Engine Mechanical - 3.7L: Removal & Installation Ford Edge I рестайлинг

Removal

Note. If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

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1. Remove the engine appearance cover. For additional information, refer to «ENGINE APPEARANCE COVER - EXPLODED VIEW»(ref-494555-S03086729622012081400000) .
2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
3. Disconnect the 2 PCM electrical connectors. Detach the 3 wiring harness retainers.
4. Disconnect the Evaporative Emission (EVAP) canister vent solenoid and throttle body electrical connectors. Detach the wiring harness pin-type retainer.
5. Disconnect the EVAP vapor tube from the EVAP canister vent solenoid. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) . Detach the pin-type retainer.
6. Release the clamps and disconnect the power brake booster vacuum supply hose and crankcase ventilation hose from the upper intake manifold.
7. Detach the 2 wiring harness/coolant tube retainers from the upper intake manifold.
8. Remove the upper intake manifold support bracket bolt.
9. Remove the 7 bolts and the upper intake manifold. Remove and discard the gasket. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.

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1. Using a new gasket, install the intake manifold and the 7 bolts. Tighten in the sequence shown in illustration in 2 stages. Stage 1: Tighten to 10 Nm (89 lb-in). Stage 2: Tighten an additional 45 degrees.
2. Install the upper intake manifold support bracket bolt. Tighten to 10 Nm (89 lb-in).
3. Attach the 2 wiring harness/coolant tube retainers to the upper intake manifold.
4. Connect the power brake booster vacuum supply hose and crankcase ventilation hose to the upper intake manifold
5. Connect the EVAP vapor tube to the EVAP canister vent solenoid. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) . Attach the pin-type retainer.
6. Connect the Evaporative Emission (EVAP) canister vent solenoid and throttle body electrical connectors. Attach the wiring harness pin-type retainer.
7. Connect the 2 PCM electrical connectors. Attach the 3 wiring harness retainers.
8. Install the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
9. Install the engine appearance cover. For additional information, refer to «ENGINE APPEARANCE COVER - EXPLODED VIEW»(ref-494555-S03086729622012081400000) .

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Note. 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.

Note. It is not necessary to remove the fuel rail from the intake manifold assembly.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
3. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-494611) .
4. Remove the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-494555-S18758340712012081400000) .
5. Remove the Air Cleaner (ACL) assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
6. Disconnect the 6 fuel injector electrical connectors.
7. Disconnect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
8. Remove the 2 thermostat housing-to-lower intake manifold bolts.
9. Remove the 10 bolts and the lower intake manifold. Remove and discard the intake manifold and thermostat housing gaskets. Clean and inspect all sealing surfaces.

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1. Using new intake manifold and thermostat housing gaskets, install the lower intake manifold and the 10 bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
2. Install the 2 thermostat housing-to-lower intake manifold bolts. Tighten to 10 Nm (89 lb-in).
3. Connect the fuel supply tube-to-fuel rail quick connect coupling. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
4. Connect the 6 fuel injector electrical connectors.
5. Install the Air Cleaner (ACL) assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
6. Install the upper intake manifold. For additional information, refer to «UPPER INTAKE MANIFOLD»(ref-494555-S18758340712012081400000) .
7. Fill and bleed the cooling system. For additional information, refer to «ENGINE COOLING»(ref-494611) .

Note. 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.

Note. Installation of new spark plug seals or Variable Camshaft Timing (VCT) seals is only required if seals are damaged.

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1. Remove the engine appearance cover. For additional information, refer to «ENGINE APPEARANCE COVER - EXPLODED VIEW»(ref-494555-S03086729622012081400000) .
2. Remove the crankcase vent tube. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
3. Remove the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.7L»(ref-494615) .
4. Remove the oil level indicator.
5. Disconnect the wiring harness connector. Detach the wiring harness connector pin-type retainer from the LH valve cover.
6. Detach the 2 wiring harness retainers from the LH valve cover stud bolts and position the harness aside.
7. Disconnect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Detach the wiring harness pin-type retainer.
8. Detach the 2 wiring harness pin-type retainers.
9. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector. Detach the wiring harness connector pin-type retainer from the LH valve cover.
10. Disconnect the 3 fuel injector electrical connectors. Detach the 2 wiring harness retainers from the LH valve cover stud bolts.
11. Detach the 2 wiring harness retainers and position the harness aside.
12. Loosen the 4 bolts and 7 stud bolts. Remove the valve cover. Discard the gasket.
13. Inspect the VCT solenoid seals. Remove any damaged seals. Using the Differential Bearing Cone Installer and Handle, remove and discard the seal(s).
14. Inspect the spark plug tube seals. Remove any damaged seals. Using the Spark Plug Tube Seal Remover and Handle, remove and discard the seal(s).
15. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.

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1. Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
2. Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).
3. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
4. Using a new gasket, install the LH valve cover and tighten the 4 bolts and 7 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
5. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
6. Attach the 2 wiring harness retainers.
7. Connect the 3 fuel injector electrical connectors. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
8. Connect the LH Heated Oxygen Sensor (HO2S) electrical connector. Attach the wiring harness connector pin-type retainer to the LH valve cover.
9. Attach the 2 wiring harness pin-type retainers.
10. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Attach the wiring harness pin-type retainer.
11. Attach the 2 wiring harness retainers to the LH valve cover stud bolts.
12. Connect the wiring harness connector. Attach the wiring harness connector pin-type retainer to the LH valve cover.
13. Install the oil level indicator.
14. Install the LH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.7L»(ref-494615) .
15. Install the crankcase vent tube. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
16. Install the engine appearance cover. For additional information, refer to «ENGINE APPEARANCE COVER - EXPLODED VIEW»(ref-494555-S03086729622012081400000) .

Note. 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.

Note. Installation of new spark plug seals or Variable Camshaft Timing (VCT) seals is only required if seals are damaged.

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1. Remove the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.7L»(ref-494615) .
2. Disconnect the HO2S and CMS electrical connectors. Detach the 2 wiring harness retainers from the RH valve cover.
3. Disconnect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Detach the 3 wiring harness retainers.
4. Disconnect the 3 fuel injector electrical connectors. Detach the 2 wiring harness retainers.
5. Detach the wiring harness retainer.
6. Remove the 2 nuts and position aside the power steering hose.
7. Loosen the 3 bolts and 8 stud bolts. Remove the valve cover. Discard the gasket.
8. Inspect the 2 VCT solenoid seals. Remove any damaged seals. Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
9. Inspect the spark plug tube seals. Remove any damaged seals. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
10. Clean the valve cover, cylinder head and engine front cover sealing surfaces with metal surface prep.

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1. Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
2. Using the Differential Bearing Cone Installer and Handle, install new VCT solenoid seal(s).
3. Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
4. Using a new gasket, install the RH valve cover and tighten the 4 bolts and 7 stud bolts. Tighten in the sequence shown in illustration to 10 Nm (89 lb-in).
5. Make sure the VCT seals in the valve cover are below the top of the VCT oil control solenoid electrical connector or the VCT seal may leak oil.
6. Position the power steering hose and install the 2 nuts. Tighten to 9 Nm (80 lb-in).
7. Attach the wiring harness retainer.
8. Connect the 3 fuel injector electrical connectors. Attach the 2 wiring harness retainers.
9. Connect the 2 Variable Camshaft Timing (VCT) oil control solenoid electrical connectors. Attach the 3 wiring harness retainers.
10. Connect the HO2S and CMS electrical connectors. Attach the 2 wiring harness retainers to the RH valve cover.
11. Install the RH ignition coils. For additional information, refer to «ENGINE IGNITION - 3.7L»(ref-494615) .

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1. Refer to the procedures and/or exploded views in this service information for any Warnings, Notices, Notes, Materials, Specifications, and Special Tools. Items in the exploded views may not be listed in order of removal.

Installation

1. Using the Front Crankshaft Seal Installer and Crankshaft Vibration Damper Installer, install a new crankshaft front seal.
2. Install the crankshaft pulley. For additional information, refer to «CRANKSHAFT PULLEY»(ref-494555-S31422447902012081400000) .

Scheme 992

1. Refer to the procedures and/or exploded views in this service information for any Warnings, Notices, Notes, Materials, Specifications, and Special Tools. Items in the exploded views may not be listed in order of removal.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Remove the transaxle. For additional information, refer to «AUTOMATIC TRANSMISSION - 6F50/6F55»(ref-494558) .
3. Remove the 8 bolts and the flexplate.

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1. Install the flexplate and the 8 bolts. Tighten in the sequence shown in illustration to 80 Nm (59 lb-ft).
2. Install the transaxle. For additional information, refer to «AUTOMATIC TRANSMISSION - 6F50/6F55»(ref-494558) .
3. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

Note. 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.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-494569) .
3. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-494597) .
4. Remove the engine appearance cover. For additional information, refer to «ENGINE APPEARANCE COVER - EXPLODED VIEW»(ref-494555-S03086729622012081400000) .
5. Remove the accessory drive belt, tensioner and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-494572) .
6. Using the Strap Wrench, remove the crankshaft pulley bolt and washer. Discard the bolt.
7. Using the 3 Jaw Puller, remove the crankshaft pulley.
8. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
9. Remove the 2 nuts and the roll restrictor heat shield.
10. Loosen the 2 roll restrictor through bolts.
11. Remove the RH front halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-494589) .
12. Remove the 2 lower power steering pump bolts.
13. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
14. If equipped, detach the engine block heater harness from the radiator support, the A/C suction tube and the engine wiring harness.
15. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
16. Remove the LH and RH valve covers. For additional information, refer to «VALVE COVER - LH»(ref-494555-S16131633692012081400000) and «VALVE COVER - RH»(ref-494555-S22477061102012081400000) .
17. Remove the bolt and detach the A/C suction tube.
18. Remove the safety clip and disconnect the A/C suction tube fitting. Remove the A/C suction tube. Discard the O-ring seal.
19. Remove the A/C pressure tube bracket bolt.
20. Remove the nut and disconnect the A/C pressure tube fitting. Discard the O-ring seal. Position the A/C pressure tube aside.
21. Remove the bolt and the ground wire from the engine front cover.
22. Remove the nut and the radio interference capacitor wire from the engine front cover stud.
23. Disconnect the PCM electrical connector and position the wiring harness aside.
24. Remove the 3 bolts and position the degas bottle aside.
25. Remove the 2 power steering reservoir nuts. Support the power steering reservoir and hose away from the front of the engine with a length of mechanic's wire.
26. Remove the top power steering pump bolt. Support the power steering pump and hose away from the front of the engine with a length of mechanic's wire.
27. Remove the generator nut and stud. Loosen the bolt and position the generator aside.
28. Position a floor jack with a block of wood under the front of the oil pan.
29. Loosen the transaxle mount through bolt.
30. Remove the nut, bolt and engine mount brace.
31. Remove the 4 engine mount nuts.
32. Remove the 3 bolts and the engine mount.
33. Remove the 2 bolts and the engine mount bracket.
34. Using the floor jack, lower the engine to access the lower engine front cover bolt. Remove the lower M10 engine front cover bolt.
35. Using the floor jack, raise the engine 100 mm (3.937 in).
36. Remove the 2 M10 engine front cover bolts.
37. Remove the 22 M8 engine front cover bolts.
38. Remove the M6 engine front cover bolt.
39. Using a suitable pry tool, locate the 7 pry pads shown in illustration and pry the engine front cover loose and remove.

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1. Clean the engine front cover using a 3M™ Roloc® 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.
2. Clean the sealing surfaces of the cylinder heads, the cylinder block and the oil pan in the following sequence. Remove any large deposits of silicone or gasket material. Apply silicone gasket remover and allow to set for several minutes. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain. 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. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
3. Install the Alignment Pins.
4. Apply a 3.0 mm (0.11 in) bead of Motorcraft® 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® 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.
5. Install the engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22. Tighten in sequence to 3 Nm (27 lb-in).
6. Remove the Alignment Pins.
7. Install the M6 engine front cover bolt.
8. Install the 2 upper M10 engine front cover bolts.
9. Using the floor jack, lower the engine to allow installation of the lower M10 engine front cover bolt. Install the lower M10 engine front cover bolt.
10. 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 illustration 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.
11. Install the engine mount bracket and the 2 bolts. Tighten to 30 Nm (22 lb-ft).
12. Use the floor jack to raise the engine to the installed position and install the engine mount and the 3 bolts. Tighten to 90 Nm (66 lb-ft).
13. Install the 4 engine mount nuts. Tighten to 63 Nm (46 lb-ft).
14. Install the engine mount brace, nut and bolt. Tighten to 20 Nm (177 lb-in).
15. Tighten the transaxle mount through bolt to 175 Nm (129 lb-ft).
16. Install the power steering pump and the 2 lower bolts. Tighten to 25 Nm (18 lb-ft).
17. Install the upper power steering pump bolt. Tighten to 25 Nm (18 lb-ft).
18. Install the power steering reservoir and the 2 nuts. Tighten to 8 Nm (71 lb-in).
19. Install the degas bottle and the 3 bolts. Tighten to 9 Nm (80 lb-in).
20. Position the generator and install the stud and nut. Tighten the stud to 8 Nm (71 lb-in). Tighten the nut to 47 Nm (35 lb-ft). Tighten the bolt to 47 Nm (35 lb-ft).
21. Connect the PCM electrical connector.
22. Install the radio interference capacitor wire and the nut to the engine front cover stud. Tighten to 10 Nm (89 lb-in).
23. Install the ground wire and bolt on the engine front cover. Tighten to 10 Nm (89 lb-in).
24. Using a new O-ring seal, connect the A/C pressure tube fitting and install the nut. Tighten to 8 Nm (71 lb-in).
25. Install the A/C pressure tube bracket and bolt. Tighten to 8 Nm (71 lb-in).
26. Install the A/C suction tube and connect the fitting. Install the safety clip onto the fitting.
27. Using a new O-ring seal, install the A/C suction tube and bolt. Tighten to 9 Nm (80 lb-in).
28. Install the LH and RH valve covers. For additional information, refer to «VALVE COVER - LH»(ref-494555-S16131633692012081400000) and «VALVE COVER - RH»(ref-494555-S22477061102012081400000) .
29. Install the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
30. If equipped, attach the engine block heater harness to the radiator support, the A/C suction tube and the engine wiring harness.
31. Install the RH front halfshaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-494589) .
32. Tighten the 2 engine roll restrictor through bolts to 115 Nm (85 lb-ft).
33. Install the roll restrictor heat shield and the 2 nuts. Tighten to 9 Nm (80 lb-in).
34. Using the Crankshaft Vibration Damper Replacer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
35. Using the Crankshaft Vibration Damper Replacer and Front Cover Oil Seal Installer, install the crankshaft pulley.
36. Using the Strap Wrench, 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.
37. Install the accessory drive belt, tensioner and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-494572) .
38. Install the engine appearance cover. For additional information, refer to «ENGINE APPEARANCE COVER - EXPLODED VIEW»(ref-494555-S03086729622012081400000) .
39. Fill the engine with clean engine oil.
40. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-494597) .
41. Evacuate and recharge the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-494569) .
42. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.

Note. 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.

All engines

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1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-494555-S26823244112012081400000) .
2. Rotate the crankshaft clockwise and align the timing marks on the intake Variable Camshaft Timing (VCT) assemblies as shown in illustration.
3. Remove the 3 bolts and the LH valve train oil tube.
4. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
5. Remove the 3 bolts and the RH valve train oil tube.
6. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
7. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
8. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
9. Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown in illustration.
10. Remove the 2 bolts and the primary timing chain tensioner.
11. Remove the primary timing chain tensioner arm.
12. Remove the 2 bolts and the lower LH primary timing chain guide.
13. Remove the bolt and the LH intake VCT oil control solenoid.
14. Remove the bolt and the RH intake VCT oil control solenoid.
15. Remove the primary timing chain.
16. Remove the crankshaft timing chain sprocket.
17. Remove the bolt and the upper LH primary timing chain guide.
18. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.
19. Remove and discard the 2 LH VCT assembly bolts.
20. Remove the 2 LH VCT assemblies and secondary timing chain.
21. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down in the hole on the rear of the secondary timing chain tensioner guide and let it hold against the mega cap to retain the tensioner in the collapsed position.
22. Remove and discard the 2 RH VCT assembly bolts.
23. Remove the 2 RH VCT assemblies and secondary timing chain.
24. Remove the bolt and the RH primary timing chain guide.
25. Engines with secondary timing chain tensioner removed NOTE: The following steps are only for the replacement of the secondary timing chain tensioners. Do not reuse the secondary timing chain tensioners if removed, or damage to the engine may occur.
26. Remove the LH exhaust VCT oil control solenoid.
27. Remove the LH secondary timing chain tensioner shoe.
28. Remove the LH secondary timing chain tensioner by pushing up from the bottom and remove.
29. Remove the RH exhaust VCT oil control solenoid.
30. Remove the RH secondary timing chain tensioner shoe.
31. Remove the RH secondary timing chain tensioner by pushing up from the bottom and remove.

All engines

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1. Install the RH primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in). Engines with secondary timing chain tensioner removed NOTE: The following steps are only for the replacement of the secondary timing chain tensioners. Do not reuse the secondary timing chain tensioners if removed or damage to the engine may occur.
2. Install the RH secondary timing chain tensioner by pushing it down all the way until a snap is heard and the tensioner is seated all the way down the mega cap bore.
3. Install the RH secondary timing chain tensioner shoe.
4. Remove and discard the RH secondary timing chain tensioner shipping clip.
5. 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.
6. Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
7. Install the 2 new RH VCT 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.
8. Activate the RH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
9. Install the RH exhaust VCT oil control solenoid. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
10. Install the LH secondary timing chain tensioner by pushing it down all the way until a snap is heard and the tensioner is seated all the way down the mega cap bore.
11. Install the LH secondary timing chain tensioner shoe.
12. Remove and discard the LH secondary timing chain tensioner shipping clip.
13. Assemble the 2 LH VCT assemblies and the LH secondary timing chain. Align the colored links with the timing marks.
14. Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
15. Install the 2 new LH VCT 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.
16. Activate the LH secondary timing chain tensioner by pressing down on the secondary tensioner shoe until it bottoms out, let go of the tensioner and it will spring up putting tension on the chain.
17. Install the LH exhaust VCT oil control solenoid. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees. Engines with secondary timing chain tensioner not removed
18. Compress the RH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
19. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
20. Position the 2 RH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
21. Install the 2 new RH VCT 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.
22. 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.
23. Compress the LH secondary timing chain tensioner and install the Secondary Chain Hold Down to retain the tensioner in the collapsed position.
24. Assemble the 2 LH VCT assemblies and the LH secondary timing chain. Align the colored links with the timing marks.
25. Position the 2 LH VCT assemblies and secondary timing chain onto the camshafts by aligning the holes in the VCT assemblies with the dowel pins in the camshafts.
26. Install the 2 new LH VCT 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.
27. 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 engines
28. Install the upper LH primary timing chain guide and the bolt. Tighten to 10 Nm (89 lb-in).
29. Install the crankshaft timing chain sprocket with timing dot mark out.
30. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
31. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
32. Install the primary timing chain tensioner arm.
33. 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.
34. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
35. As a post-check, verify correct alignment of all timing marks. There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2). There is 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
36. Install the LH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
37. Install the RH intake VCT oil control solenoid and the bolt. Tighten to 8 Nm (71 lb-in) then an additional 20 degrees.
38. Remove the RH Camshaft Holding Tool.
39. 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.
40. Remove the LH Camshaft Holding Tool.
41. 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.
42. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-494555-S26823244112012081400000) .

Scheme 1100

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Remove and discard the engine oil filter.
3. Remove the 3 bolts and the oil filter adapter. Discard the gasket. Clean and inspect all sealing surfaces.

1. Using a new gasket, install the oil filter adapter and the 3 bolts. Tighten to 10 Nm (89 lb-in) plus an additional 45 degrees.
2. Install a new the engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
3. Remove the EOP switch. To install, tighten to 14 Nm (124 lb-in) plus an additional 180 degrees.
4. To install, reverse the removal procedure. Apply thread sealant with PTFE to the EOP switch threads prior to installation.

All vehicles

Scheme 1101

Scheme 1102

Scheme 1103

Scheme 1104

Scheme 1105

Scheme 1106

Scheme 1107

Scheme 1108

Scheme 1109

Scheme 1110

Scheme 1111

Scheme 1112

Scheme 1113

Scheme 1114

Scheme 1115

Scheme 1116

Scheme 1117

1. Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 engine front cover-to-cylinder block joint areas on the sealing surface of the oil pan.
2. Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan-to-engine block and to the oil pan-to-engine front cover mating surface.
3. Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 crankshaft seal retainer plate-to-cylinder block joint areas on the sealing surface of the oil pan.
4. Install the oil pan and bolts 10, 11, 13 and 14 finger tight.
5. Draw the bellhousing up to the engine by tightening the LH bellhousing-to-engine bolt. Do not torque at this time.
6. Draw the bellhousing up to the engine by tightening the RH engine-to-bellhousing bolt. Do not torque at this time.
7. Install the 4 oil pan-to-bellhousing bolts. Do not torque at this time.
8. Install the A/C compressor nut and stud. Tighten the stud to 9 Nm (80 lb-in). Hand tighten the nut.
9. Tighten bolts 10, 11, 13 and 14 in the sequence shown in illustration to 3 Nm (27 lb-in).
10. Install the 4 lower engine front cover bolts. Do not torque at this time.
11. Install the remaining oil pan bolts and tighten in the sequence shown in illustration. Tighten bolts 1 through 9 and 11 through 14 to 20 Nm (177 lb-in), then rotate an additional 45 degrees. Tighten bolts 15 and 16 to 10 Nm (89 lb-in), then rotate an additional 45 degrees. Tighten bolt 10 to 20 Nm (177 lb-in), then rotate an additional 90 degrees.
12. Tighten the 4 lower engine front cover bolts to 24 Nm (18 lb-ft).
13. Tighten the A/C compressor nut to 25 Nm (18 lb-ft).
14. Tighten the 4 oil pan-to-bellhousing bolts to 48 Nm (35 lb-ft).
15. Tighten the RH engine-to-bellhousing bolt to 48 Nm (35 lb-ft).
16. Tighten the 3 LH bellhousing-to-engine bolts to 48 Nm (35 lb-ft).
17. Install the inspection cover and the 2 fasteners. All-Wheel Drive (AWD) vehicles
18. Install the Power Transfer Unit (PTU) support bracket, the 5 PTU support bracket bolts the 2 intermediate shaft support bolts. Tighten the Power Transfer Unit (PTU) support bracket bolts to 70 Nm (52 lb-ft). Tighten the 2 intermediate shaft support bolts to 40 Nm (30 lb-ft).
19. Install the RH catalytic converter. For additional information, refer to «EXHAUST SYSTEM»(ref-494567) .
20. Install the RH wheel and tire. For additional information, refer to «WHEELS AND TIRES»(ref-494563) . All vehicles
21. Tighten the 3 upper bellhousing-to-engine bolts to 48 Nm (35 lb-ft).
22. Install a new engine oil filter. Tighten to 5 Nm (44 lb-in) and then rotate an additional 180 degrees.
23. Install the engine roll restrictor. For additional information refer to, «AUTOMATIC TRANSMISSION - 6F50/6F55»(ref-494558) .
24. Install the starter stud bolt. Tighten to 27 Nm (20 lb-in). Attach the wiring harness retainer to the starter stud bolt.
25. Install the oil level indicator.
26. Install the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-494597) .
27. Install the Air Cleaner (ACL) assembly. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
28. Fill the engine with clean engine oil.

Scheme 1118

Note. 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.

1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-494555-S08591500722012081400000) .
2. Remove the 2 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.

1. Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
2. Install the oil pan. For additional information, refer to «OIL PAN»(ref-494555-S08591500722012081400000) .

Note. 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.

Scheme 1119

Scheme 1120

Scheme 1121

Scheme 1122

Scheme 1123

Scheme 1124

Scheme 1125

Scheme 1126

Scheme 1127

Scheme 1128

Scheme 1129

1. Remove the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-494555-S26823244112012081400000) .
2. Rotate the crankshaft clockwise and align the timing marks on the intake Variable Camshaft Timing (VCT) assemblies as shown in illustration.
3. Remove the 3 bolts and the LH valve train oil tube.
4. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
5. Remove the 3 bolts and the RH valve train oil tube.
6. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
7. Mark the timing chain link that aligns with the timing mark on the LH intake VCT assembly as shown in illustration.
8. Mark the timing chain link that aligns with the timing mark on the RH intake VCT assembly as shown in illustration.
9. Mark the 2 timing chain links that align with the timing mark on the crankshaft sprocket as shown in illustration.
10. Remove the 2 bolts and the primary timing chain tensioner.
11. Remove the primary timing chain tensioner arm.
12. Remove the 2 bolts and the lower LH primary timing chain guide.
13. Position the primary timing chain aside and remove the crankshaft timing chain sprocket.
14. Remove the 2 bolts and the oil pump screen and pickup tube. Discard the O-ring seal.
15. Remove the 3 bolts and the oil pump.

Scheme 1130

Scheme 1131

Scheme 1132

Scheme 1133

Scheme 1134

Scheme 1135

Scheme 1136

Scheme 1137

Scheme 1138

Scheme 1139

Scheme 1140

1. Install the oil pump and the 3 bolts. Tighten to 10 Nm (89 lb-in).
2. Using a new O-ring seal, install the oil pump screen and pickup tube and the 2 bolts. Tighten to 10 Nm (89 lb-in).
3. Install the crankshaft timing chain sprocket with timing dot mark out.
4. Position the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.
5. Install the lower LH primary timing chain guide and the 2 bolts. Tighten to 10 Nm (89 lb-in).
6. Install the primary timing chain tensioner arm.
7. 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.
8. Install the primary tensioner and the 2 bolts. Tighten to 10 Nm (89 lb-in). Remove the lockpin.
9. As a post-check, verify correct alignment of all timing marks. There is 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly colored link (2). There is 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links (3).
10. Remove the RH Camshaft Holding Tool.
11. 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.
12. Remove the LH Camshaft Holding Tool.
13. 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.
14. Install the engine front cover. For additional information, refer to «ENGINE FRONT COVER»(ref-494555-S26823244112012081400000) .

SPECIAL TOOLS CHART 2, 200# Floor Crane, Fold Away 300-OTC1819E Adjustable Grip Arm, 1735A 014-00001 Disconnect Tool, Transmission Cooler Tube 307-569 Eye, Engine Lift 303-1245 Powertrain Lift 300-OTC1585AE Remover, Tie-Rod End 211-105 Spreader Bar 303-D089 (D93P-6001-A3) or equivalent

Scheme 1141

Scheme 1142

Scheme 1143

Scheme 1144

Scheme 1145

All vehicles

Scheme 1146

Scheme 1147

Scheme 1148

Scheme 1149

Scheme 1150

Scheme 1151

Scheme 1152

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Scheme 1155

Scheme 1156

Scheme 1157

Scheme 1158

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Scheme 1160

Scheme 1161

Scheme 1162

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Scheme 1170

Scheme 1171

Scheme 1172

Scheme 1173

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Scheme 1180

Scheme 1181

Scheme 1182

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Scheme 1187

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Scheme 1189

Scheme 1190

Scheme 1191

Scheme 1192

Scheme 1193

Scheme 1194

Scheme 1195

Scheme 1196

Scheme 1197

Scheme 1198

Scheme 1199

Scheme 1200

Scheme 1201

Scheme 1202

Scheme 1203

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-494560) .
2. Remove the engine appearance cover. For additional information, refer to «ENGINE APPEARANCE COVER - EXPLODED VIEW»(ref-494555-S03086729622012081400000) .
3. Recover the A/C system. For additional information, refer to «CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS»(ref-494569) .
4. Release the fuel system pressure. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
5. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
6. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-494611) .
7. Remove the accessory drive belt and the power steering belt. For additional information, refer to «ACCESSORY DRIVE»(ref-494572) .
8. Remove the LH halfshaft and intermediate shaft. For additional information, refer to «FRONT DRIVE HALFSHAFTS»(ref-494589) .
9. Disconnect the power steering cooler hose and drain the power steering fluid into a suitable drain pan.
10. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-494611) .
11. Remove the engine Air Cleaner (ACL) and ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-494599) .
12. Remove the battery tray. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-494597) .
13. Remove the 2 nuts and disconnect the power feed from the battery terminal. Disconnect the wiring harness electrical connector.
14. Remove the nut and the ground wire. Disconnect the wiring harness electrical connector.
15. Detach the 2 wiring harness retainers from the stud bolt and bracket.
16. Disconnect the wiring harness electrical connector.
17. Detach the 3 wiring harness retainers from the bracket and inner fender.
18. Disconnect the vacuum hose from the upper intake manifold.
19. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
20. Disconnect the transaxle control cable from the control lever. Detach the control cable from the bracket.
21. If equipped, detach the engine block heater harness retainers from the radiator support and the A/C suction tube.
22. Remove the nut and disconnect the A/C pressure tube fitting. Discard the O-ring seal.
23. Remove the safety clip from the A/C fitting. Disconnect the A/C suction tube fitting.
24. Disconnect the hose from the power steering reservoir.
25. Disconnect the 2 PCM electrical connectors. Detach the 2 wiring harness retainers from the stud bolts.
26. Disconnect the wiring harness electrical connector. Detach the wiring harness retainer from the RH valve cover stud bolt.
27. Remove the oil level indicator.
28. Remove the bolt and the ground wire from the engine front cover.
29. Remove the nut and the radio interference capacitor wire from the engine front cover stud.
30. Remove the exhaust Y-pipe. For additional information, refer to «EXHAUST SYSTEM»(ref-494567)
31. Remove the LH inner splash shield. For additional information, refer to «FRONT END BODY PANELS»(ref-494576) .
32. Remove the 2 secondary latches from the transmission fluid cooler tubes.
33. Using the Transmission Cooler Tube Disconnect Tool, disconnect the transmission cooling tubes.
34. Remove the 4 oil pan-to-transaxle bolts.
35. Remove the 2 fasteners and the inspection cover.
36. Remove and discard the 3 torque converter bolts.
37. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 27 Nm (20 lb-ft).
38. Remove and discard the engine oil filter.
39. Remove the power steering cooler bracket bolt from the RH side of the subframe. All-Wheel Drive (AWD) vehicles
40. Remove the 4 bolts and support the driveshaft with a length of mechanic's wire. All vehicles
41. Remove the 2 nuts and the roll restrictor heat shield.
42. Remove the engine roll restrictor-to-subframe through bolt.
43. Remove and discard the Power Steering Pressure (PSP) tube-to-steering gear banjo bolt and the 2 seals.
44. Remove and discard the steering intermediate shaft bolt. Separate the steering intermediate shaft from the steering gear.
45. Remove and discard the cotter pins and tie-rod end nuts. Using the Tie-Rod End Remover, separate the tie-rod ends from the wheel knuckles.
46. Remove the 3 RH subframe-to-lower bumper nuts.
47. Remove the 3 LH subframe-to-lower bumper nuts and separate the lower bumper from the subframe.
48. Mark the relationship of the front subframe to the underbody at the mounting locations.
49. Position the Powertrain Lift under the subframe assembly.
50. Remove the 2 bolts and the subframe brace.
51. Remove the 2 nuts, 2 bolts and the 2 subframe support brackets.
52. Remove the 2 front subframe nuts.
53. Remove the 2 middle subframe nuts.
54. Using the Powertrain Lift, lower the subframe assembly from the vehicle. AWD vehicles
55. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
56. Remove the 4 nuts (3 shown in illustration) and the RH catalytic converter. Discard the gasket and the nuts.
57. Remove the 5 bolts and the Power Transfer Unit (PTU) support bracket.
58. Remove the 5 bolts and the PTU. All vehicles
59. Disconnect the fuel supply tube and Evaporative Emission (EVAP) tube quick connect couplings. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
60. Install the Powertrain Lift and Adjustable Grip Arms.
61. Remove the transaxle support insulator through bolt and nut.
62. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
63. Remove the nut, bolt and engine mount brace.
64. Remove the 4 engine mount nuts.
65. Remove the 3 bolts and the engine mount.
66. Lower the engine and transaxle assembly from the vehicle.
67. Disconnect the EVAP tube quick connect coupling from the purge valve. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) . Detach the EVAP tube retainer.
68. Disconnect the fuel supply tube. For additional information, refer to the quick connect coupling procedure in «FUEL SYSTEM - GENERAL INFORMATION»(ref-494614) .
69. Disconnect the transmission control electrical connector. Detach the wiring harness retainer.
70. Position the starter cable boot back and remove the 2 nuts. Detach the 2 wire terminals from the starter.
71. Disconnect the wiring harness retainer from the starter motor stud bolt.
72. Remove the bolt, stud bolt and the starter.
73. Install the Engine Lift Eye on the LH cylinder head.
74. Using the Floor Crane and Spreader Bar, remove the engine and transaxle from the lift table.
75. Remove the 2 engine-to-transaxle bolts.
76. Remove the 5 transaxle-to-engine bolts. Separate the transaxle from the engine.