Installation

Fig. 25 Lefthand timing chain index mark alignment:

CAUTION:
- Crankshaft keyway must be at the 11 o'clock location prior to reassembly. Failure to do so may lead to engine damage.

1. Install lefthand (LH) timing chain crankshaft sprocket onto crankshaft. Align crankshaft key with keyway on crankshaft sprocket.
2. Install LH timing chain guide and retaining bolts to engine. Tighten LH timing chain guide retaining bolts to 20-30Nm (15-22 lb-ft).

NOTE:
- Verify alignment arrows on the camshafts are aligned with each other prior to installation of the timing chain.

3. Install LH timing chain over LH crankshaft sprocket and LH camshaft sprockets.Align timing index marks on LH timing chain with timing index marks on LH crankshaft sprocket and camshaft sprockets.
4. Install LH timing chain tensioner arm over alignment dowel on LH cylinder head.

NOTE:
- Timing chain tensioners must be reinstalled onto engine while compressed and locked. Failure to compress timing chain tensioners before installation may cause damage to engine.

5 Install compressed LH timing chain tensioner and retaining bolts onto cylinder block. Tighten LH timing chain tensioner bolts to 20-30 N.m (15-22 lb-ft).


6. Verify timing index marks on LH timing chain are in alignment with timing index marks on LH crankshaft sprocket and camshaft sprockets.
7. Install righthand (RH) timing chain crankshaft sprocket onto crankshaft. Align crankshaft key with keyway on crankshaft sprocket.
8. Install righthand timing chain guide and retaining bolts to engine. Tighten RH timing chain guide retaining bolts to 20-30 N.m (15-22 lb-ft).

Fig. 25 Lefthand timing chain index mark alignment:

NOTE
- Verify the alignment arrows on camshafts are aligned with each other prior installation of the timing chain.

9. Install RH timing chain over RH crankshaft sprocket and RH camshaft sprockets. Align timing index marks on RH timing chain with timing index marks on RH crankshaft sprocket and camshaft sprockets.
10. Install RH timing chain tensioner arm over alignment dowel on RH cylinder head.

NOTE:
- Timing chain tensioners must be reinstalled onto engine while compressed and locked. Failure to compress timing chain tensioners prior to installation may cause damage to engine.

11. Install compressed RH timing chain tensioner and timing chain tensioner bolts onto cylinder block. Tighten RH timing chain tensioner retaining bolts to 20-30 N.m (15-22 lb-ft).

Fig. 26 Righthand timing chain index mark alignment:

12. Verify timing index marks on RH timing chain are in alignment with timing index marks on RH crankshaft sprocket and camshaft sprockets.

CAUTION:
- Crankshaft keyway must be at the 11 o'clock location prior to installation of the LH cylinder head rocker arms. Failure to do so may lead to engine damage.

13. Lubricate rocker arms with engine assembly lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install rocker arms onto LH cylinder head under camshafts.


CAUTION:
- Do not install cylinder head camshaft journal thrust caps until camshaft journal caps are installed or damage to thrust caps may occur.

camshaft journal cap bolt tightening sequence.:

14. With LH cylinder head rocker arms installed, tighten LH cylinder head camshaft journal cap bolts in sequence, as shown, in several passes, to 8-12N.m (71-106 lb-in).
15. With LH cylinder head camshaft journal caps installed and camshafts aligned with thrust caps, install LH cylinder head thrust caps and tighten retaining bolts to 8-12 N.m (71-106 lb-in).
16. Rotate crankshaft two revolutions and position crankshaft keyway to three o'clock location. This will position RH cylinder head camshafts to neutral position (base circle).

CAUTION:
- Crankshaft keyway must be at the three o'clock location. This will position the camshafts in neutral positions prior to installation of the RH rocker arms.Failure to do so may lead to engine damage.

NOTE:
- Ensure rocker arms are installed in original locations.

17. Lubricate rocker arms with engine assembly lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install rocker arms onto RH cylinder head under camshafts.

CAUTION:
- Install cylinder head camshaft journal thrust cap last to ensure that damage to 1 journal cap does not occur.

18. With RH cylinder head rocker arms installed, tighten RH cylinder head camshaft journal cap bolts in sequence shown, in several passes, to 8-12 N.m (71-106 lb-ft).
19. With RH cylinder head camshaft journal caps installed and camshafts aligned with thrust caps, install RH cylinder head thrust caps and tighten retaining bolts to 8-12 N.m (71-106 lb-in).
20. Remove lock pins from LH and RH timing chain tensioners.

Fig. 25 Lefthand timing chain index mark alignment:

21. Verify timing index marks on timing chains are in alignment with timing index marks on crankshaft sprockets and camshaft sprockets.
22. Install engine front cover.