Thursday, March 15, 2012

How to replace Camshaft & Lifters on Ford Fusion, Lincoln MKZ & Mercury Milan?


The procedure is similar for both Ford, Lincoln and Mercury car models:----
The details to replace Camshaft & Lifters is as follows:---

Camshaft & Lifters 

Removal & Installation





Click image to see an enlarged view
Fig. Special tools needed for this procedure

WARNING
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.


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.

  1. With the vehicle in NEUTRAL, position it on a hoist.
  2. Recover the A/C system.
  3. Release the fuel system pressure.
  4. Drain the engine cooling system.
  5. Remove the accessory drive belt and the power steering belt.
  6. Remove the LH halfshaft and intermediate shaft.
  7. Disconnect the power steering cooler hose and drain the power steering fluid into a suitable drain pan.
  8. Remove the degas bottle.
  9. Remove the engine Air Cleaner (ACL) and ACL outlet pipe.
  10. Remove the battery tray.
  11. Disconnect the battery harness electrical connector.
  12. Remove the nut and disconnect the power feed from the battery terminal.
  13. Remove the bolt and the ground wire. Detach the 2 wiring harness retainers from the cowl.
  14. Disconnect the vacuum hose from the upper intake manifold.
  15. Disconnect the Evaporative Emission (EVAP) tube quick connect coupling from the purge valve.
  16. Disconnect the upper radiator hose, lower radiator hose and 2 heater hoses from the thermostat housing.
  17. Detach the wiring harness retainer from the transaxle control cable bracket.
  18. Disconnect the transaxle control cable from the control lever. Detach the control cable from the bracket.
  19. Disconnect the transaxle control electrical connector.

    Click image to see an enlarged view
    Fig. Disconnecting the transaxle control electrical connector
  20. If equipped, detach the engine block heater harness retainers from the radiator support and the A/C suction tube.
  21. Remove the nut and disconnect the A/C pressure tube fitting. Discard the O-ring seal.
  22. Remove the safety clip from the A/C fitting. Disconnect the A/C suction tube fitting.
  23. Disconnect the hose from the power steering reservoir.
  24. Disconnect the fuel supply tube.
  25. Disconnect the fuel hose routing clip from the transaxle stud and position the fuel hose aside.
  26. Disconnect the 2 engine wiring harness electrical connectors. Detach the electrical connector from the LH valve cover.

    Click image to see an enlarged view
    Fig. Disconnecting the 2 engine wiring harness electrical connectors from the LH valve cover
  27. Remove the oil level indicator.
  28. Detach the wiring harness retainer from the RH valve cover stud bolt.
  29. Remove the bolt and the ground wire from the engine front cover.
  30. Remove the nut, the ground wire and the radio interference capacitor wire from the engine front cover stud.
  31. Loosen the exhaust flexible pipe clamp and disconnect the 2 exhaust hangers.
  32. Remove the 4 nuts and the exhaust flexible pipe and Y-pipe as an assembly. Discard the nuts and the gasket.
  33. Remove the 3 pin-type retainers, the 7 screws and the radiator splash shield.
  34. Remove the LH inner splash shield.
  35. Remove the 2 secondary latches from the transmission fluid cooler tubes.

    Click image to see an enlarged view
    Fig. Removing the 2 secondary latches from the transmission fluid cooler tubes
  36. Using the Transmission Cooler Line Disconnect Tool, disconnect the transmission cooling tubes.
  37. Remove the drain plug and drain the engine oil. Install the drain plug and tighten to 20 ft. lbs. (27 Nm).
  38. Remove and discard the engine oil filter.
  39. Remove the power steering cooler bracket bolt from the RH side of the subframe.
    NOTE
    Index-mark the driveshaft for installation.
  40. AWD vehicles, remove the 4 bolts and support the driveshaft with a length of mechanic's wire.
    NOTE
    Use a steering wheel holding device (such as Hunter® 28-75-1 or equivalent).



    Click image to see an enlarged view
    Fig. Removing the 4 bolts and supporting the driveshaft


  41. Using a suitable holding device, hold the steering wheel in the straight-ahead position.
  42. Remove the 2 nuts and the roll restrictor heat shield.
  43. Remove the engine roll restrictor-to-subframe through bolt.
  44. Remove and discard the Power Steering Pressure (PSP) tube-to-pump banjo bolt and the 2 seals.
    NOTE
    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.
  45. Remove and discard the steering intermediate shaft bolt. Separate the steering intermediate shaft from the steering gear.
    NOTE
    RH shown, LH similar.
  46. 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.

    Click image to see an enlarged view
    Fig. Using the Tie Rod End Remover to separate the tie rod ends from the wheel knuckles
  47. Remove the 3 RH subframe-to-lower bumper nuts.
  48. Remove the 3 LH subframe-to-lower bumper nuts and separate the lower bumper from the subframe.
  49. Position the Powertrain Lift under the subframe assembly.
  50. Remove the 2 nuts, 4 bolts and the subframe support brackets.
  51. Remove the 2 front subframe nuts.
  52. Remove the 2 middle subframe nuts.
  53. Using the Powertrain Lift, lower the subframe assembly from the vehicle.
  54. If equipped, disconnect the oil cooler coolant hoses.
    NOTE
    Position a block of wood under the transaxle.
  55. Install the Powertrain Lift and Universal Adapter Brackets.

    Click image to see an enlarged view
    Fig. Installing the Powertrain Lift and Universal Adapter Brackets
  56. Remove the transaxle support insulator through bolt and nut.
  57. Remove the 3 nuts, the bolt and the transaxle support insulator bracket.
  58. Remove the nut, bolt and engine mount brace.
  59. Remove the 4 engine mount nuts.
  60. Remove the 3 bolts and the engine mount.
  61. Lower the engine and transaxle assembly from the vehicle.
  62. If equipped, detach the engine block heater wiring harness retainers and position the harness aside.
  63. Disconnect the PCV hose from the PCV valve.
  64. Disconnect the Throttle Body (TB) electrical connector.
  65. Detach the wiring harness retainers from the upper intake manifold.
  66. Remove the upper intake manifold support bracket bolt.
  67. Remove the 6 bolts and the upper intake manifold in the following sequence. Discard the gaskets.

    Click image to see an enlarged view
    Fig. Identifying the 6 bolts and upper intake manifold removal sequence
  68. Disconnect the RH Catalyst Monitor Sensor (CMS) electrical connector.
  69. Disconnect the PSP switch electrical connector.
  70. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
  71. Disconnect the 3 RH coil-on-plug electrical connectors.
  72. Detach all of the wiring harness retainers from the RH valve cover and stud bolts.
  73. Disconnect the LH VCT solenoid electrical connector.
  74. Disconnect the 3 LH coil-on-plug electrical connectors.
  75. Detach all of the wiring harness retainers from the LH valve cover and stud bolts.
    NOTE
    LH shown, RH similar.
  76. Remove the 6 bolts and the 6 coil-on-plugs.

    Click image to see an enlarged view
    Fig. Removing the 6 bolts and the 6 coil-on plugs
  77. Loosen the 11 stud bolts and remove the LH valve cover. Discard the gasket.
  78. Loosen the bolt, the 10 stud bolts and remove the RH valve cover. Discard the gasket.
    NOTE
    VCT solenoid seal removal shown, spark plug tube seal removal similar.
  79. Inspect the VCT solenoid seals and the spark plug tube seals. Install new seals if damaged. Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seals.

    Click image to see an enlarged view
    Fig. Removing the seals
  80. Remove the 3 bolts and the power steering pump.
  81. Remove the 3 bolts and the accessory drive belt tensioner.
  82. Using the Strap Wrench, remove the crankshaft bolt and washer. Discard the bolt.
  83. Using the 3-Jaw Puller, remove the crankshaft pulley.
  84. Using the Oil Seal Remover, remove and discard the crankshaft front seal.
  85. Remove the 2 bolts and the engine mount bracket.
    NOTE
    Only use hand tools to remove the studs.
  86. Remove the 2 engine mount studs.
  87. Remove the 3 bolts and the engine mount bracket.
  88. Remove the 22 engine front cover bolts.

    Click image to see an enlarged view
    Fig. Removing the 22 engine front cover bolts
  89. Install 6 of the engine front cover bolts (finger tight) into the 6 threaded holes in the engine front cover. Tighten the bolts one turn at a time in a criss-cross pattern until the engine front cover-to-cylinder block seal is released. Remove the engine front cover.
    NOTE
    Only use a 3M Roloc® Bristle Disk (2-in white, part number 07528) to clean the engine front cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean the engine front cover. These tools cause scratches and gouges that make leak paths.
  90. 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.
    NOTE
    Place clean, lint-free shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.


    NOTE
    Do not use wire brushes, power abrasive discs or 3M Roloc® Bristle Disk (2-in white part number 07528) to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. They also cause contamination that will cause premature engine failure. Remove all traces of the gasket.
  91. Clean the sealing surfaces of the cylinder block in the following sequence.
    1. Remove any large deposits of silicone or gasket material.
    2. Apply silicone gasket remover and allow to set for several minutes.
    3. Remove the silicone gasket remover. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep to remove any remaining traces of oil or coolant and to prepare the surfaces to bond. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
    5. Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
  92. Rotate the crankshaft clockwise and align the timing marks on the Variable Camshaft Timing (VCT) assemblies as shown.
    NOTE
    The Camshaft Holding Tool will hold the camshafts in the Top Dead Center (TDC) position.



    Click image to see an enlarged view
    Fig. Aligning the timing marks on the VCT assemblies
  93. Install the Camshaft Holding Tool onto the flats of the LH camshafts.
    NOTE
    The Camshaft Holding Tool will hold the camshafts in the TDC position.
  94. Install the Camshaft Holding Tool onto the flats of the RH camshafts.
  95. Remove the 3 bolts and the RH VCT housing.
  96. Remove the 3 bolts and the LH VCT housing.
  97. Remove and discard the VCT housing seals.
  98. Remove the 2 bolts and the primary timing chain tensioner.
  99. Remove the primary timing chain tensioner arm.
  100. Remove the 2 bolts and the lower LH primary timing chain guide.
  101. Remove the primary timing chain.
  102. LH camshafts perform the following:
    1. Compress the LH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
      NOTE
      The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
    2. Remove and discard the LH VCT assembly bolt and the LH exhaust camshaft sprocket bolt. Remove the LH VCT assembly, secondary timing chain and the LH exhaust camshaft sprocket as an assembly.
      NOTE
      When the Camshaft Holding Tool is removed, valve spring pressure will rotate the LH camshafts approximately 3 degrees to a neutral position.
    3. Remove the Camshaft Holding Tool from the LH camshafts.
      NOTE
      The camshafts must remain in the neutral position during removal or engine damage may occur.
    4. Verify the LH camshafts are in the neutral position.
      NOTE
      Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.



      Click image to see an enlarged view
      Fig. Verifying the LH camshafts are in the neutral position
    5. Remove the bolts and the LH camshaft bearing caps. Remove the LH camshafts.

      Click image to see an enlarged view
      Fig. Removing the LH camshafts
  103. RH camshafts perform the following:
    1. Compress the RH secondary timing chain tensioner and install a suitable lockpin to retain the tensioner in the collapsed position.
      NOTE
      The VCT bolt and the exhaust camshaft bolt must be discarded and new ones installed. However, the exhaust camshaft washer is reusable.
    2. Remove and discard the RH VCT assembly bolt and the RH exhaust camshaft sprocket bolt. Remove the RH VCT assembly, secondary timing chain and the RH exhaust camshaft sprocket as an assembly.
    3. Remove the Camshaft Holding Tool from the RH camshafts.
      NOTE
      The camshafts must remain in the neutral position during removal or engine damage may occur.
    4. Rotate the RH camshafts counterclockwise to the neutral position.
      NOTE
      Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.



      Click image to see an enlarged view
      Fig. Rotating the RH camshafts to the neutral position
    5. Remove the bolts and the RH camshaft bearing caps. Remove the RH camshafts.

      Click image to see an enlarged view
      Fig. Removing the RH camshafts
To install:

NOTE
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.

    Click image to see an enlarged view
    Fig. Rotating the crankshaft counterclockwise until the crankshaft dowel pin is in the 9 o-clock position
  2. LH camshafts perform the following:
    NOTE
    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.

    1. Position the camshafts onto the LH cylinder head in the neutral position.
      NOTE
      Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
    2. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

      Click image to see an enlarged view
      Fig. Installing the LH camshaft caps and bolts
  3. RH camshafts perform the following:
  4. RH camshafts perform the following:
    NOTE
    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.

    1. Position the camshafts onto the RH cylinder head in the neutral position.
      NOTE
      Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions. If not reassembled in their original positions, severe engine damage may occur.
    2. Install the 8 camshaft caps and the 16 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).
      NOTE
      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.



      Click image to see an enlarged view
      Fig. Installing the RH camshaft caps and bolts
  5. 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.
  6. LH camshafts perform the following:
    NOTE
    Use a camshaft sprocket bolt to turn the camshafts.

    1. Rotate the LH camshafts to the Top Dead Center (TDC) position and install the Camshaft Holding Tool on the flats of the camshafts.
    2. 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.
    3. Position the LH secondary timing assembly onto the camshafts.
    4. Install 2 new bolts and the original washer. Tighten in 4 stages.

      Stage 1: Tighten to 30 ft. lbs. (40 Nm)
      Stage 2: Loosen one full turn
      Stage 3: Tighten to 89 inch lbs. (10 Nm)
      Stage 4: Tighten 90°
    5. Remove the lockpin from the LH secondary timing chain tensioner.
  7. RH camshafts perform the following:
    NOTE
    Use a camshaft sprocket bolt to turn the camshafts.

    1. Rotate the RH camshafts to the TDC position and install the Camshaft Holding Tool on the flats of the camshafts.
    2. Assemble the RH VCT assembly, the RH exhaust camshaft sprocket and the RH secondary timing chain. Align the colored links with the timing marks.
    3. Position the RH secondary timing assembly onto the camshafts.
    4. Install 2 new bolts and the original washer. Tighten in 4 stages.

      Stage 1: Tighten to 30 ft. lbs. (40 Nm)
      Stage 2: Loosen one full turn
      Stage 3: Tighten to 89 inch lbs. (10 Nm)
      Stage 4: Tighten 90°
    5. Remove the lockpin from the RH secondary timing chain tensioner.
  8. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
  9. Install the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket.

    Click image to see an enlarged view
    Fig. Installing the primary timing chain with the colored links aligned with the timing marks on the VCT assemblies and the crankshaft sprocket
  10. Install the lower LH primary timing chain guide and the 2 bolts and tighten to 89 inch lbs. (10 Nm).
  11. Install the primary timing chain tensioner arm.
  12. Reset the primary timing chain tensioner.
    1. Rotate the lever counterclockwise.
    2. Using a soft-jawed vise, compress the plunger.
    3. Align the hole in the lever with the hole in the tensioner housing.
    4. Install a suitable lockpin.
      NOTE
      It may be necessary to rotate the crankshaft slightly to remove slack from the timing chain and install the tensioner.
  13. Install the primary tensioner and the 2 bolts. Tighten to 89 inch lbs. (10 Nm). Remove the lockpin.
  14. As a post-check, verify correct alignment of all timing marks.
  15. Install new VCT housing seals.
    NOTE
    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.
  16. Install the RH VCT housing and the 3 bolts. Tighten the bolts in sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Installing the RH VCT housing and identifying the bolt tightening sequence
  17. Install the Alignment Pins.
    NOTE
    Failure to use Motorcraft 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. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  18. 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 3 engine mount bracket 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.
    NOTE
    Make sure the 2 locating dowel pins are seated correctly in the cylinder block.



    Click image to see an enlarged view
    Fig. Applying sealant to the engine front cover
  19. Install the engine front cover and bolts 17, 18, 19 and 20. Tighten in sequence to 27 inch lbs. (3 Nm).

    Click image to see an enlarged view
    Fig. Installing the engine front cover and bolts
  20. Remove the Alignment Pins.
    NOTE
    DO NOT tighten the bolts at this time.
  21. Install the engine mount bracket and the 3 bolts.
    NOTE
    Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
  22. 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:
    NOTE
    The thread sealer on the engine mount studs (including new engine mount studs if applicable) must be cleaned off with a wire brush and new thread sealer applied prior to installing the engine mount studs. Failure to follow this procedure may result in damage to the engine mount studs or engine.



    Stage 1: Tighten bolts 1 thru 22 to 89 inch lbs. (10 Nm) and 23, 24 and 25 to 133 inch lbs. (15 Nm)
    Stage 2: Tighten bolts 1 thru 22 to 18 ft. lbs. (24 Nm) and 23, 24 and 25 to 55 ft. lbs. (75 Nm)

    Click image to see an enlarged view
    Fig. Identifying remaining engine front cover bolt tightening sequence and torque specifications
  23. Install the engine mount studs in the following sequence:
    1. Clean the front cover engine mount stud holes with pressurized air to remove any foreign material.
    2. Clean all the thread sealer from the engine mount studs (old and new studs).
    3. Apply new thread sealer to the engine mount stud threads.
    4. Install the 2 engine mount studs and tighten to 15 ft. lbs. (20 Nm).
  24. Install the engine mount bracket and the 2 bolts and tighten to 22 ft. lbs (30 Nm).
    NOTE
    Apply clean engine oil to the crankshaft front seal bore in the engine front cover.
  25. Using the Crankshaft Vibration Damper Installer and Front Crankshaft Seal Installer, install a new crankshaft front seal.
    NOTE
    Lubricate the outside diameter sealing surfaces with clean engine oil.
  26. Using the Crankshaft Vibration Damper Installer and Front Cover Oil Seal Installer, install the crankshaft pulley.
  27. Using the Strap Wrench, install the crankshaft pulley washer and new bolt and tighten in 4 stages.

    Stage 1: Tighten to 89 ft. lbs. (120 Nm)
    Stage 2: Loosen one full turn
    Stage 3: Tighten to 37 ft. lbs. (50 Nm)
    Stage 4 Tighten an additional 90°
  28. Install the accessory drive belt tensioner and the 3 bolts and tighten to 97 inch lbs. (11 Nm).
  29. Install the power steering pump and the 3 bolts. Tighten to 18 ft. lbs. (24 Nm).
    NOTE
    Installation of new seals is only required if damaged seals were removed during disassembly of the engine.


    NOTE
    Spark plug tube seal installation is shown, VCT seal installation is similar.
  30. Using the VCT Spark Plug Tube Seal Installer and Handle, install a new VCT solenoid and/or plug tube seals.
    NOTE
    Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.


    NOTE
    If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.



    Click image to see an enlarged view
    Fig. Installing VCT solenoid and/or spark plug tube seals
  31. Apply a 0.31 inch (8 mm) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-RH cylinder head joints.
  32. Using a new gasket, install the RH valve cover, bolt and the 10 stud bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).
    NOTE
    Failure to use Motorcraft High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.


    NOTE
    If the valve cover is not installed and the fasteners tightened within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.



    Click image to see an enlarged view
    Fig. Identifying the RH valve cover bolt and stud tightening sequence
  33. Apply a 8 mm (0.31 in) bead of Motorcraft High Performance Engine RTV Silicone to the engine front cover-to-LH cylinder head joints.
  34. Using a new gasket, install the LH valve cover and 11 stud bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Identifying the LH valve cover bolt tightening sequence
  35. Install the 6 coil-on-plug assemblies and the 6 bolts. Tighten to 62 inch lbs. (7 Nm).
  36. Attach all of the wiring harness retainers to the LH valve cover and stud bolts.
  37. Connect the 3 LH coil-on-plug electrical connectors.
  38. Connect the LH camshaft VCT solenoid electrical connector.
  39. Attach all of the wiring harness retainers to the RH valve cover and stud bolts.
  40. Connect the 3 RH coil-on-plug electrical connectors.
  41. Connect the RH VCT solenoid electrical connector.
  42. Connect the Power Steering Pressure (PSP) switch electrical connector.
  43. Connect the RH Catalyst Monitor Sensor (CMS) sensor electrical connector.
  44. Using new gaskets, install the upper intake manifold and the 6 bolts. Tighten in the sequence shown to 89 inch lbs. (10 Nm).

    Click image to see an enlarged view
    Fig. Installing the upper intake manifold
  45. Install the upper intake manifold support bracket bolt and tighten to 89 inch lbs. (10 Nm).
  46. Attach the wiring harness retainers to the upper intake manifold.
  47. Connect the Throttle Body (TB) electrical connector.
  48. Connect the PCV hose to the PCV valve.
  49. If equipped, attach the engine block heater wiring harness retainers.
  50. Raise the engine and transaxle assembly into the vehicle.
  51. Install the engine mount and the 3 bolts. Tighten to 66 ft. lbs. (90 Nm).
  52. Install the 4 engine mount nuts and tighten to 46 ft. lbs. (63 Nm).
  53. Install the engine mount brace, the nut and the bolt and tighten to 15 ft. lbs. (20 Nm).
  54. Install the transaxle support insulator bracket, the 3 nuts and the bolt. Tighten the 3 nuts to 46 ft. lbs. (63 Nm). Tighten the bolt to 59 ft. lbs. (80 Nm).
  55. Install the transaxle support insulator through bolt and nut and tighten to 129 ft. lbs. (175 Nm).
  56. If equipped, connect the oil cooler coolant hoses.
  57. Using the Powertrain Lift, raise the subframe into the installed position.
  58. Install the 2 middle subframe nuts and tighten to 98 ft. lbs. (133 Nm).
  59. Install the 2 front subframe nuts and tighten to 98 ft. lbs. (133 Nm).
  60. Position the subframe support brackets in place and loosely install the 4 bolts.
  61. Install the 2 rear subframe bracket nuts and tighten to 98 ft. lbs. (133 Nm).
  62. Tighten the 4 subframe support bracket bolts and tighten to 66 ft. lbs. (90 Nm).
  63. Position the lower bumper on the subframe and install the 3 LH nuts and tighten to 80 inch lbs. (9 Nm).
  64. Install the 3 RH lower bumper-to-subframe nuts and tighten to 80 inch lbs. (9 Nm).
  65. Install the tie-rod ends and nuts. Tighten to 35 ft. lbs. (48 Nm). Install new cotter pins.
    NOTE
    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.
  66. Install the intermediate shaft onto the steering gear and install a new bolt and tighten to 35 ft. lbs. (48 Nm).
  67. Install the engine roll restrictor-to-subframe through bolt and tighten to 76 ft. lbs. (103 Nm).
  68. Install the roll restrictor heat shield and the 2 nuts and tighten to 80 inch lbs. (9 Nm).
  69. AWD vehicles, 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 the bolts to 52 ft. lbs. (70 Nm).
  70. Install the power steering cooler bracket bolt to the RH side of the subframe. Tighten to 80 inch lbs. (9 Nm).
  71. Connect the power steering cooler hose.
    NOTE
    Lubricate the engine oil filter gasket with clean engine oil prior to installing the oil filter.
  72. Install a new engine oil filter. Tighten to 44 inch lbs. (5 Nm) and then rotate and additional 180°.
  73. Connect the 2 transmission fluid cooler tubes.
  74. Install the 2 secondary latches onto the transmission fluid cooler tubes.
  75. Install the LH inner splash shield.
  76. Install the radiator splash shield, the 3 pin-type retainers and the 7 screws.
  77. Using a new gasket, install the Y-pipe and exhaust flexible pipe assembly and 4 new nuts and tighten to 30 ft. lbs. (40 Nm).
  78. Install the 2 exhaust hangers and tighten the exhaust clamp and tighten to 30 ft. lbs. (40 Nm).
  79. Install the ground wire, the radio interference capacitor wire and the nut to the engine front cover stud and tighten to 89 inch lbs. (10 Nm).
  80. Install the ground wire and bolt to the engine front cover and tighten to 89 inch lbs. (10 Nm).
  81. Attach the wiring harness retainer to the RH valve cover stud bolt.
  82. Install the oil level indicator.
  83. Connect the 2 engine wiring harness electrical connectors. Attach the electrical connector to the LH valve cover.
  84. Connect the fuel hose routing clip to the transaxle stud.
  85. Connect the fuel supply tube.
  86. Connect the hose to the power steering reservoir.
  87. Connect the A/C suction tube fitting. Install the safety clip onto the A/C fitting.
  88. Using a new O-ring seal, connect the A/C pressure tube fitting and install the nut and tighten to 71 inch lbs. (8 Nm).
  89. If equipped, attach the engine block heater harness retainers from to the radiator support and the A/C suction tube.
  90. Connect the transaxle control electrical connector.
  91. Attach the control cable to the bracket. Connect the transaxle control cable to the control lever.
  92. Attach the wiring harness retainer to the transaxle control cable bracket.
  93. Connect the upper radiator hose, lower radiator hose and 2 heater hoses to the thermostat housing.
  94. Connect the upper Evaporative Emission (EVAP) tube quick connect coupling to the purge valve.
  95. Connect the vacuum hose to the upper intake manifold.
  96. Install the ground wire and the bolt. Tighten to 89 inch lbs. (10 Nm). Attach the 2 wiring harness retainers to the cowl.
  97. Connect the power feed to the battery terminal and install the nut. Tighten to 71 inch lbs. (8 Nm).
  98. Connect the battery harness electrical connector.
  99. Install the battery tray.
  100. Install the engine Air Cleaner (ACL) and the ACL outlet pipe.
  101. Install the degas bottle.
  102. Install the LH halfshaft and intermediate shaft.
  103. Install the accessory drive belt and the power steering belt.
    NOTE
    Do not expose the Motorcraft High Performance Engine RTV Silicone to engine oil for at least 90 minutes after installing the engine front cover. Failure to follow this instruction may cause oil leakage.
  104. Fill the engine with clean engine oil.
  105. Fill and bleed the cooling system.
  106. Fill the power steering system.
  107. Recharge the A/C system.




These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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