028972Courtesy of FORD MOTOR CO.

    Front wheel drive (FWD) vehicles 

    NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new if necessary.
  71. Position the RH halfshaft/intermediate shaft assembly in the transaxle and in the steering knuckle and install the 2 stud bolts.
    • Tighten to 55 Nm (41 lb-ft).
    72. Fig 65: Locating Stud Bolts & RH Halfshaft/Intermediate Shaft Assembly
    GF0031402Courtesy of FORD MOTOR CO.
    NOTE: Do not tighten the 2 catalytic converter support bracket bolts at this time.
  72. Install the converter support bracket and the 2 bolts.
    73. Fig 66: Identifying RH Catalytic Converter Support Bracket Bolts
    GF0029147Courtesy of FORD MOTOR CO.
  73. Install the catalytic converter bracket bolt and the nut.
    1. Tighten the nut to 40 Nm (30 lb-ft).
    2. Tighten the bolt to 55 Nm (41 lb-ft).
    74. Fig 67: Locating Catalytic Converter Bracket Bolt & Nut
    GF0031422Courtesy of FORD MOTOR CO.
  74. Tighten the 2 RH catalytic converter support bracket bolts to 20 Nm (15 lb-ft).
    75. Fig 68: Identifying RH Catalytic Converter Support Bracket Bolts
    GF0029147Courtesy of FORD MOTOR CO.

    All vehicles 

    NOTE: Prior to installation of the halfshaft, inspect the halfshaft sealing surface for wear or damage and install new, if necessary.
  75. Install the LH halfshaft into the transaxle.
    76. Fig 69: Identifying LH Halfshaft
    GF0029079Courtesy of FORD MOTOR CO.
  76. If equipped, connect the oil cooler coolant hoses.
    77. Fig 70: Locating Oil Cooler Coolant Hoses
    GF0031399Courtesy of FORD MOTOR CO.
  77. Using the special tool, raise the subframe into the installed position.
    78. Fig 71: Positioning Special Tool (014-00765) Under Subframe Assembly
    GF0028656Courtesy of FORD MOTOR CO.
  78. Install the 2 middle subframe nuts.
    • Tighten to 133 Nm (98 lb-ft).
    79. Fig 72: Locating Middle Subframe Nuts
    GF0031313Courtesy of FORD MOTOR CO.
  79. Install the 2 front subframe nuts.
    • Tighten to 133 Nm (98 lb-ft).
    80. Fig 73: Locating Front Subframe Nuts
    GF0031312Courtesy of FORD MOTOR CO.
  80. Position the subframe support brackets in place and loosely install the 4 bolts.
    81. Fig 74: Locating Subframe Support Brackets And Bolts
    GF0029660Courtesy of FORD MOTOR CO.
  81. Install the 2 rear subframe bracket nuts.
    • Tighten to 133 Nm (98 lb-ft).
    82. Fig 75: Locating Rear Subframe Nuts
    GF0029659Courtesy of FORD MOTOR CO.
  82. Tighten the 4 subframe support bracket bolts.
    • Tighten to 90 Nm (66 lb-ft).
    83. Fig 76: Locating Subframe Support Brackets And Bolts
    GF0029660Courtesy of FORD MOTOR CO.
  83. Position the lower bumper on the subframe and install the 3 LH nuts.
    • Tighten to 9 Nm (80 lb-in).
    84. Fig 77: Locating LH Subframe-To-Lower Bumper Nuts
    GF0031301Courtesy of FORD MOTOR CO.
  84. Install the 3 RH lower bumper-to-subframe nuts.
    • Tighten to 9 Nm (80 lb-in).
    85. Fig 78: Locating RH Subframe-To-Lower Bumper Nuts
    GF0031300Courtesy of FORD MOTOR CO.
    NOTE: RH side shown, LH side similar.
  85. Install the ball joints in the steering knuckles and install the pinch bolts.
    • Tighten to 55 Nm (41 lb-ft).
    86. Fig 79: Locating Ball Joint Pinch Bolt
    GF0031304Courtesy of FORD MOTOR CO.
    NOTE: RH side shown, LH side similar.
  86. Position the stabilizer bar links in the lower control arms and install the nuts.
    • Tighten to 90 Nm (66 lb-ft).
    87. Fig 80: Locating Stabilizer Bar Link Nut
    GF0031349Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  87. Install the tie-rod ends and nuts.
    • Tighten to 48 Nm (35 lb-ft).
    • Install new cotter pins.
    88. Fig 81: Locating Tie-Rod Ends Nuts And Cotter Pin
    GF0028751Courtesy of FORD MOTOR CO.
    CAUTION: Do not allow the intermediate shaft to rotate while it is disconnected from the gear or damage to the clockspring can occur. If there is evidence that the intermediate shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to SUPPLEMENTAL RESTRAINT SYSTEM .
  88. Install the intermediate shaft onto the steering gear and install a new bolt.
    • Tighten to 23 Nm (17 lb-ft).
    89. Fig 82: Identifying Steering Intermediate Shaft Bolt
    GF0031398Courtesy of FORD MOTOR CO.
  89. Using a new banjo bolt and 2 new seals, install the PSP tube.
    • Tighten to 48 Nm (35 lb-ft).
    90. Fig 83: Locating Power Steering Pressure (PSP) Tube-To-Pump Banjo Bolt & Seals
    GF0031397Courtesy of FORD MOTOR CO.
  90. Install the engine roll restrictor-to-subframe through bolt.
    • Tighten to 103 Nm (76 lb-ft).
    91. Fig 84: Locating Roll Restrictor-To-Subframe Bolt
    GF0031346Courtesy of FORD MOTOR CO.
  91. Install the roll restrictor heat shield and the 2 nuts.
    • Tighten to 11 Nm (8 lb-ft).
    92. Fig 85: Locating Roll Restrictor Heat Shield Nuts
    GF0031344Courtesy of FORD MOTOR CO.
    NOTE: Apply the brake to keep the halfshaft from rotating.
  92. Install a new RH front halfshaft nut.
    • Tighten to 350 Nm (258 lb-ft).
    93. Fig 86: Locating RH Front Halfshaft Nut
    GF0031348Courtesy of FORD MOTOR CO.

    AWD vehicles 

  93. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and install the 4 bolts.
    • Tighten to 70 Nm (52 lb-ft).
    94. Fig 87: Locating Driveshaft Aside Bolts
    GF0031396Courtesy of FORD MOTOR CO.

    All vehicles 

  94. Install the power steering cooler bracket bolt to the RH side of the subframe.
    • Tighten to 9 Nm (80 lb-in).
    95. Fig 88: Identifying Power Steering Cooler Bracket Bolt
    GF0031395Courtesy of FORD MOTOR CO.
  95. Connect the power steering cooler hose.
    96. Fig 89: Identifying Power Steering Cooler Hose
    GF0031376Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
  96. Install a new engine oil filter.
    • Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
    97. Fig 90: Identifying Engine Oil Filter
    GF0029141Courtesy of FORD MOTOR CO.
  97. Connect the 2 transmission fluid cooler tubes.
    98. Fig 91: Locating Transmission Fluid Cooler Tubes
    GF0031423Courtesy of FORD MOTOR CO.
  98. Install the 2 secondary latches onto the transmission fluid cooler tubes.
    99. Fig 92: Locating Secondary Latches From Transmission Fluid Cooler Tubes
    GF0031391Courtesy of FORD MOTOR CO.
  99. Install the LH inner splash shield. For additional information, refer to FRONT END BODY PANELS .
  100. Install the radiator splash shield, the 3 pin-type retainers and the 7 screws.
    101. Fig 93: Locating Push Pin Fasteners & Front Splash Shield Screws
    GF0031299Courtesy of FORD MOTOR CO.
  101. Using a new gasket, install the Y-pipe and exhaust flexible pipe assembly and 4 new nuts.
    • Tighten to 40 Nm (30 lb-ft).
    102. Fig 94: Locating Exhaust Flexible Pipe, Y-Pipe & Nuts
    GF0031306Courtesy of FORD MOTOR CO.
  102. Install the 2 exhaust hangers and tighten the exhaust clamp.
    • Tighten to 40 Nm (30 lb-ft).
    103. Fig 95: Locating Exhaust Flexible Pipe Clamp & Exhaust Hangers
    GF0031305Courtesy of FORD MOTOR CO.
  103. Install the ground wire, the radio interference capacitor wire and the nut to the engine front cover stud.
    • Tighten to 10 Nm (89 lb-in).
    104. Fig 96: Removing Nut, Ground Wire & Radio Interference Capacitor Wire From Engine Front Cover Stud
    GF0031358Courtesy of FORD MOTOR CO.
  104. Install the ground wire and bolt to the engine front cover.
    • Tighten to 10 Nm (89 lb-in).
    105. Fig 97: Removing Bolt & Ground Wire From Engine Front Cover
    GF0031357Courtesy of FORD MOTOR CO.
  105. Attach the wiring harness retainer to the RH valve cover stud bolt.
    106. Fig 98: Identifying Wiring Harness Retainer From RH Valve Cover Stud Bolt
    GF0031390Courtesy of FORD MOTOR CO.
  106. Install the oil level indicator.
    107. Fig 99: Identifying Oil Level Indicator
    GF0029134Courtesy of FORD MOTOR CO.
  107. Connect the 2 engine wiring harness electrical connectors.
    • Attach the electrical connector to the LH valve cover.
    108. Fig 100: Identifying Engine Wiring Harness Electrical Connectors
    GF0031389Courtesy of FORD MOTOR CO.
  108. Connect the fuel hose routing clip to the transaxle stud.
    109. Fig 101: Identifying Fuel Hose Routing Clip From Transaxle Stud
    GF0031388Courtesy of FORD MOTOR CO.
  109. Connect the fuel supply tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    110. Fig 102: Identifying Fuel Supply Tube
    GF0031387Courtesy of FORD MOTOR CO.
  110. Connect the hose to the power steering reservoir.
    111. Fig 103: Disconnecting Hose From Power Steering Reservoir
    GF0031386Courtesy of FORD MOTOR CO.
  111. Connect the A/C suction tube fitting.
    • Install the safety clip onto the A/C fitting.
    112. Fig 104: Identifying Safety Clip On A/C Suction Tube Fitting
    GF0031353Courtesy of FORD MOTOR CO.
  112. Using a new O-ring seal, connect the A/C pressure tube fitting and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    113. Fig 105: Identifying A/C Pressure Tube Fitting Nut
    GF0031385Courtesy of FORD MOTOR CO.
  113. If equipped, attach the engine block heater harness retainers from to the radiator support and the A/C suction tube.
    114. Fig 106: Identifying Engine Block Heater Harness, Radiator Support, A/C Suction Tube & Engine Wiring Harness
    GF0031352Courtesy of FORD MOTOR CO.
  114. Connect the transaxle control electrical connector.
    115. Fig 107: Identifying Transaxle Control Electrical Connector
    GF0031384Courtesy of FORD MOTOR CO.
  115. Attach the control cable to the bracket.
    • Connect the transaxle control cable to the control lever.
    116. Fig 108: Locating Transaxle Control Cable From Control Lever
    GF0031383Courtesy of FORD MOTOR CO.
  116. Attach the wiring harness retainer to the transaxle control cable bracket.
    117. Fig 109: Locating Wiring Harness Retainer From Transaxle Control Cable Bracket
    GF0031382Courtesy of FORD MOTOR CO.
  117. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
    118. Fig 110: Locating Upper Radiator Hose, Lower Radiator Hose & Heater Hoses
    GF0031381Courtesy of FORD MOTOR CO.
  118. Connect the upper evaporative emissions (EVAP) tube quick connect coupling. to the purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION .
    119. Fig 111: Locating Upper Evaporative Emissions (EVAP) Tube Quick Connect Coupling
    GF0031380Courtesy of FORD MOTOR CO.
  119. Connect the vacuum hose to the upper intake manifold.
    120. Fig 112: Identifying Vacuum Hose From Upper Intake Manifold
    GF0031379Courtesy of FORD MOTOR CO.
  120. Install the ground wire and the bolt.
    • Tighten to 10 Nm (89 lb-in).
    • Attach the 2 wiring harness retainers to the cowl.
    121. Fig 113: Identifying Wiring Harness Retainers From Cowl
    GF0031378Courtesy of FORD MOTOR CO.
  121. Connect the power feed to the battery terminal and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    122. Fig 114: Locating Power Feed To Battery Terminal And Nut
    GF0028941Courtesy of FORD MOTOR CO.
  122. Connect the battery harness electrical connector.
    123. Fig 115: Identifying Battery Harness Electrical Connector
    GF0031377Courtesy of FORD MOTOR CO.
  123. Install the battery tray. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  124. Install the engine air cleaner and the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  125. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  126. Install the accessory drive belt and the power steering belt. For additional information, refer to ACCESSORY DRIVE .
    127. CAUTION: Do not expose the RTV Silicone Sealant (TA-357) to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
  127. Fill the engine with clean engine oil.
  128. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  129. Fill the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION .
  130. Recharge the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
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