303 01C - Engine 3.5L Duratec (212kW - 278PS) 2015

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30301C Engine 3.5L Duratec (212kW/278PS) 2015 Edge

Removal and Installation Procedure revision date: 06/17/2015
Camshafts
Special Tool(s) / General Equipment
205142 (T80T4000J)
Installer, Differential Bearing Cone
205153 (T80T4000W)
Handle
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303102
Installer, Crankshaft Pulley
3031247
VCT Spark Plug Tube Seal Remover and Installer
TKIT2006UFFLM
TKIT2006UFROW
3031248
Camshaft holding tools
TKIT2006UFFLM
TKIT2006UFROW
3031251
Installer, Front Seal
TKIT2006UFFLM
TKIT2006UFROW
3031530
Tool, Chain Tensioner Hold Down
TKIT2010AF
TKIT2010ALM
TKIT2010AROW
303335 (T88T6701A)
Installer, Front Cover Oil Seal
TKIT1988F
TKIT1988FLM
http://www.fordtechservice.dealerconnection.com/vdirs/protech/global/default.asp?comefrom=Motocraft 1/139
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303409 (T92C6700CH)
Remover, Crankshaft Seal
TKIT1992FH/FMH/FLMH
TKIT1993LMH/MH
307399
Alignment Pins, Transmission Fluid Pump
TKIT2000APFLM/LM
TKIT2002NDEW
307569
Disconnect Tool TOC Line (1/2)
TKIT2006UF/FM
TKIT2006UFLM/LM
TKIT2006UROW1
TKIT2006UROW2
Feeler Gauge
Strap Wrench
Adjustable Mounting Arm
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Plastic Scraper
Oil Drain Equipment
Cable Ties
Hose Clamp Remover/Installer
Puller
Powertrain Jack
Wooden Block
Materials
Name Specification
Engine Oil SAE 5W20 Synthetic Blend WSSM2C945A
CXO5W20LSP12
Motorcraft® High Performance Engine RTV Silicone WSEM4G323A6
TA357
Motorcraft® Silicone Gasket Remover
ZC30A
Motorcraft® Metal Surface Prep
ZC31B
Brake Cleaner
CPM4
Removal
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including
any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan,
may cause engine failure.
All camshafts
1. With the vehicle in NEUTRAL, position it on a hoist.

Refer to: Jacking and Lifting Overview (10002 Jacking and Lifting, Description and Operation).
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2. Release the fuel pressure.

Refer to: Fuel System Pressure Release (31000C Fuel System General Information 3.5L Duratec
(212kW/278PS), General Procedures).
3. NOTE: Use a steering wheel holding device (such as Hunter® 28751 or equivalent).
Using a suitable holding tool, hold the steering wheel in the straightahead position.
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4. NOTICE: 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. Refer to Section 50120B.
Remove and discard the steering intermediate shaft bolt.

Separate the steering intermediate shaft from the steering gear.
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5. Remove the engine appearance cover.
6. Recover the A/C system.

Refer to: Air Conditioning (A/C) System Recovery, Evacuation and Charging (41200 Climate Control System
General Information, General Procedures).
7. Drain the engine cooling system.

Refer to: Cooling System Draining and Vacuum Filling (30303C Engine Cooling 3.5L Duratec (212kW/278PS),
General Procedures).
8. Remove the following items:

1. Remove the degas bottle.
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Refer to: Degas Bottle (30303C Engine Cooling 3.5L Duratec (212kW/278PS), Removal and Installation).
2. Remove the accessory drive belt.
Refer to: Accessory Drive Belt (30305C Accessory Drive 3.5L Duratec (212kW/278PS), Removal and
Installation).
3. Remove the air cleaner.
Refer to: Air Cleaner (30312C Intake Air Distribution and Filtering 3.5L Duratec (212kW/278PS), Removal
and Installation).
4. Remove the air cleaner outlet pipe.
Refer to: Air Cleaner Outlet Pipe (30312C Intake Air Distribution and Filtering 3.5L Duratec
(212kW/278PS), Removal and Installation).
5. Remove the battery tray.
Refer to: Battery Tray (41401 Battery, Mounting and Cables, Removal and Installation).
9. Remove the stud bolt and position aside the ground cable.
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Release the tabs.
Lift and position the top part of the junction box aside.
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11. Release the tab and open the cover.
12. Remove the nuts and position aside the wires. Disconnect the electrical connector.
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13. Remove the bolt and disconnect the wire harness retainer. Position aside the wire harness.
14. Disconnect the vacuum hose and the EVAP tube.

Refer to: Quick Release Coupling (31000C Fuel System General Information 3.5L Duratec (212kW/278PS),
Use the General Equipment: Hose Clamp Remover/Installer
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15. Disconnect the fuel supply tube.
16. Remove the bolt. Disconnect and position aside the transaxle control cable aside.
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Disconnect the upper and lower radiator hoses.
Disconnect the heater hoses.
18. Remove the bolt for the A/C tube bracket.
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19. NOTICE: Make sure that all openings are sealed.
Disconnect the A/C pressure switch. Remove the nut and disconnect the A/C hose.
Remove and discard the Oring.
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Remove the nut and disconnect the A/C tube fitting.

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21. Disconnect the electrical connector and the wire harness retainer.
22. Disconnect the PCM electrical connector and the wire harness retainer.
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23. Remove the bolt and disconnect the wire retainer. Position aside the ground wire.
24. Remove the degas bottle hose.
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25. Remove the retainers and the upper air deflector.
26. NOTICE: Make sure the cooling module is secure before removing the bottom cooling module support
panel.
Remove the upper cooling module support brackets.

Using cables ties or mechanics wire through the upper location holes, support the cooling module.
Use the General Equipment: Cable Ties
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1. Remove the front wheels and tires.
Refer to: Wheel and Tire (20404A Wheels and Tires, Removal and Installation).
2. Remove the fender splash shields.
Refer to: Fender Splash Shield (50102 Front End Body Panels, Removal and Installation).
28. Remove the retainers and the underbody shields.
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30. Detach and disconnect the engine harness electrical connector.
31. Remove the transmission fluid cooler tube secondary latches.
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32. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal
bypass valve.
Use Special Service Tool: 307569 Disconnect Tool TOC Line (1/2).
33. Remove the bolt and the LH antilock sensor.
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34. Remove the bolt and the RH antilock sensor.
35. NOTICE: Use the internal or external hexholding feature to prevent the ball and stud from turning while
removing or installing the stabilizer bar link nuts. The link boot seal must not be allowed to twist while
loosening the link nuts or damage to the boot seal will occur.
Remove the nut and position the LH sway bar link.
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Remove the nut and position the RH sway bar link.
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37. NOTICE: Do not allow the brake caliper and the anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the front brake discs.

Refer to: Brake Disc (20603 Front Disc Brake, Removal and Installation).
38. Remove the retainers and the cooling module support panel.
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39. Disconnect the coolant hose retainers from the subframe.
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40. If equipped, disconnect the oil cooler hoses.
41. Disconnect the coolant hose retainer.
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42. Remove the exhaust Ypipe.
Refer to: Exhaust YPipe (30900C Exhaust System 3.5L Duratec (212kW/278PS), Removal and Installation).
43. Remove the drain plug and drain the engine oil.
Use the General Equipment: Oil Drain Equipment
Torque: 20 lb.ft (27 Nm)
44. Remove and discard the engine oil filter.

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45. NOTE: Indexmark the driveshaft for installation.
If equipped, remove the bolts and support the driveshaft with a length of mechanic's wire.
46. NOTE: RH side shown, LH side similar.
Mark the subframe location.
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47. Using a 2 x 6 board, 50 in (1,270 mm) and two 2 x 6 boards 24 in (609.6 mm), position the powertrain jack with the
50 in (1,270 mm) board under the 2 control arms and the two 24 in (609.6 mm) boards under the transmission and
oil pan.
Use the General Equipment: Powertrain Jack
Use the General Equipment: Wooden Block
48. Install the adjustable mounting arm from the powertrain jack table to the LH enginetotransmission bolt hole.
Use the General Equipment: Adjustable Mounting Arm
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49. Install a ratchet strap from the front of the subframe under the powertrain jack to the rear of the subframe, to
secure the subframe to the powertrain jack.
50. NOTE: The struts will need to come off of the knuckles when the powertrain and subframe assembly is lowered.
Remove the nuts and push the bolts out and remove.
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52. Remove and discard the engine mount nuts.
Remove and discard the nut and bolts.

Remove the engine mount.
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54. Remove and discard the transmission mount bolts.
Remove and discard the subframe rear bolts.

Remove the subframe bolts.
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56. Remove and discard the subframe front bolts.
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57. Lower the subframe and powertrain assembly from the vehicle.
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Remove the crankshaft pulley bolt and washer.
Discard the bolt.
59. Using a 3 Jaw Puller, remove the crankshaft pulley.

Use the General Equipment: Puller
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60. Using the special tool, remove and discard the crankshaft front seal.
Use Special Service Tool: 303409 (T92C6700CH) Remover, Crankshaft Seal.
61. Remove the bolts and the accessory drive belt tensioner.
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62. Remove the crankcase vent tube.
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Position back the boot and remove the generator nut.
Disconnect the electrical connector and the wire retainers.
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64. Disconnect the wire harness retainers and position aside the wiring harness.
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65. Disconnect the electrical connector and the wire retainer.
Disconnect the LH electrical connectors and wire harness retainers.

Position aside the engine wire harness.
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67. Disconnect the wire harness retainer.
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68. Disconnect the electrical connectors and wire retainer.
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69. Disconnect the electrical connector and wire retainer.
70. Disconnect the retainers for the coolant hose.
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71. Disconnect the engine vent hose.
72. Remove the upper intake manifold bracket bolt.
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73. NOTICE: 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.
Remove the bolts and the upper intake manifold.
74. Remove and discard the upper intake manifold gaskets.
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75. Remove the engine vent hose.
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76. Disconnect the wire harness retainer.
77. Disconnect the CHT electrical connector.
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78. Disconnect the electrical connectors and the wire retainer.
Disconnect the RH electrical connectors and the wire harness retainers.

Position aside the engine wire harness.
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Remove the nut and the bolt.
Remove the stud and the generator.
81. NOTE: When removing the ignition coilonplugs, a slight twisting motion will break the seal and ease removal.
Remove the bolts and the ignition coilonplugs.

Remove the oil level indicator.
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82. Inspect the coil seals for rips, nicks or tears and replace if necessary.
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83. NOTICE: While removing the valve cover do not apply excessive force to the VCT oil control solenoid or
damage may occur.
NOTICE: If the VCT oil control solenoid sticks to the VCT seal, carefully wiggle the valve cover until the
bond breaks free or damage to the VCT seal and VCT oil control solenoid may occur.
Loosen the bolts and remove the LH valve cover.
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84. Remove and discard the gasket.
85. NOTE: Inspect the VCT solenoid seals. Remove any damaged seals.
Using the special tools, remove and discard the seal(s).

Use Special Service Tool: 205142 (T80T4000J) Installer, Differential Bearing Cone. , 205153 (T80T4000W)
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Handle.
86. NOTE: Inspect the spark plug tube seals. Remove any damaged seals.

Use Special Service Tool: 205153 (T80T4000W) Handle. , 3031247 VCT Spark Plug Tube Seal Remover and
Installer.
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damage may occur.
Loosen the bolts and remove the RH valve cover.
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Handle.
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Installer.
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91. Remove the engine front cover bolts.
92. Using a pry tool, locate the pry pads shown and pry the engine front cover loose and remove.
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93. NOTICE: Only use a 3M™ Roloc® Bristle Disk (2in 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. These tools
cause scratches and gouges that make leak paths.
Clean the engine front cover using a 3M™ Roloc® Bristle Disk (2in white, part number 07528) in a suitable
tool turning at the recommended speed of 15,000 rpm.
Material: Motorcraft® Silicone Gasket Remover / ZC30A

Material: Motorcraft® Metal Surface Prep / ZC31B
Thoroughly wash the engine front cover to remove any foreign material, including any abrasive particles
created during the cleaning process.
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94. NOTICE: Place clean, lintfree 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.
NOTICE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2in 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.
Make sure that the mating faces are clean and free of foreign material.
Refer to: RTV Sealing Surface Cleaning and Preparation (30300 Engine System General Information, General
Procedures).
Use the General Equipment: Plastic Scraper
Material: Brake Cleaner / CPM4
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95. NOTE: Rotate the crankshaft in a clockwise direction only.
Rotate the crankshaft clockwise and align the timing marks on the VCT units as shown.
96. Remove the bolts and the LH oil tube.
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97. NOTE: The Camshaft Holding Tool will hold the camshafts in the TDC position.
Install Special Service Tool: 3031248 Camshaft holding tools.
98. Remove the bolts and the RH oil tube.
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NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
100. Mark the timing chain link that aligns with the timing mark on the LH intake VCT unit as shown.
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101. Mark the timing chain link that aligns with the timing mark on the RH intake VCT unit as shown.
102. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Mark the timing chain link that aligns with the timing mark on the crankshaft sprocket as shown.
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103. Remove the bolts and the timing chain tensioner.
104. Remove the timing chain tensioner arm.
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105. Remove the bolts and the lower LH timing chain guide.
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106. NOTE: Removal of the VCT oil control solenoids will aid in the removal of the timing chain.
NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
NOTE: Keep the VCT oil control solenoids clean of dirt and debris.
Remove the bolts and the VCT oil control solenoids.
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107. Remove the timing chain.
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LH camshafts
108. NOTE: The 2 VCT oil control solenoids are removed for clarity.
Install Special Service Tool: 3031530 Tool, Chain Tensioner Hold Down.
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109. Remove and discard the LH VCT unit bolts.
110. Remove the LH VCT units and the secondary timing chain.
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111.
Remove Special Service Tool: 3031530 Tool, Chain Tensioner Hold Down.
112.
Remove Special Service Tool: 3031248 Camshaft holding tools.
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113. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original
positions.
NOTE: Mark the exhaust and intake camshafts for installation into their original locations.
Remove the bolts, camshaft cap and the camshafts.
RH camshafts
114. NOTE: The 2 RH VCT oil control solenoids are removed for clarity.
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115. Remove and discard the RH VCT unit bolts.
116. Remove the RH VCT units and the secondary timing chain.
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117.
118.
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positions.
Remove the bolts, camshaft caps and the camshafts.
Installation
RH camshafts
1. NOTE: Coat the camshafts with clean engine oil prior to installation.
Lubricate the camshafts with clean engine oil and position the camshafts onto the RH cylinder head in the neutral
position as shown.
Material: Engine Oil SAE 5W20 Synthetic Blend / CXO5W20LSP12 (WSSM2C945A)
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2. NOTICE: 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.
Rotate counterclockwise to the 9 o'clock position.
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3. NOTICE: The camshaft seal gaps must be at the 12 o'clock position or damage to the engine may occur.
Position the RH camshaft seal gaps as shown.
positions.
Install the camshaft caps, oil tube and the bolts.

Torque:
Stage 1: 71 lb.in (8 Nm)
Stage 2: 45°
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5. Loosen the camshaft cap bolts.
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6. Tighten the camshaft cap bolts.
Torque:
Stage 2: 45°
7. NOTICE: If any components are installed new, the engine valve clearance must be checked/adjusted or
engine damage may occur.
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.
Refer to: Valve Clearance Adjustment (30301C Engine 3.5L Duratec (212kW/278PS), General Procedures).
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Use the General Equipment: Feeler Gauge
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8. Remove the bolts and the oil tube.
9. Rotate the RH camshafts to the TDC position as shown.
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12. Align the colored links with the timing marks and assemble the RH VCT units.
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13. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.
Position the RH VCT units and the secondary timing chain onto the camshafts by aligning the holes in the VCT
units with the dowel pins in the camshafts.
14. Install the new RH VCT unit bolts.

Torque:
Stage 1: 30 lb.ft (40 Nm)
Stage 2: Loosen:: 1 turn(s)
Stage 4: 180°
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Make sure the secondary timing chain is centered on the timing chain tensioner guides.
LH camshafts
Lubricate the camshafts with clean engine oil and position the camshafts onto the LH cylinder head in the neutral
position as shown.
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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.
Rotate counterclockwise to the 9 o'clock position.
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Position the LH camshaft seal gaps as shown.
positions.

Torque:
Stage 2: 45°
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20. Loosen the camshaft bolts.
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Torque:
Stage 2: 45°
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24. Rotate the LH camshafts to the TDC position as shown.
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27. Align the colored links with the timing marks and assemble the LH VCT units.
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28. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.
Position the LH VCT units and the secondary timing chain onto the camshafts by aligning the holes in the VCT
units with the dowel pins in the camshafts.
29. Install the new LH VCT unit bolts.

Torque:
Stage 4: 180°
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Make sure the secondary timing chain is centered on the timing chain tensioner guides.
All camshafts
31. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
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32. NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.
Install the timing chain with the colored links aligned with the timing marks on the VCT units and the crankshaft
sprocket.
33. Install the lower LH timing chain guide and the bolts.
Torque: 89 lb.in (10 Nm)
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34. Install the timing chain tensioner arm.
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Release the ratchet detent.
Using a softjawed vise, compress the ratchet plunger.
Align the hole in the ratchet plunger with the hole in the tensioner housing and install a lockpin.
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36. NOTE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to install the
tensioner.
Install the timing chain tensioner and the bolts.

Remove the lockpin.
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As a postcheck, verify correct alignment of all timing marks.
There are 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT
assembly colored link (2).
There are 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links
(3).
38. NOTICE: Do not use excessive force when installing the VCT oil control solenoid. Damage to the mega cap
could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect
the bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present
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on the mating surface. Only clean the external surfaces as necessary.
NOTE: A slight twisting motion will aid in the installation of the VCT oil control solenoid.
NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
Install the VCT oil control solenoids and the bolts.

Torque:
Stage 2: 20°
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39.
40. Install the RH oil tube and the bolt.

Torque:
Stage 2: 60°
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41.
42. Install the LH oil tube and the bolt.

Torque:
Stage 2: 60°
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43.
Install Special Service Tool: 307399 Alignment Pins, Transmission Fluid Pump.
44. NOTICE: 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 must be installed within 4 minutes of the initial sealant application. The
remainder of the engine front cover bolts must be installed and tightened within 35 minutes of the initial sealant
application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant
reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this
procedure can cause future oil leakage.
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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 inner bolt bosses.
Material: Motorcraft® High Performance Engine RTV Silicone / TA357 (WSEM4G323A6)
Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil panto
cylinder block joint and the cylinder block joint areas of the engine front cover in places as indicated.
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45. NOTE: Make sure the 2 locating dowel pins are seated correctly in the cylinder block.
Install the engine front cover and the bolts.

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46.
Remove Special Service Tool: 307399 Alignment Pins, Transmission Fluid Pump.
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47. Install the remaining engine front cover bolts.
Torque:
Stage 1: Tighten bolts 1 thru 22 to:: 89 lb.in (10 Nm)
Stage 2: Tighten bolts 23, 24 and 25 to:: 133 lb.in (15 Nm)
Stage 3: Tighten bolt 26 to:: 89 lb.in (10 Nm)
Stage 4: Loosen bolt 26:: 1 turn(s)
Stage 5: Tighten bolts 23, 24 and 25 to 30 Nm (22 lbft) plus an additional:: 90°
Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lbin) plus an additional:: 45°
Stage 7: Tighten bolt 26 to 10 Nm (89 lbin) plus an additional:: 45 °
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48. NOTE: Installation of new seals is only required if damaged seals were removed.
If removed, using the special tools, install the spark plug tube seals.
Use Special Service Tool: 3031247 VCT Spark Plug Tube Seal Remover and Installer. , 205153 (T80T4000W)
Handle.
If removed, using the special tools, install the VCT oil control solenoid seals.
Handle.
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50. 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. Failure to follow this procedure can cause future oil leakage.
Apply an 8 mm (0.31 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front coverto
cylinder head joints.
51. Install a new valve cover gasket.
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52. Install the valve cover and tighten the bolts.

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53. 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.
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Handle.
Handle.
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56. 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. Failure to follow this procedure can cause future oil leakage.
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59. 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.
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Install the coilonplugs and the bolts.
Torque:
Stage 2: 50 °
Install the oil level indicator.
Install the generator and the stud.

Install the nut and bolt.
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Position back the engine wire harness on the engine.
Connect the RH electrical connectors and the wire harness retainers.
63. Connect the electrical connectors and the wire retainer.
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64. Connect the CHT electrical connector.
65. Connect the wire harness retainer.
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66. Install the engine vent hose.
67. Install the upper intake manifold gaskets.
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68. Install the upper intake manifold and the bolts.
Torque:
Tighten bolts 1 and 37 to 10 Nm (89 lbin) plus an additional:: 45 °
Tighten bolt 2 to 10 Nm (89 lbin) plus an additional:: 90 °
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69. Install the upper intake manifold bracket bolt.
70. Connect the engine vent hose.

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71. Connect the retainers for the coolant hose.
72. Connect the wire retainer and the electrical connector.
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73. Connect the wire retainer and the electrical connectors.
74. Connect the wire harness retainer.
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Position back the engine wire harness on the engine.
Connect the LH electrical connectors and the wire harness retainers.
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77. Position back the wire harness and connect the wire harness retainers.
Connect the electrical connectors and the wire retainers.

Install the generator nut and position back the boot.
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79. Install the crankcase vent tube.
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80. Install the accessory drive belt tensioner and the bolts.
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81. Lubricate the crankshaft front seal bore with clean engine oil.
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82. Using the special tool, install the crankshaft front seal.
Use Special Service Tool: 303102 Installer, Crankshaft Pulley. , 3031251 Installer, Front Seal.
83. Lubricate the crankshaft front seal and the crankshaft pulley with clean engine oil.
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84. Using the special tools, install the crankshaft pulley.
Use Special Service Tool: 303102 Installer, Crankshaft Pulley. , 303335 (T88T6701A) Installer, Front Cover Oil
Seal.
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85. Install the new crankshaft bolt and the washer.
Use the General Equipment: Strap Wrench
Torque:
Stage 2: Loosen: 1 turn(s)
Stage 4: 90°
86. Using the powertrain jack, raise the subframe and powertrain assembly into the vehicle.
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87. Install the transmission mount bolts.
Install the engine mount and bolts.

Install the engine mount nut.
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89. Install the engine mount nuts.
90. NOTE: Align the reference marks made during removal.
Install the subframe front bolts finger tight.
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Install the subframe rear bolts finger tight.

Install the subframe bolts finger tight.
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92. NOTE: While tightening the subframe bolts, make sure the front subframe does not move.
Tighten the subframe front bolts.

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Tighten the subframe rear bolts.

Torque:
Stage 2: 270°
Tighten the subframe bolts.
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94. Install the RH struttowheel knuckle nuts and bolts.
95. Install the LH struttowheel knuckle nuts and bolts.

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96. Remove the adjustable mounting arm and the powertrain jack.
97. If equipped, line up the index marks on the rear driveshaft to the index marks on the PTU flange made during
removal and install the bolts.
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98. NOTE: Do not lubricate the engine oil filter seal.
Install the new engine oil filter.

Torque:
Stage 2: 180°
99. Install the exhaust Ypipe.

100. Connect the coolant hose retainer.
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101. If equipped, connect the oil cooler hoses.
102. Connect the coolant hose retainers to the subframe.
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103. Install the cooling module support panel and the retainers.
104. Install the front brake discs.

tightening the link nuts or damage to the boot seal will occur.
Position back the RH sway bar link and install the nut.
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Position back the LH sway bar link and install the nut.
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107. Install the RH antilock sensor and bolt.
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108. Install the LH antilock sensor and bolt.
109. Connect the transmission cooling tubes.
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110. Install the transmission cooler tube secondary latches.
111. Connect and attach the engine harness electrical connector.
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112. Install the underbody shields and retainers.
113. Install the front underbody shield and the retainers.
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115. Install the following items:

1. Install the fender splash shields.
2. Install the front wheels and tires.
Remove the cable ties or the mechanics wire.

Install the upper cooling support brackets.
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117. Install the upper air deflector and the retainers.
118. Install the degas bottle hose.
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119. Position back the ground wire and install the bolt. Connect the wire retainer.
120. Connect the PCM electrical connector and the wire harness retainer.
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121. Connect the electrical connector and the wire harness retainer.
122. Using a new Oring, connect the A/C tube fitting and install the nut.
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Using a new Oring, connect the A/C hose and install the nut.
Connect the A/C pressure switch.
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124. Install the bolt for the A/C tube bracket.
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Connect the heater hoses.
Connect the upper and lower heater hoses.
126. Position back the transaxle control cable and connect the cable. Install the bolt.
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127. Connect the fuel supply tube.
128. Connect the vacuum hose and the EVAP hose.

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129. Position back the wire harness and connect the wire harness retainer. Install the bolt.
130. Connect the electrical connector. Position back the wires and install the nuts.
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131. Close the cover.
Position back the top part of the junction box

Latch the tabs.
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133. Position back the ground cable and install the stud bolt.

1. Install the battery tray.
2. Install the air cleaner outlet pipe.
3. Install the air cleaner.
and Installation).
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4. Install the accessory drive belt.
Installation).
5. Install the degas bottle.
135. Install the engine appearance cover.
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136. NOTICE: Do not allow the intermediate shaft to rotate while it is connecting 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. Refer to Section 50120B.
Position back the steering shaft and install the new bolt.
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137. Remove the steering wheel holding tool.
138. Fill the engine with clean engine oil.
Refer to: Specifications (30301C Engine 3.5L Duratec (212kW/278PS), Specifications).

139. Fill and bleed the engine cooling system.

140. Recharge the A/C system.

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141. Check the selector lever cable adjustment.

Refer to: Selector Lever Cable Adjustment 6Speed Automatic Transmission 6F35 (30705 Automatic
Transmission External Controls, General Procedures).
142. After completing the repairs, perform the Misfire Monitor Neutral Profile Correction procedure.
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Crankshaft Front Seal
Base Part Number: 6700
303102
3031251
TKIT2006UFFLM
TKIT2006UFROW
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303335 (T88T6701A)
TKIT1988F
TKIT1988FLM
303409 (T92C6700CH)
TKIT1992FH/FMH/FLMH
TKIT1993LMH/MH
Strap Wrench
Trolley Jack
Puller
Wooden Block
Materials
Name Specification
CXO5W20LSP12
Removal


Installation).
2. Remove the engine mount.
Refer to: Engine Mount (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
3. Using the floor jack, lower the front of the engine to access the crankshaft pulley.
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Use the General Equipment: Trolley Jack
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Discard the bolt.

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Installation
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2. Using the special tools, install the crankshaft front seal.
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Use Special Service Tool: 303335 (T88T6701A) Installer, Front Cover Oil Seal. , 303102 Installer, Crankshaft
Pulley.
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Torque:
Stage 1:: 89 lb.ft (120 Nm)
Stage 2: Loosen: : 1 turn(s)
Stage 3:: 37 lb.ft (50 Nm)
Stage 4:: 90°
6. Using the floor jack, raise the front of the engine to the installed position.
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1. Install the engine mount.
Refer to: Engine Mount (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
Installation).
8. After completing the repairs, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure
following the onscreen instructions.
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Crankshaft Rear Seal
Plastic Scraper
Materials
Name Specification
CXO5W20LSP12
TA357
ZC30A
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ZC31B
Brake Cleaner
CPM4
Removal
may cause engine failure.
1. Remove the flexplate.

Refer to: Flexplate (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
2. Remove the crankshaft sensor ring.
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3. Disconnect the CKP sensor electrical connector.
4. Remove the bolt and the CKP sensor.
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5. Remove oil pantocrankshaft rear seal bolts.
6.
Remove the bolts and the crankshaft rear seal.
Discard the seal.
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7. NOTICE: Do not use wire brushes, power abrasive discs or 3M™ Roloc® Bristle Disk (2in white, part
number 07528) to clean the sealing surfaces of the engine block. These tools cause scratches and gouges
that make leak paths. They also cause contamination that causes premature engine failure. Remove all
traces of the gasket.
Procedures).
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Installation
NOTE: The crankshaft rear seal retainer must be installed and the bolts tightened within 10 minutes of sealant
application.
Apply 5 mm (0.196 in) bead of silicone sealant.

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application.
Apply 3 mm (0.11 in) bead of silicone sealant.

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3. Lubricate the crankshaft rear seal with clean engine oil.
1. Install the crankshaft rear seal retainer at an angle above the oil pan flange to avoid scraping off the sealer.
2. Tilt the seal retainer up and onto the rear of the cylinder block.
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5. Install the bolts and tighten in sequence shown.
6. Install oil pantocrankshaft rear seal bolts.

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7. Install the CKP sensor and the bolt.
8. Connect the CKP sensor electrical connector.
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9. Install the crankshaft sensor ring.
10. Install the flexplate.

Refer to: Flexplate (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
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Disassembly and Assembly of Subassemblies Procedure revision date: 12/16/2014
Cylinder Head
3031249
Valve Spring Compressor
TKIT2006UFFLM
TKIT2006UFROW
303300 (T87C6565A)
Set, Valve Spring Compressor
T88C1000ST
TKIT1988FESTIVA
TKIT1988TRACER
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TKIT2009TCF
303350 (T89P6565A)
Compressor, Valve Spring
TKIT1989F
TKIT1989FLM
TKIT1989FM
TKIT1990LMH
303470 (T94P6510CH)
Installer, Valve Stem Oil Seal
TKIT1994FH/FMH/FLMH
TKIT1994LMH/MH2
TKIT2009TCF
Materials
Name Specification
CXO5W20LSP12
DISASSEMBLY
LH cylinder head
NOTICE: If replacing the cylinder head, do not reuse the secondary timing chain tensioners, they must be
replaced or damage to the engine may occur. Refer to Timing Drive Components.
1. Remove the timing chain guide pin.
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2. NOTICE: If a spark plug is dropped, internal damage may result and the spark plug must be discarded. The
use of a damaged spark plug may cause cylinder misfire resulting in engine damage.
NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.
Remove the spark plugs.
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RH cylinder head
3. Remove the timing chain tensioner arm and timing chain guide pins.
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4. Remove and discard the CHT sensor.
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NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs.
Remove the spark plugs.
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All cylinder heads
6. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components
for installation into their original locations.
Using the special tools, remove the valve collet, valve spring retainer and the valve spring.
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Use Special Service Tool: 303300 (T87C6565A) Set, Valve Spring Compressor. , 303350 (T89P6565A)
Compressor, Valve Spring. , 3031249 Valve Spring Compressor.
7. Remove the valve stem seal.
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8. Remove the valve.
9. Repeat the above steps for each valve.
ASSEMBLY
All cylinder heads
1. Install the valve.
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2. Lubricate with clean engine oil and using the special tool, install the valve stem seal.
Use Special Service Tool: 303470 (T94P6510CH) Installer, Valve Stem Oil Seal.
3. Using the special tools, install the valve spring, valve spring retainer and the valve collet.
Use Special Service Tool: 303300 (T87C6565A) Set, Valve Spring Compressor. , 303350 (T89P6565A)
Compressor, Valve Spring. , 3031249 Valve Spring Compressor.
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4. Repeat the above steps for each valve.
RH cylinder head
Install the spark plugs.

6. Install a new CHT sensor.

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7. Install the timing chain tensioner arm and timing chain guide pins.
LH cylinder head
Install the spark plugs.

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9. Install the timing chain guide pin.

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Cylinder Head LH
Materials
Name Specification
CXO5W20LSP12
ZC30A
ZC31B
Removal
can cause engine failure.
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NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.
1. Remove the LH camshafts.

Refer to: Camshafts (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
2. Disconnect the electrical connectors and the wire harness retainers.
3. Remove the bolts and the CMP sensors.
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4. Remove the bolts and the heat shield.
Remove the nuts and LH catalytic converter.

Discard the nuts.
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Remove and discard the exhaust manifold gasket.
Remove and discard the studs.
7. Clean and inspect the catalytic converter flange.
Refer to: Exhaust Manifold Cleaning and Inspection (30300 Engine System General Information, General
Procedures).
8. Remove the LH block coolant drain plug and allow coolant to drain from the cylinder block.
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9. Remove the RH block coolant drain plug or block heater and allow coolant to drain from the cylinder block.
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10. Remove the thermostat housing bolts.
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NOTICE: Make sure that the fuel rail and the fuel injectors do not come out of the lower intake manifold.
Remove the bolts and the lower intake manifold.
12. Remove and discard the lower intake manifold gaskets.
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13. Remove and discard the thermostat housing gasket.
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14. NOTICE: Do not use power tools to remove the bolt or damage to the upper LH primary timing chain guide
may occur.
Remove the bolt and the upper LH timing chain guide.
Remove the valve tappets.
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16. Inspect and install new components as necessary.
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17. Remove and discard the M6 bolt.
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18. NOTICE: Place clean 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.
NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket
surface, unprotected, on a bench surface
NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are tightentoyield
designed and cannot be reused.
Remove and discard the bolts from the cylinder head.

Remove the cylinder head.
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19. Remove and discard the head gasket.
20. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean
the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping
tool to remove all traces of the head gasket.
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NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging.
21. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the
cylinder block distortion.
Refer to: Cylinder Head Distortion (30300 Engine System General Information, General Procedures).
Refer to: Cylinder Block Distortion (30300 Engine System General Information, General Procedures).
Installation
1. Install a new cylinder head gasket.
2. NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.
Install the LH cylinder head and new bolts.

Torque:
Stage 3: 90°
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Stage 4: 90°
Stage 5: 45°
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3. Install the M6 bolt.
4. NOTE: The valve tappets must be installed in their original positions.
Coat the valve tappets with clean engine oil and install.
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5. Install the upper LH timing chain guide.

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6. Install a new thermostat housing gasket.
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7. Install the new lower intake manifold gaskets.
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Install the lower intake manifold and the bolts.

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9. Install the thermostat housing bolts.
Torque:
Stage 2: 90 °
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Install the RH block coolant drain plug.
Torque:
Stage 2: 720°
If equipped, install the block heater.
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11. Install the LH block coolant drain plug.
Torque:
Stage 2: 180°
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Install the new studs.
Install the new exhaust manifold gasket.
13. Install LH catalytic converter and the 3 new lower nuts finger tight.
Torque:
Stage 1: Install the 3 new upper LH catalytic converter nuts and tighten to:: 18 lb.ft (25 Nm)
Stage 2: Tighten the 3 lower LH catalytic converter nuts to:: 18 lb.ft (25 Nm)
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14. Install the heat shield and the bolts.
15. NOTE: Lubricate the Oring seals with clean engine oil.
Install the CMP sensors and the bolts.

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16. Connect the wire harness retainers and the electrical connectors.
17. Install the LH camshafts.

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Cylinder Head RH
Materials
Name Specification
CXO5W20LSP12
ZC30A
ZC31B
Removal
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NOTE: If the cylinder head is replaced, a new secondary timing chain tensioner will need to be installed.
1. Remove the RH camshafts.

2. Disconnect the CMP electrical connectors.
3. Remove the bolts and the CMP sensors.
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4. Remove the bolt and position aside the ground cable.
5. NOTE: Indexmark the location of the bracket on the cylinder head for installation..
Remove the bolt and the upper intake manifold bracket.
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Remove the nuts and the RH catalytic converter.

Discard the nuts.
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Procedures).
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16. Remove the CHT jumper harness.
17. NOTICE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may
occur.
Remove the bolt and the RH timing chain guide.
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Remove the valve tappets.
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22. Remove and discard the head gasket.
24. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the
cylinder block distortion.
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Installation
1. Install a new cylinder head gasket.
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Install the RH cylinder head and new bolts.
Torque:
Stage 3: 90°
Stage 4: 90°
Stage 5: 45°

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Coat the valve tappets with clean engine oil and install.
5. Install the RH timing chain guide and the bolt.

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6. Install the CHT jumper harness.
7. Install a new thermostat housing gasket.
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Torque:
Stage 2: 90 °
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Tighten the cylinder block drain plug to:
Torque:
Stage 2: 720°
If equipped, tighten the block heater to:
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Torque:
Stage 2: 180°
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14. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust
manifold to develop an exhaust leak.
Install the RH catalytic converter and new nuts.

Torque:
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16. NOTE: Align the bracket with the index mark made during removal.
Install the upper intake manifold bracket and the bolt.

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17. Position back the ground cable and install the bolt.
18. NOTE: Lubricate the Oring seals with clean engine oil.
Install the CMP sensor and the bolts.

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19. Connect the CMP electrical connectors.
20. Install the RH camshafts.

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Description and Operation Procedure revision date: 12/16/2014
Engine Overview
Base Part Number: 6L084
Overview
The 3.5L (4V) is a V6 engine with the following features:
Dual overhead camshafts

Four valves per cylinder
Sequential MultiPort Fuel Injection (SFI)
Composite upper and lower intake manifold
Aluminum cylinder head
An aluminum, 60degree Vcylinder block
Timing chain driven coolant pump
Twin independent variable cam timing (TiVCT)
An electronic ignition system with 6 ignition coils
Engine Identification
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For quick identification, refer to the safety certification decal.
The decal is located on the LH front door lock face panel.
Engine Code Information Label
The engine code information label, located on the front side of the valve cover, contains the following:
Item Description
1 Engine part number
2 Engine plant (Cleveland)
3 Engine displacement
4 Engine configuration
5 Twin independent VCT
6 Bar code
7 Bar code
8 Running number
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9 Engine build date (DDMMYY)
10 Plant shift line
11 Derivative code
Engine Cylinder Identification
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System Operation
Lubrication System
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Item Description
Yellow High pressure oil flow
Blue Oil return/low pressure oil flow
Oil Pump
The engine lubrication system is of the forcefeed type in which oil is supplied under full pressure to the crankshaft,
connecting rod bearings, timing chain tensioners, piston oil cooling jets and VCT solenoids. The flow of oil to the valve
tappets and valve train is controlled by a restricting orifice located in the cylinder head, front camshaft cap.
The lubrication system is designed to provide optimum oil flow to critical components of the engine through its entire
operating range.
The heart of the system is a positive displacement internal gear oil pump.
Generically, this design is known as a gerotor pump, which operates as follows:
The oil pump is mounted on the front face of the cylinder block.
The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
System pressure is limited by an integral, internallyvented relief valve which directs the bypassed oil back to the
inlet side of the oil pump.
Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure both at
hot idle and maximum speed.
The relief valve calibration protects the system from excessive pressure during highviscosity conditions.
The relief valve is designed to provide adequate connecting rod bearing lubrication under high temperature and
highspeed conditions.
Valve Train
The valve train uses direct acting mechanical buckets (DAMB). The camshaft lobes are positioned directly above
mechanical buckets which are positioned on top of the valves.
Twin Independent Variable Cam Timing (TiVCT)
The twin independent VCT system allows variable control of the valves that optimizes combustion at full load providing
improved power and low speed torque (broadening the torque curve) which enables variable valve overlap which provides
better fuel economy and emissions and provides optimized cold start operation with improved exhaust emissions
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Disassembly Procedure revision date: 12/16/2014
Engine
205142 (T80T4000J)
205153 (T80T4000W)
Handle
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303103 (T74P6375A)
Holding Tool, Flywheel
T74P77000A
TKIT2009TCF
3031245
Engine Lift Eye
TKIT2006UFFLM
TKIT2006UFROW
3031247
TKIT2006UFFLM
TKIT2006UFROW
3031248
TKIT2006UFFLM
TKIT2006UFROW
3031529
Lift Eye, Engine
TKIT2010AF
TKIT2010ALM
TKIT2010AROW
3031530
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TKIT2010AF
TKIT2010ALM
TKIT2010AROW
303409 (T92C6700CH)
TKIT1992FH/FMH/FLMH
TKIT1993LMH/MH
Floor Crane
Mounting Stand
Plastic Scraper
Puller
Materials
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Name Specification
ZC30A
ZC31B
Brake Cleaner
CPM4
NOTE: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.
NOTE: Refer to the exploded view under the Engine Component View in the Description and Operation.
Install Special Service Tool: 303103 (T74P6375A) Holding Tool, Flywheel.

Remove the bolts and the flexplate.
Remove Special Service Tool: 303103 (T74P6375A) Holding Tool, Flywheel.
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2. Remove the crankshaft sensor ring.
3. NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the oil pan.
Mount the engine to the mounting stand.

Use the General Equipment: Mounting Stand
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4. Remove the floor crane.
Use the General Equipment: Floor Crane
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5.
Remove Special Service Tool: 3031529 Lift Eye, Engine.
6.
Remove Special Service Tool: 3031245 Engine Lift Eye.
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Discard the bolt.

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10. Remove the bolts and the accessory drive belt tensioner.
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11. Remove the crankcase vent tube.
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12. Disconnect the LH electrical connectors and wire harness retainers.
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14. Disconnect the LH CMP and CMS (catalyst monitor sensor) electrical connectors. Disconnect the wire harness
retainers.
15. Remove the nut, bolt and the heat shield.
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16. Remove the wiring harness retainer stud bolt.
17. Remove the wiring harness grommet.
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18. Disconnect the CKP electrical connector.
19. Disconnect the electrical connectors and wire retainer.
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20. Disconnect the electrical connector and wire retainer.
21. Disconnect the retainers for the coolant hose.
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22. Disconnect the engine vent hose.
23. Remove the upper intake manifold bracket bolt.
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Remove the bolts and the upper intake manifold.
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26. NOTE: Indexmark the location of the bracket on the cylinder head for installation.
Remove the bolt and the upper intake manifold bracket.
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27. Remove the engine vent hose.
28. Disconnect the RH CMP and KS sensor electrical connectors. Disconnect the wire harness retainer.
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29. Disconnect the CHT electrical connector.
Disconnect the RH electrical connectors and the wire harness retainers.

Remove the engine wire harness.
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31. Remove the bolts and the A/C compressor.
Remove the nut and the bolt.

Remove the stud and the generator.
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Remove the nuts and the LH catalytic converter.

Discard the nuts.
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Procedures).
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39. Remove the pintype retainer and the cover.
40. Remove the bolts and the LH CMP sensors.
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41. Remove the bolts and the RH CMP sensors.
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43. NOTICE: Make sure that the fuel rail and the fuel injectors do not come out of the lower intake manifold.
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45. Remove the coolant tube assembly.
46. Remove and discard the Oring seals.
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47. Remove the bolt and the CKP sensor.
48. NOTICE: If metal or aluminum material is present in the oil cooler, mechanical concerns exist. Failure to
correct these concerns may cause engine failure.
Remove the bolts and the oil cooler.

Discard the oil cooler.
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49. Remove and discard the oil cooler Oring gaskets.
50. Remove the bolts and the oil filter adapter.
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51. Remove and discard the oil filter adapter gasket.
52. Remove the oil pressure switch.
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53. NOTE: When removing the ignition coilonplugs, a slight twisting motion will break the seal and ease removal.
Remove the bolts and the ignition coilonplugs.

Remove the oil level indicator.
54. Inspect the coil seals for rips, nicks or tears and replace if necessary.
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damage may occur.
Loosen the bolts and remove the LH valve cover.
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Handle.

Installer.
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damage may occur.
Loosen the bolts and remove the RH valve cover.
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Handle.
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Installer.
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63. Remove the CHT jumper harness.
64. Remove the engine front cover bolts.
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cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean. These tools
cause scratches and gouges that make leak paths.

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67. NOTE: Rotate the crankshaft in a clockwise direction only.
Rotate the crankshaft clockwise and align the timing marks on the intake VCT units as shown.
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68. Remove the bolts and the LH oil tube.
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70. Remove the bolts and the RH oil tube.
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NOTE: The following 3 steps are for primary timing chains that the colored links are not visible.
72. Mark the timing chain link that aligns with the timing mark on the LH intake VCT unit as shown.
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73. Mark the timing chain link that aligns with the timing mark on the RH intake VCT unit as shown.
74. NOTE: The crankshaft sprocket timing mark should be between the 2 colored links.
Mark the timing chain links that aligns with the timing mark on the crankshaft sprocket as shown.
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75. Remove the bolts and the timing chain tensioner.
76. Remove the timing chain tensioner arm.
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77. Remove the bolts and the lower LH timing chain guide.
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78. NOTE: Removal of the VCT oil control solenoids will aid in the removal of the timing chain.
NOTE: A slight twisting motion will aid in the removal of the VCT oil control solenoid.
NOTE: Keep the VCT oil control solenoid clean of dirt and debris.
Remove the bolts and the VCT oil control solenoids.
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79. Remove the timing chain.
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80. Remove the crankshaft sprocket.
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81. NOTICE: Do not use power tools to remove the bolt or damage to the LH primary timing chain guide may
occur.
Remove the bolt and the upper LH timing chain guide.
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83. Remove and discard the LH VCT unit bolts.
84. Remove the LH VCT units and the secondary timing chain.
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85.
86.
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positions.
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89. Remove and discard the RH VCT unit bolts.
90. Remove the RH VCT units and the secondary timing chain.
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91.
92.
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93. NOTICE: Do not use power tools to remove the bolt or damage to the RH primary timing chain guide may
occur.
Remove the bolt and the RH timing chain guide.
positions.
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NOTE: RH shown, LH similar.
Remove the valve tappets from the cylinder heads.
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99. Remove and discard the cylinder head gasket.
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102. Remove and discard the cylinder head gasket.
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104. Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion.
105. Remove the bolts and the KS.
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106. Remove the bolts and the coolant pump.
107. Inspect and replace if necessary.
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108. Remove the oil pan bolts.
109. Using a pry tool, locate the pry pads at the LH and RH side of the oil pan and pry the oil pan loose and remove.
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110. NOTICE: Only use a 3M™ Roloc® Bristle Disk (2in white, part number 07528) to clean the oil pan. Do not
use metal scrapers, wire brushes or any other power abrasive disk to clean. These tools cause scratches
and gouges that make leak paths.
Clean the engine oil pan using a 3M™ Roloc® Bristle Disk (2in white, part number 07528) in a suitable tool
turning at the recommended speed of 15,000 rpm.
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Thoroughly wash the oil pan to remove any foreign material, including any abrasive particles created during
the cleaning process.
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111. Remove the bolts and the oil pump screen and pickup tube.
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112. Remove and discard the oil pump screen and pickup tube Oring seal.
113. Remove the bolts and the oil pump.
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Remove the bolts and the crankshaft rear seal.
Discard the crankshaft rear seal.
115. Inspect and clean the specified component with a abrasive pad.
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Remove and discard the bolts in the sequence shown.
Remove the main bearing cap support brace.
117. NOTE: The connecting rod cap bolts are a torquetoyield design. The original connecting rod cap bolts will be
used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be
discarded after measurement.
NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod
bearings for reassembly.
Remove the connecting rod cap bolts and caps.
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118. NOTICE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Remove the piston/rod assembly from the engine block.
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119. Inspect the pistons.

Refer to: Piston Inspection (30300 Engine System General Information, General Procedures).
120. NOTE: Clearly mark the position and orientation of the main bearing caps for reassembly.
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Remove and discard the main bearing cap bolts in the sequence shown.
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121. NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.
NOTE: Note the position of the thrust washer on the outside of the No. 4 rear main bearing cap.
Remove the main bearing caps.
122. Remove the lower crankshaft thrust washer from the back side of the No. 4 rear main bearing cap.
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Remove the crankshaft main bearing from the main bearing caps.
124. NOTE: Note the position of the 2 thrust washers on the inside and outside of the rear main bearing bulkhead.
Remove the crankshaft.
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125. Remove the crankshaft thrust bearings from the rear main bearing bulkhead.
Remove the crankshaft main bearings from the cylinder block.
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127. Using a hex bit, remove the piston oil cool valves.
128. Check the cylinder block distortion.

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Make sure that the mating faces of the cylinder block are clean and free of foreign material.
Procedures).
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Assembly Procedure revision date: 12/17/2015
Engine
100002 (TOOL4201C)
Holding Fixture with Dial Indicator Gauge
205142 (T80T4000J)
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205153 (T80T4000W)
Handle
303102
303103 (T74P6375A)
Holding Tool, Flywheel
T74P77000A
TKIT2009TCF
3031245
Engine Lift Eye
TKIT2006UFFLM
TKIT2006UFROW
3031247
TKIT2006UFFLM
TKIT2006UFROW
3031248
TKIT2006UFFLM
TKIT2006UFROW
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3031251
TKIT2006UFFLM
TKIT2006UFROW
3031529
Lift Eye, Engine
TKIT2010AF
TKIT2010ALM
TKIT2010AROW
3031530
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TKIT2010AF
TKIT2010ALM
TKIT2010AROW
303335 (T88T6701A)
TKIT1988F
TKIT1988FLM
307399
TKIT2000APFLM/LM
TKIT2002NDEW
Feeler Gauge
Strap Wrench
Floor Crane
Mounting Stand
RoundEnded Steel Rule
Piston Ring Compressor
Materials
Name Specification
CXO5W20LSP12
Thread Sealant with PTFE WSKM2G350A2
TA24B
TA357
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ZC30A
ZC31B
Antifreeze WSSM97B44D
CVC3B2
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any
material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may
cause engine failure.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components. These
inspections/measurements will aid in determining if the engine components will require replacement. Refer to Section 303
00.
NOTE: If the cylinder head(s) is replaced, a new secondary timing chain tensioner will need to be installed.
1. Using a hex bit, install the oil piston cool valves.
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2. NOTE: This step is for selecting the correct main bearings.
NOTE: The #1 main bearing is at the front of the engine block.
Select the crankshaft main bearings for each crankshaft journal.
Record the code that is on the cylinder block face.
Record the code that is on the crankshaft flange.
The first letter is for main No. 1 and the next letters are for mains 2, 3 and 4.
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3. NOTE: This chart is continued in the next step.
NOTE: This chart is for selecting main bearings 1 and 4 only.
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required
bearing grade for main bearings 1 and 4.
Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing
code.
Read down the column below the engine block main bearing code letter and across the row next to the
crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade(s) for the No. 1
crankshaft main bearing.
As an example, if the engine block code letter is "M" and the crankshaft code letter is "M", the correct bearing
grade for this main bearing is a "2" for the upper bearing and a "2" for the lower bearing.
Repeat the above steps using the fourth letter of the block and crankshaft codes to select the No. 4 bearing.
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4. NOTE: This chart is for selecting main bearings 1 and 4 only.
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5. NOTE: This chart is continued in the next step.
NOTE: This chart is for selecting main bearings 2 and 3 only.
Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required
bearing grade for main bearings 2 and 3.
Read the second letter of the engine block main bearing code and the second letter of the crankshaft main
bearing code.
Read down the column below the engine block main bearing code letter and across the row next to the
crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 2
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crankshaft main bearing.
As an example, if the engine block code letter is "N" and the crankshaft code letter is "H", the correct bearing
grade for this main bearing is "2".
Repeat the above steps using the third letter of the block and crankshaft codes to select the No. 3.
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6. NOTE: This chart is for selecting main bearings 2 and 3 only.
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7. NOTICE: The rod cap installation must keep the same orientation as marked during disassembly or engine
damage may occur.
NOTE: Use the original connecting rod cap bolts.
Using the original rod cap bolts, install the connecting rod caps and bolts.
Torque:
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Stage 3: 90°
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8. Measure the connecting rod large end bore in 2 directions.
Remove the bolts and the rod cap.
Discard the bolts.
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10. Measure each of the crankshaft connecting rod bearing journal diameters in at least 2 directions.
11. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
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12. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign
material. Also, make sure the coolant and oil passages are clear.
Lubricate the upper crankshaft main bearings with clean engine oil and install in the cylinder block.
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13. NOTE: Do not install the upper thrust bearings until the crankshaft is installed.
NOTE: Lubricate the thrust surfaces of the crankshaft with clean engine oil.
Install the crankshaft.
14. NOTE: Make sure the side of the thrust washer, with the wide oil grooves, faces the crankshaft thrust surface.
Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 4 rear
bulkhead.
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Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 4 rear
bulkhead.
16. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps.
Check the seating and squarness of the bearings to make sure of proper seating in the caps.
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17. Position the No. 1, No. 2 and No. 3 main bearing caps on the cylinder block and, keeping the caps as square as
possible, alternately draw the caps down evenly using the new bolts until the main bearing caps are seated.
NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
Install the lower crankshaft thrust washer to the back side of the No. 4 rear main bearing cap, with the tab aligned
with the cutout in the main bearing cap.
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19. Position main bearing cap No. 4 on the cylinder block and keeping the cap as square as possible, alternately draw
the cap down evenly using the new bolts until the main bearing cap is seated.
20. NOTE: While tightening the main bearing vertical bolts, push the crankshaft forward and the No. 4 main bearing cap
rearward to seat the crankshaft thrust washers.
Tighten the main bearing bolts.
Torque:
Stage 2: 135°
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21. Install the new main bearing cap side bolts.
Torque:
Stage 2: 90°
1. Position the crankshaft to the rear of the cylinder block.
Use Special Service Tool: 100002 (TOOL4201C) Holding Fixture with Dial Indicator Gauge.
2. Zero the Dial Indicator Gauge.
3. Move the crankshaft to the front of the cylinder block. Measure and record the crankshaft end play.
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damage may occur.
Prepare the connecting rod and cap.
Insert the new bolts in the rod cap.
Insert the upper and lower rod bearings into the rod and cap.
1. Center line of the piston parallel to the wrist pin bore.
2. Upper compression ring gap location.
3. Upper oil control segment ring gap location.
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4. Lower oil control segment ring gap location.
5. Expander ring and lower compression ring gap location.
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25. NOTICE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the
piston down until the connecting rod bearing seats on the crankshaft journal.
NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine
oil.
NOTE: Make sure the piston rings are positioned to specifications for installation. Refer to Piston in this section.
NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on
the top of the dome of the piston should be facing toward the front of the engine block.
NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as
disassembled.
Using the Piston Ring Compressor, install the piston and the connecting rod assemblies. Repeat until all 6 piston
assemblies are installed.
Use the General Equipment: Piston Ring Compressor

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damage may occur.
NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to verify smooth
operation.
Install the connecting rod cap and the new bolts.
Torque:
Stage 3: 90°
27. Install the main bearing cap support brace and the new bolts.
Torque:
Stage 2: 180°
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application.
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Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the
crankshaft rear seal retainer.
29. Lubricate the crankshaft rear seal with clean engine oil.
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30. Install the crankshaft rear seal and the bolts.
31. Install the oil pump and the bolts.

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32. Install a new oil pump screen and pickup tube Oring seal.
33. Install the oil pump screen and pickup tube and the bolts.
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34. NOTE: The A/C compressor must be installed on the cylinder block and the 2 bolts tightened prior to installing the oil
pan.
Install the A/C compressor and the stud bolts.

Apply a 3 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil
pan.
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Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the 2 crankshaft seal
retainer platetocylinder block joint areas on the sealing surface of the oil pan.
37. Install the oil pan and the bolts.

Torque:
Stage 2: Loosen:: 180°
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38. Position the oil pan so the mounting boss is against the A/C compressor and using a Ended Steel Rule, align the oil
pan flush with the rear of the cylinder block at the 2 areas shown.
Use the General Equipment: RoundEnded Steel Rule
39. Tighten the bolts in the sequence shown.

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40. Install the remaining oil pan bolts.
Torque:
Stage 1: Tighten bolts 19 and 1114 to: 18 lb.ft (24 Nm)
Stage 2: Tighten bolt 10 to: 177 lb.in (20 Nm)
Stage 3: Tighten bolt 10 an additional : 90°
Stage 4: Tighten bolt 15 and 16 to: 89 lb.in (10 Nm)
41. Install the A/C compressor bolt.

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42. Install the coolant pump and the bolts.
Torque:
Stage 2: 45°
43. Install the KS and the bolts.

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44. Install the RH cylinder head gasket.
Install the RH cylinder head and the new bolts.

Torque:
Stage 3: 90°
Stage 4: 90°
Stage 5: 45°
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47. Install the LH cylinder head gasket.
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Install the LH cylinder head and the new bolts.

Torque:
Stage 3: 90°
Stage 4: 90°
Stage 5: 45°

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NOTE: Coat the valve tappets with clean engine oil prior to installation.
NOTE: RH shown, LH similar.
Install the valve tappets.

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.
Position the crankshaft dowel pin in the 9 o'clock position.
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Lubricate the camshafts with clean engine oil and position the camshafts onto the RH cylinder head in the neutral
position as shown.
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Position the RH camshaft seal gaps as shown.
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positions.

Torque:
Stage 2: 45°
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Torque:
Stage 2: 45°
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NOTE: Use a camshaft sprocket bolt to turn the camshafts.
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58. Install the RH primary timing chain guide and the bolt.
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60. Rotate the RH camshafts to TDC.
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62. NOTE: The VCT oil control solenoids are removed for clarity.
63. Align the colored links with the timing marks and assemble the RH VCT units.
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64. NOTE: It may be necessary to rotate the camshafts slightly, to install the RH secondary timing assembly.
Position the RH VCT units and the secondary timing chain onto the camshafts by aligning the holes in the VCT units
with the dowel pins in the camshafts.
65. Install the new RH VCT unit bolts.

Torque:
Stage 4: 180°
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66. NOTE: Make sure the secondary timing chain is centered on the timing chain tensioner guides.
NOTE: The VCT oil control solenoids are removed for clarity.
Lubricate the camshafts with clean engine oil and position the camshafts onto the LH cylinder head in the neutral
position as shown.
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Position the LH camshaft seal gaps as shown.
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positions.

Torque:
Stage 2: 45°
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Torque:
Stage 2: 45°
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NOTE: Use a camshaft sprocket bolt to turn the camshafts.
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74. Rotate the LH camshafts to TDC.
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76. NOTE: The VCT oil control solenoids are removed for clarity.
77. Align the colored links with the timing marks and assemble the LH VCT units.
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78. NOTE: It may be necessary to rotate the camshafts slightly, to install the LH secondary timing assembly.
Position the LH VCT units and the secondary timing chain onto the camshafts by aligning the holes in the VCT units
with the dowel pins in the camshafts.
79. Install the new LH VCT unit bolts.

Torque:
Stage 4: 180°
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80. NOTE: Make sure the secondary timing chain is centered on the timing chain tensioner guides.
NOTE: The VCT oil control solenoids are removed for clarity.
81. Install the upper LH timing chain guide and the bolt.
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82. Rotate the crankshaft clockwise 60 degrees to the TDC position (crankshaft dowel pin at 11 o'clock).
83. Install the crankshaft sprocket.
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84. NOTE: It may be necessary to rotate the camshafts slightly, to align the timing marks.
Install the timing chain with the colored links aligned with the timing marks on the VCT units and the crankshaft
sprocket.
85. Install the lower LH timing chain guide and the bolts.
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86. Install the timing chain tensioner arm.
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1. Release the ratchet detent.
2. Using a softjawed vise, compress the ratchet plunger.
3. Align the hole in the ratchet plunger with the hole in the tensioner housing and install a lockpin.
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NOTICE: It may be necessary to rotate the camshafts slightly to remove slack from the timing chain to
install the timing chain tensioner.
Install the timing chain tensioner and the bolts.

Remove the lockpin.
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As a postcheck, verify correct alignment of all timing marks.
There are 48 links in between the RH intake VCT assembly colored link (1) and the LH intake VCT assembly
colored link (2).
There are 35 links in between LH intake VCT assembly colored link (2) and the 2 crankshaft sprocket links
(3).
90. NOTICE: Do not use excessive force when installing the VCT oil control solenoid. Damage to the mega cap
could cause the cylinder head to be inoperable. If difficult to install the VCT oil control solenoid, inspect the
bore and VCT oil control solenoid to ensure there are no burrs, sharp edges or contaminants present on the
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mating surface. Only clean the external surfaces as necessary.
Install the VCT oil control solenoids and the bolts.

Torque:
Stage 2: 20 °
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91.
92. Install the RH oil tube and the bolts.

Torque:
Stage 2: 60 °
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93.
94. Install the LH oil tube and the bolts.

Torque:
Stage 2: 60 °
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95.
Install Special Service Tool: 307399 Alignment Pins, Transmission Fluid Pump.
NOTE: The engine front cover and bolts must be installed within 4 minutes of the initial sealant application. The
remainder of the engine front cover bolts must be installed and tightened within 35 minutes of the initial sealant
application. If the time limits are exceeded, the sealant must be removed, the sealing area cleaned and sealant
reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep. Failure to follow this
procedure can cause future oil leakage.
Apply a 3.0 mm (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front
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cover sealing surfaces including the inner bolt bosses.
Apply a 5.5 mm (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil panto
cylinder block joint and the cylinder block joint areas of the engine front cover in places as indicated.
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98.
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99. Install the remaining engine front cover bolts.
Torque:
Stage 1: Tighten bolts 1 thru 22 to:: 89 lb.in (10 Nm)
Stage 2: Tighten bolts 23, 24 and 25 to:: 133 lb.in (15 Nm)
Stage 3: Tighten bolt 26 to:: 89 lb.in (10 Nm)
Stage 4: Loosen bolt 26:: 1 turn(s)
Stage 5: Tighten bolts 23, 24 and 25 to 30 Nm (22 lbft) plus an additional:: 90°
Stage 6: Tighten bolts 1 thru 22 to 20 Nm (177 lbin) plus an additional:: 45°
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100. Install the CHT jumper harness.
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Handle.
Handle.
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103. 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. Failure
to follow this procedure can cause future oil leakage.
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106. 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.
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Handle.
Handle.
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109. 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. Failure
to follow this procedure can cause future oil leakage.
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112. 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.
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Install the coilonplugs and the bolts.
Torque:
Stage 2: 50 °
Install the oil level indicator.
114. Install the oil pressure switch.

Material: Thread Sealant with PTFE / TA24B (WSKM2G350A2)
Torque:
Stage 2: 180°
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115. Install a new oil filter adapter gasket.
116. Install the oil filter adapter and the bolts.

Torque:
Stage 2: 45°
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117. Install a new oil cooler Oring gaskets.
118. Install the oil cooler and the bolts.

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119. Install the CKP sensor and bolt.
120. Install new Oring seals and apply clean coolant the Orings.
Material: Antifreeze / CVC3B2 (WSSM97B44D)
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121. Install the coolant tube assembly.
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Torque:
Stage 2: 90 °
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125. NOTE: Apply clean engine oil to the CMP sensor Oring seals.
Install the RH CMP sensors and bolts.

126. NOTE: Apply clean engine oil to the CMP sensor Oring seals.
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Install the LH CMP sensors and bolts.
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127. Install the cover and the pintype retainer.

Torque:
Stage 2: 180°
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Install the RH block coolant drain plug or block heater.
Torque:
Stage 1: Tighten the cylinder block drain plug to:: 89 lb.in (10 Nm)
Stage 2: Plus an additional:: 720°
Tighten the block heater to:
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131. Install the LH catalytic converter and the 3 new lower nuts finger tight.
Torque:
Stage 1: Install the 3 new upper LH catalytic converter nuts and tighten to:: 18 lb.ft (25 Nm)
Stage 2: Tighten the 3 lower LH catalytic converter nuts to:: 18 lb.ft (25 Nm)

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Install the generator and the stud.
Install the nut and bolt.
Position the engine wire harness on the engine.

Connect the RH electrical connectors and the wire harness retainers.
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135. Connect the CHT electrical connector.
136. Connect the RH CMP and KS electrical connectors. Connect the wire harness retainer.
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137. Install the engine vent hose.
NOTICE: 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.
138. NOTE: Align the bracket with the index mark made during removal.
Install the upper intake manifold bracket and bolt.

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139. Install the upper intake manifold gaskets.
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140. Install the upper intake manifold and the bolts.
Torque:
Tighten bolts 1 and 37 to 10 Nm (89 lbin) plus an additional: : 45 °
Tighten bolt 2 to 10 Nm (89 lbin) plus an additional: : 90 °
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141. Install the upper intake manifold bracket bolt.
142. Connect the engine vent hose.

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143. Connect the retainers for the coolant hose.
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145. Connect the wire retainer and the electrical connectors.
146. Connect the CKP sensor electrical connector.
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147. Position back the wire harness grommet.
148. Install the wiring harness retainer stud bolt.

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149. Install the heat shield, nut and bolt.
150. Connect the LH CMP and the CMS (catalyst monitor sensor) electrical connectors. Connect the wire harness
retainers.
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Position the engine wire harness on the engine.

Connect the LH electrical connectors and the wire harness retainers.
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153. Install the crankcase vent tube.
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154. Install the accessory drive belt tensioner and the bolts.
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156. Using the special tool, install the crankshaft front seal.
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Use Special Service Tool: 303102 Installer, Crankshaft Pulley. , 303335 (T88T6701A) Installer, Front Cover Oil
Seal.
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Torque:
Stage 2: Loosen: 1 turn(s)
Stage 4: 90°
160.
Install Special Service Tool: 3031529 Lift Eye, Engine.
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161.
Install Special Service Tool: 3031245 Engine Lift Eye.
162. Install the floor crane.

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163. Remove the engine from the mounting stand.
Use the General Equipment: Mounting Stand
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164. Install the crankshaft sensor ring.
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NOTE: One of the 8 flexplate holes are offset so the flexplate can only be installed in one position
Using the special tool, install the flexplate and the bolts.
Remove Special Service Tool: 303103 (T74P6375A) Holding Tool, Flywheel.
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Removal Procedure revision date: 12/16/2014
Engine
3031245
Engine Lift Eye
TKIT2006UFFLM
TKIT2006UFROW
3031529
Lift Eye, Engine
TKIT2010AF
TKIT2010ALM
TKIT2010AROW
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307346 (T97T7902A)
Retainer, Torque Converter
TKIT1997F/FLM/LT
TKIT1998LM (NavigatoR)
307569
Disconnect Tool TOC Line (1/2)
TKIT2006UF/FM
TKIT2006UFLM/LM
TKIT2006UROW1
TKIT2006UROW2
Floor Crane
Oil Drain Equipment
Cable Ties
Powertrain Jack
Wooden Block
2WD/4WD


3. NOTE: Use a steering wheel holding device (such as Hunter® 28751 or equivalent).
Using a suitable holding tool, hold the steering wheel in the straightahead position.
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4. NOTICE: 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. Refer to Section 50120B.
Remove and discard the steering intermediate shaft bolt.

Separate the steering intermediate shaft from the steering gear.
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Installation).
and Installation).
5. Remove the battery tray.
9. Remove the stud bolt and position aside the ground cable.
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Release the tabs.
Lift and position the top part of the junction box aside.
11. Release the tab and open the cover.
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12. Remove the nuts and position aside the wires. Disconnect the electrical connector.
13. Remove the bolt and disconnect the wire harness retainer. Position aside the wire harness.
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14. Disconnect the vacuum hose and the EVAP tube.

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16. Remove the bolt. Disconnect and position aside the transaxle control cable aside.
Disconnect the upper and lower radiator hoses.

Disconnect the heater hoses.
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18. Remove the bolt for the A/C tube bracket.
NOTICE: Make sure that all openings are sealed.
Disconnect the A/C pressure switch. Remove the nut and disconnect the A/C hose.
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NOTICE: Make sure that all openings are sealed.

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22. Disconnect the PCM electrical connector and the wire harness retainer.
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23. Remove the bolt and disconnect the wire retainer. Position aside the ground wire.
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panel.

Using cables ties or mechanics wire through the upper location holes, support the cooling module.
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1. Remove the front wheels and tires.
2. Remove the fender splash shields.
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30. Detach and disconnect the engine harness electrical connector.
31. Remove the transmission fluid cooler tube secondary latches.
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32. Using the special tool, disconnect the transmission fluid cooler tubes from the transmission fluid cooler thermal
bypass valve.
Use Special Service Tool: 307569 Disconnect Tool TOC Line (1/2).
33. Remove the bolt and the LH antilock sensor.
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34. Remove the bolt and the RH antilock sensor.
Remove the nut and position the LH sway bar link.
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Remove the nut and position the RH sway bar link.
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37. NOTICE: Do not allow the brake caliper and the anchor plate assembly to hang from the brake hose or
damage to the hose can occur.
Remove the front brake discs.

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39. Disconnect the coolant hose retainers from the subframe.
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40. If equipped, disconnect the oil cooler hoses.
41. Disconnect the coolant hose retainer.
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42. Remove the exhaust Ypipe.
43. Remove the retainers and the inspection cover.
44. Remove and discard the torque converter bolts.
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45. Remove the oil pantotransaxle bolts.
46. Remove the drain plug and drain the engine oil.
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4WD
48. NOTE: Indexmark the driveshaft for installation.
Remove the bolts and support the driveshaft with a length of mechanic's wire.
Discard the bolts.
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2WD/4WD
49. NOTE: RH side shown, LH side similar.
Mark the subframe location.
50. Using a 2 x 6 board, 50 in (1,270 mm) and two 2 x 6 boards 24 in (609.6 mm), position the powertrain jack with the
50 in (1,270 mm) board under the 2 control arms and the two 24 in (609.6 mm) boards under the transmission and
oil pan.
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51. Install the adjustable mounting arm from the powertrain jack table to the LH enginetotransmission bolt hole.
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57. Remove and discard the transmission mount bolts.
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Remove and discard the subframe rear bolts.
Remove the subframe bolts and the crossmember.
59. Remove and discard the subframe front bolts.
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60. Lower the subframe and powertrain assembly from the vehicle.
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61.
Install Special Service Tool: 3031245 Engine Lift Eye.
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62.
Install Special Service Tool: 3031529 Lift Eye, Engine.
63. Using the Floor Crane and Spreader Bar, support the powertrain and subframe assembly.
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64. Install a ratchet strap from the RH knuckle to the subframe to keep the RH halfshaft from coming out of the PTU
(power transfer unit) or transmission.
65. Remove the starter wiring nuts.
66. Disconnect the wire harness retainers and position aside.
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67. Remove the stud bolts and the starter.
68. Disconnect the wire retainer and the transmission electrical connector.
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69. Remove the bolt and position aside the ground cable.
70. Disconnect the RH electrical connectors and the wire retainer.
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Remove the nuts and the RH catalytic converter.

Discard the nuts.
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Remove and discard the exhaust manifold studs.
Position back the boot and remove the generator nut.

Disconnect the electrical connector and the wire retainers.
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75. Disconnect the wire harness retainers and position aside the wiring harness.
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4WD
76. Remove the bolts and the PTU (power transfer unit) bracket.
77. Disconnect the PTU vent hose.
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2WD/4WD
78. Remove the adjustable mounting arm.

79. Remove the ratchet strap from the front of the subframe under the powertrain lift table to the rear of the subframe.
80. NOTE: LH shown, RH similar.
Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the
RH engine lift eye.
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81. NOTE: Position wood blocks under the engine and transmission.
Using the Floor Crane and Spreader Bar, remove the powertrain and subframe as an assembly from the powertrain
lift table and set on the ground.
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Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the
RH engine lift eye.
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83. Remove the bolts for the RH halfshaft bracket.
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84. Remove the transaxletoengine and the enginetotransaxle bolts.
Remove the transaxletoengine bolts.

Separate the transaxle from the engine.
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86. Remove the engine from the transaxle.
87.
Install Special Service Tool: 307346 (T97T7902A) Retainer, Torque Converter.
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Description and Operation Procedure revision date: 12/16/2014
Engine Component View
Engine Upper
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Item Part Number Description
1 9424 Upper intake manifold
2 9F797 Fuel rail
3 9J444 Upper intake manifold support bracket
4 9J447 Lower intake manifold
5 8A586 Thermostat housing
6 9N271 Coolant tube
7 12A699 Knock Sensor (KS)
8 8A561 Coolant transfer connector bracket
Engine Front
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1 W701512 Crankshaft pulley bolt
2 N806165 Crankshaft pulley washer
3 6316 Crankshaft pulley
4 6700 Crankshaft front seal
5 6B209 Accessory drive belt tensioner
6 6019 Engine front cover
Engine Upper — LH Cylinder Head
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1 6083 LH cylinder head gasket
2 6050 LH cylinder head
3 12405 Spark plug (3 required)
4 6500 Valve tappet (12 required)
5 6A269 LH exhaust camshaft
6 6A267 LH intake camshaft
7 6C525 Exhaust camshaft Variable Camshaft Timing (VCT) Unit
8 6C524 Intake camshaft VCT unit
9 6C256 LH secondary timing chain

10 6B297 Exhaust camshaft VCT oil control solenoid
11 6B297 Intake camshaft VCT oil control solenoid
12 6B280 Camshaft mega cap
13 6K297 LH secondary tensioner shoe
14 6A258 LH camshaft cap (6 required)
15 6K602 Valve train oil feed tube
16 6C270 LH secondary timing chain tensioner
17 6K273 LH valve cover
18 6750 Oil level indicator
Engine Upper — RH Cylinder Head
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1 6051 RH cylinder head gasket
2 14B485 Cylinder Head Temperature (CHT) sensor jumper harness
3 6G004 CHT sensor
4 6049 RH cylinder head
5 12405 Spark plug (3 required)
6 6500 Valve tappet (12 required)
7 6A266 RH intake camshaft
8 6A268 RH exhaust camshaft
9 6A258 RH camshaft cap (8 required)

10 6K602 Valve train oil feed tube
11 6C525 Exhaust camshaft VCT unit
12 6C524 Intake camshaft VCT unit
13 6C256 RH secondary timing chain
14 6B280 Camshaft mega cap
15 6K297 RH secondary tensioner shoe
16 6B297 Exhaust camshaft VCT unit oil control solenoid
17 6B297 Intake camshaft VCT unit oil control solenoid
18 6C270 RH secondary timing chain tensioner
19 6K271 RH valve cover
Timing Drive Components
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1 6268 Timing chain
2 6306 Crankshaft timing sprocket
3 6L266 Primary timing chain tensioner
4 6K255 Primary timing chain tensioner arm
5 6B274 LH lower primary timing chain guide
6 6K297 RH primary timing chain guide
7 6K297 LH upper primary timing chain guide
8 8501 Coolant pump
Lower Engine Block (View 1)
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1 6675 Oil pan
2 6622 Oil pump screen and pickup tube
3 6625 Oil pump screen and pickup tube Oring seal
4 6621 Oil pump
5 6010 Cylinder block
6 6D327 Crankshaft rear seal retainer
7 12A227 Crankshaft sensor ring
8 6375 Flexplate
9 9278 Oil pressure switch
10 6881 Oil filter adapter
11 6714 Engine oil filter
12 6A642 Oil cooler assembly
Lower Engine Block (View 2)
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1 — Piston compression upper ring (part of 6148) (6 required)
2 — Piston compression lower ring (part of 6148) (6 required)
3 — Piston oil control upper segment ring (part of 6148) (6 required)
4 — Piston oil control spacer (part of 6148) (6 required)
5 — Piston oil control lower segment ring (part of 6148) (6 required)
6 6140 Piston pin retainer (12 required)
7 6135 Piston pin (6 required)
8 6110 Piston (6 required)
9 6200 Connecting rod (6 required)
10 6211 Connecting rod upper bearing (6 required)
11 6211 Connecting rod lower bearing (6 required)
12 — Connecting rod cap (part of 6200) (6 required)
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13 6010 Cylinder block

14 6K868 Piston oil cool valve (6 required)
15 6333 Cylinder block crankshaft main bearing (4 required)
16 6A341 Crankshaft upper thrust washer (2 required)
17 6303 Crankshaft
18 6A338 Lower crankshaft main bearings (4 required)
19 6K302 Crankshaft lower thrust washer
20 6325 Lower crankshaft main bearing caps (4 required)
21 6C364 Main bearing cap support brace
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Engine Front Cover
Base Part Number: 6C086
307399
TKIT2000APFLM/LM
TKIT2002NDEW
Oil Drain Equipment

Cable Ties
Materials
Name Specification
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CXO5W20LSP12
TA357
ZC30A
ZC31B
Brake Cleaner
CPM4
Removal


3. Disconnect the battery ground cable.

Refer to: Battery Disconnect and Connect (41401 Battery, Mounting and Cables, General Procedures).

5. Remove the retainers and the splash shields.
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1. Remove the cowl panel.
Refer to: Cowl Panel (50102 Front End Body Panels, Removal and Installation).
3. Remove the accessory drive belt tensioner.
Refer to: Accessory Drive Belt Tensioner (30305C Accessory Drive 3.5L Duratec (212kW/278PS),
Removal and Installation).
4. Remove the RH half shaft.
Refer to: Front Halfshaft RH FWD (20504 Front Drive Halfshafts, Removal and Installation).
Refer to: Front Halfshaft RH 3.5L Duratec (212kW/278PS), AllWheel Drive (AWD) (20504 Front Drive
Halfshafts, Removal and Installation).
7. Remove the plug and drain the engine oil.

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8. Remove and discard the oil filter.
9. Loosen the roll restrictor bolts.
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1. Remove the LH valve cover.
Refer to: Valve Cover LH (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
2. Remove the RH valve cover.
Refer to: Valve Cover RH (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
3. Remove the PCM.
Refer to: Powertrain Control Module (PCM) (30314C Electronic Engine Controls 3.5L Duratec
12. Detach the wiring harness retainers from the PCM bracket.
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13. Remove the nut, bolts and the PCM bracket.
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14. Remove the bolt. Disconnect the wire retainer and position aside the ground wire.
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panel.

Using cable ties or mechanics wire through the upper location holes, support the cooling module.
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19. Disconnect the coolant hose retainers and position aside.
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20. Disconnect the A/C electrical connector and wire retainers.
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Remove the nut and disconnect the A/C tube.


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Remove the nut.
Remove the stud.
Loosen the bolt.
Position out the generator.
24. Remove the crankshaft front seal.

Refer to: Crankshaft Front Seal (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
NOTICE: Do not allow the A/C compressor to contact the subframe. Failure to follow this direction
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may result in damage to the A/C compressor.
Using the floor jack, lower the engine to access the lower engine front cover bolt.
Remove the lower M10 engine front cover bolt.
26. Using the floor jack, raise the engine 100 mm (3.937).
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27. Remove the M10 engine front cover bolts.
28. Remove the M6 engine front cover bolt.
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29. Remove the remaining engine front cover bolts.
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Installation
cover. Do not use metal scrapers, wire brushes or any other power abrasive disk to clean front cover.

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Procedures).
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3. Install Special Service Tool: 307399 Alignment Pins, Transmission Fluid Pump.
NOTE: The engine front cover and bolts 7, 8, 15, 17, 18, 21 and 22 must be installed within 4 minutes of the initial
sealant application. The remainder of the engine front cover bolts must be installed and tightened within 35 minutes
of the initial sealant application. If the time limits are exceeded, the sealant must be removed, the sealing area
cleaned and sealant reapplied. To clean the sealing area, use silicone gasket remover and metal surface prep.
Failure to follow this procedure can cause future oil leakage.
Apply a 3.0 (0.11 in) bead of Motorcraft® High Performance Engine RTV Silicone to the engine front cover
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sealing surfaces including the inner bolt bosses.

Apply a 5.5 (0.21 in) bead of Motorcraft® High Performance Engine RTV Silicone to the oil pantocylinder
block joint and the cylinder block joint areas of the engine front cover in the places indicated.
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6.
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7. NOTE: Do not tighten the bolt at this time.
Install the M6 engine front cover bolt.
8. NOTE: Do not tighten the bolts at this time.
Install the M10 engine front cover bolts.
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NOTICE: Do not allow the A/C compressor to contact the subframe. Failure to follow this direction
may result in damage to the A/C compressor.
NOTE: Do not tighten the bolt at this time.
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Using the floor jack, lower the engine to allow installation of the M10 engine front cover bolt.
Install the lower M10 engine front cover bolt.
10. NOTICE: 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.
Install the remaining engine front cover bolts.

Torque:
Stage 1: Tighten bolts 1 thur 22 to: 89 lb.in (10 Nm)
Stage 2: Tighten bolts 23, 24 and 25 to: 133 lb.in (15 Nm)
Stage 3: Tighten bolt 26 to: 89 lb.in (10 Nm)
Stage 4: Loosen bolt 26: 1 turn(s)
Stage 5: Tighten bolts 23, 24 and 25 to 30 Nm (22 lbft) plus an additional: 90°
Stage 6: Tighten bolts 1 thur 22 to 20 Nm (177 lbin) plus an additional: 45°
Stage 7: Tighten bolt 26 to 10 Nm (89 lbin) plus an additional: 45 °
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11. Install the crankshaft front seal.
Refer to: Crankshaft Front Seal (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
1. Position back the generator.

2. Install the stud.
3. Install the nut.
4. Tighten the bolt.
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Using a new Oring, position back the A/C tube and install the nut.
Install the A/C bracket nut.
15. Connect the A/C electrical connector and wire retainers.
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16. Position back and connect the coolant hose retainers.
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22. Install the PCM bracket, nut and the bolts.
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23. Attach the wiring harness retainers to the PCM bracket.
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1. Install the PCM.
Refer to: Powertrain Control Module (PCM) (30314C Electronic Engine Controls 3.5L Duratec
2. Install the RH valve cover.
Refer to: Valve Cover RH (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
3. Install the LH valve cover.
Refer to: Valve Cover LH (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
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Tighten the roll restrictor bolt.
Tighten the roll restrictor bolt.
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Install a new engine oil filter.

Torque:
Stage 2: 180°

1. Install the RH half shaft.
Refer to: Front Halfshaft RH FWD (20504 Front Drive Halfshafts, Removal and Installation).
Refer to: Front Halfshaft RH 3.5L Duratec (212kW/278PS), AllWheel Drive (AWD) (20504 Front Drive
Halfshafts, Removal and Installation).
2. Install the accessory drive belt tensioner.
Refer to: Accessory Drive Belt Tensioner (30305C Accessory Drive 3.5L Duratec (212kW/278PS),
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4. Install the cowl panel.
Refer to: Cowl Panel (50102 Front End Body Panels, Removal and Installation).
29. Install the underbody shields and the retainers.
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30. NOTICE: 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 these instructions may cause engine oil
leakage.
Fill the engine with clean engine oil.

31. Fill the engine cooling system.

32. Connect the battery ground cable.

Refer to: Battery Disconnect and Connect (41401 Battery, Mounting and Cables, General Procedures).
33. Evacuate and recharge the A/C system.

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Installation Procedure revision date: 12/16/2014
Engine
3031245
Engine Lift Eye
TKIT2006UFFLM
TKIT2006UFROW
3031529
Lift Eye, Engine
TKIT2010AF
TKIT2010ALM
TKIT2010AROW
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307346 (T97T7902A)
Retainer, Torque Converter
TKIT1997F/FLM/LT
TKIT1998LM (NavigatoR)
Floor Crane
Powertrain Jack
Wooden Block
Materials
Name Specification
Motorcraft® MultiPurpose Grease Spray ESBM1C93B
XL5A
CXO5W20LSP12
2WD/4WD
1. Remove Special Service Tool: 307346 (T97T7902A) Retainer, Torque Converter.
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2. Lubricate the torque converter pilot hub.
Material: Motorcraft® MultiPurpose Grease Spray / XL5A (ESBM1C93B)
3. Inspect the dowel pins and replace if necessary.
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4. Using the floor crane and spreader bar, align the engine to the transaxle.
5. Install the transaxletoengine bolts.

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6. Install the transaxletoengine and enginetotransaxle bolts.
7. Install the bolts for the RH halfshaft bracket.

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Install the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the
RH engine lift eye.
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9. Using the floor crane and the spreader bar, install the powertrain and subframe as an assembly on the powertrain
jack.
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Remove the ratchet strap from the front subframe to the LH engine lift eye and from the rear of the subframe to the
RH engine lift eye.
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11. Install the adjustable mounting arm.
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4WD
13. Connect the PTU (power takeoff unit) vent hose.
Install the PTU bracket and hand start the bolts at the PTU.
Install the bolts at the cylinder block.
Tighten the bolts at the PTU.
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2WD/4WD
15. Position back the wire harness and connect the wire harness retainers.
Connect the electrical connectors and the wire retainers.

Install the generator nut and position back the boot.
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Install the new exhaust manifold studs.
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18. NOTICE: Failure to tighten the exhaust manifold nuts to specification a second time will cause the exhaust
manifold to develop an exhaust leak.
Install the RH catalytic converter and new nuts.

Torque:

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20. Connect the RH electrical connectors and the wire retainer.
21. Position back the ground cable and install the bolt.
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22. Connect the wire retainer and the transmission electrical connector.
23. Install the starter and the stud bolts.

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24. NOTE: Make sure the starter wiring is on the starter terminals.
Position back the wire harness and connect the retainers.
1. Install the starter positive cable nut.

2. Install the starter control nut.
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26. Remove the ratchet strap from the RH knuckle to subframe.
27. Remove the floor crane and the spreader bar.

28.
Remove Special Service Tool: 3031529 Lift Eye, Engine.
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29.
Remove Special Service Tool: 3031245 Engine Lift Eye.
30. Using the powertrain jack, raise the subframe and powertrain assembly into the vehicle.
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31. Install the transmission mount bolts.
1. Install the engine mount bolts.

2. Install the engine mount nut.
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Install the subframe front bolts finger tight.
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Install the crossmember and the subframe rear bolts finger tight.
Install the subframe bolts finger tight.
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36. NOTE: While tightening the subframe bolts, make sure the front subframe does not move.
Tighten the subframe front bolts.

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Tighten the subframe rear bolts.

Torque:
Stage 2: 270°
Tighten the subframe bolts.
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38. Install the RH struttowheel knuckle nuts and bolts.
39. Install the LH struttowheel knuckle nuts and bolts.

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40. Remove the ratchet strap from the front of the subframe to the rear of the subframe.
41. Remove the adjustable mounting arm and the powertrain jack.
4WD
42. Line up the index marks on the rear driveshaft to the index marks on the PTU flange made during removal and
install the bolts.
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2WD/4WD

Torque:
Stage 2: 180°
44. Install the oil pantotransaxle bolts.

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45. Install the new torque converter bolts.
46. Install the inspection cover and the retainers.
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47. Install the exhaust Ypipe.
48. Connect the coolant hose retainer.
49. If equipped, connect the oil cooler hoses.

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50. Connect the coolant hose retainers to the subframe.
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52. Install the front brake discs.

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Position back the RH sway bar link and install the nut.
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Position back the LH sway bar link and install the nut.
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55. Install the RH antilock sensor and bolt.
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56. Install the LH antilock sensor and bolt.
57. Connect the transmission cooling tubes.
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58. Install the transmission cooler tube secondary latches.
59. Connect and attach the engine harness electrical connector.
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61. Install the front underbody shield and the retainers.
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1. Install the fender splash shields.
2. Install the front wheels and tires.

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68. Connect the PCM electrical connector and the wire harness retainer.
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Using a new Oring, connect the A/C hose and install the nut.
Connect the A/C pressure switch.
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72. Install the bolt for the A/C tube bracket.
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Connect the heater hoses.
Connect the upper and lower heater hoses.
74. Position back the transaxle control cable and connect the cable. Install the bolt.
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76. Connect the vacuum hose and the EVAP hose.

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77. Position back the wire harness and connect the wire harness retainer. Install the bolt.
78. Connect the electrical connector. Position back the wires and install the nuts.
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79. Close the cover.
Position back the top part of the junction box

Latch the tabs.
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81. Position back the ground cable and install the stud bolt.

1. Install the battery tray.
and Installation).
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Installation).
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84. NOTICE: Do not allow the intermediate shaft to rotate while it is connecting 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. Refer to Section 50120B.
Position back the steering shaft and install the new bolt.
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85. Remove the steering wheel holding tool.
86. Fill the engine with clean engine oil.

87. Fill and bleed the engine cooling system.

88. Recharge the A/C system.

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89. Check the selector lever cable adjustment.

Refer to: Selector Lever Cable Adjustment 6Speed Automatic Transmission 6F50/6F55 (30705 Automatic
Transmission External Controls, General Procedures).
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Engine Mount
Base Part Number: 6F012
Trolley Jack
Wooden Block
Removal

2. Remove the retainers and the underbody shield.
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3. NOTICE: Failure to position the wood block and floor jack as illustrated can result in damage to the oil
pan.
Support the engine with a floor jack and a wooden block.

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4. Remove the bolt and position aside the degas bottle.
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Installation
Install the engine mount and the bolts.

Install the engine mount nut.
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3. Position back the degas bottle and install the bolt.

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4. Remove the floor jack and the wooden block.
5. Install the underbody shield and the retainers.
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Lower Intake Manifold
Removal
NOTE: It is not necessary to remove the fuel rail from the intake manifold assembly.



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4. Remove the upper intake manifold.

Refer to: Upper Intake Manifold (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).

Refer to: Air Cleaner (30312C Intake Air Distribution and Filtering 3.5L Duratec (212kW/278PS), Removal and
Installation).

7. Disconnect the fuel injector electrical connectors and position aside the wiring harness as needed.
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12. Clean and inspect all sealing surfaces.
Installation
1. Install the new thermostat housing gasket.
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Torque:
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Stage 2: 90 °
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5. Position back the wire harness and connect the fuel injector electrical connectors.

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Refer to: Air Cleaner (30312C Intake Air Distribution and Filtering 3.5L Duratec (212kW/278PS), Removal and
Installation).
8. Install the upper intake manifold.

Refer to: Upper Intake Manifold (30301C Engine 3.5L Duratec (212kW/278PS), Removal and Installation).
9. Fill the engine cooling system.

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Oil Cooler
Oil Drain Equipment

Locking Pliers
Materials
Name Specification
CXO5W20LSP12
Antifreeze WSSM97B44D2
CVC3DILB
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Removal

2. Remove the cooling fan motor and shroud.

Refer to: Cooling Fan Motor and Shroud (30303C Engine Cooling 3.5L Duratec (212kW/278PS), Removal and
Installation).

Installation).
Using hose locking pliers, clamp the oil cooler coolant hoses.
Use the General Equipment: Locking Pliers
Using the hose clamp remover, remove the coolant hoses.
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6. Disconnect the electrical connectors and detach the wire harness retainers.
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7. Remove the nut and position out the line bracket.
8. Remove the stud bolts and bolt. Position out the A/C compressor and secure.
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9. NOTICE: If metal or foreign material is present in the oil cooler, mechanical concerns exist. To diagnose
the mechanical concerns refer to section 30300.
Remove the bolts and the oil cooler.
10. Remove and discard the oil cooler Orings.
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Installation
1. Install the oil cooler Orings.
2. Install the oil cooler and the bolts.

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3. Position back the A/C compressor. Install the stud bolts and the bolt.
1. Torque: 18 lb.ft (25 Nm)
4. Position back the line bracket and install the nut.

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5. Connect the electrical connectors and attach the wire harness retainers.

Torque:
Stage 2: 180 °
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Using the hose clamp installer, install the coolant hoses.
Remove the hose locking pliers.
Use the General Equipment: Locking Pliers

Installation).
9. Install the cooling fan motor and shroud.

Refer to: Cooling Fan Motor and Shroud (30303C Engine Cooling 3.5L Duratec (212kW/278PS), Removal and
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Installation).
10. Inspect and adjust the coolant level in the degas bottle.
Material: Antifreeze / CVC3DILB (WSSM97B44D2)
11. Inspect and adjust the engine oil level.

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20402 Rear Suspension 2015 Edge

Upper Arm
Vehicle/Axle Stands
Removal
NOTICE: Suspension fasteners are critical parts that affect the performance of vital components and systems.
Failure of these fasteners may result in major service expense. Use the same or equivalent parts if replacement is
necessary. Do not use a replacement part of lesser quality or substitute design. Tighten fasteners as specified.
NOTE: Removal steps in this procedure may contain installation details.
1. Remove the wheel and tire.

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2. Raise suspension to curb height.
Use the General Equipment: Vehicle/Axle Stands
3. NOTICE: Tighten the suspension bushing fasteners with the suspension loaded or with the weight of the
vehicle resting on the wheels and tires, otherwise incorrect clamp load and bushing damage may occur.
1. Remove and discard the upper armtowheel knuckle bolt and nut.
2. Remove and discard the upper armtoframe bolt and nut and remove the upper arm.
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Installation
1. To install, reverse the removal procedure.
2. Check and if necessary adjust rear camber.

Refer to: Rear Camber Adjustment (20400 Suspension System General Information, General Procedures).
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Upper Intake Manifold
Removal
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Refer to: Air Cleaner Outlet Pipe (30312C Intake Air Distribution and Filtering 3.5L Duratec (212kW/278PS),
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4. Disconnect the electrical connectors and the wire retainer.
5. Disconnect the EVAP tube.

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6. Disconnect the vacuum hoses.
7. Disconnect the retainers and position aside the coolant hose.
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8. Remove the upper intake manifold support bolt.
9. Remove the bolts and the upper intake manifold.
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11. Clean and inspect all of the sealing surfaces of the upper and lower intake manifold.
Installation
1. Install the new upper intake manifold gaskets.
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2. Install the intake manifold and the bolts.
Torque:
Stage 1: Tighten bolts 1 and 37 to 10 Nm (89 lbin) plus an additional:: 45 °
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3. Install the upper intake manifold support bolt.
4. Position back the coolant hose and connect the retainers.
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5. Connect the vacuum hoses.
6. Connect the EVAP tube.

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7. Connect the electrical connectors and the wire retainer.
8. Connect the electrical connector and the wire retainer.
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Refer to: Air Cleaner Outlet Pipe (30312C Intake Air Distribution and Filtering 3.5L Duratec (212kW/278PS),
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303 01C - Engine 3.5L Duratec (212kW - 278PS) 2015

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303 01C - Engine 3.5L Duratec (212kW - 278PS) 2015

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7/30/2016 2015 Edge

303­01C Engine ­ 3.5L Duratec (212kW/278PS) 2015 Edge

Special Tool(s) / General Equipment

1. With the vehicle in NEUTRAL, position it on a hoist.

2. Release the fuel pressure.

Remove and discard the steering intermediate shaft bolt.

6. Recover the A/C system.

7. Drain the engine cooling system.

8. Remove the following items:

14. Disconnect the vacuum hose and the EVAP tube.

18. Remove the bolt for the A/C tube bracket.

Remove the nut and disconnect the A/C tube fitting.

24. Remove the degas bottle hose.

Remove the upper cooling module support brackets.

28. Remove the retainers and the underbody shields.

29. Remove the retainers and the underbody shields.

31. Remove the transmission fluid cooler tube secondary latches.

33. Remove the bolt and the LH anti­lock sensor.

Remove the nut and position the LH sway bar link.

Remove the nut and position the RH sway bar link.

Remove the front brake discs.

41. Disconnect the coolant hose retainer.

44. Remove and discard the engine oil filter.

46. NOTE: RH side shown, LH side similar.

Mark the subframe location.

Remove and discard the nut and bolts.

Remove and discard the subframe rear bolts.

56. Remove and discard the subframe front bolts.

59. Using a 3 Jaw Puller, remove the crankshaft pulley.

Disconnect the LH electrical connectors and wire harness retainers.

67. Disconnect the wire harness retainer.

70. Disconnect the retainers for the coolant hose.

72. Remove the upper intake manifold bracket bolt.

Remove the bolts and the upper intake manifold.

74. Remove and discard the upper intake manifold gaskets.

77. Disconnect the CHT electrical connector.

Disconnect the RH electrical connectors and the wire harness retainers.

Remove the bolts and the ignition coil­on­plugs.

Loosen the bolts and remove the LH valve cover.

Using the special tools, remove and discard the seal(s).

Using the special tools, remove and discard the seal(s).

Loosen the bolts and remove the RH valve cover.

88. Remove and discard the gasket.

Using the special tools, remove and discard the seal(s).

Material: Motorcraft® Silicone Gasket Remover / ZC­30­A

96. Remove the bolts and the LH oil tube.

Install Special Service Tool: 303­1248 Camshaft holding tools.

98. Remove the bolts and the RH oil tube.

Install Special Service Tool: 303­1248 Camshaft holding tools.

104. Remove the timing chain tensioner arm.

Remove the bolts and the VCT oil control solenoids.

Remove the bolts, camshaft cap and the camshafts.

Remove the bolts, camshaft caps and the camshafts.

Rotate counterclockwise to the 9 o'clock position.

Position the RH camshaft seal gaps as shown.

Install the camshaft caps, oil tube and the bolts.

5. Loosen the camshaft cap bolts.

9. Rotate the RH camshafts to the TDC position as shown.

Install Special Service Tool: 303­1248 Camshaft holding tools.

14. Install the new RH VCT unit bolts.

Rotate counterclockwise to the 9 o'clock position.

Position the LH camshaft seal gaps as shown.

Install the camshaft caps, oil tube and the bolts.

30301C Engine 3.5L Duratec (212kW/278PS) 2015 Edge

33. Remove the bolt and the LH antilock sensor.

Remove the bolts and the ignition coilonplugs.

Material: Motorcraft® Silicone Gasket Remover / ZC30A

Install Special Service Tool: 3031248 Camshaft holding tools.

Install Special Service Tool: 3031248 Camshaft holding tools.

Install Special Service Tool: 3031248 Camshaft holding tools.

Install Special Service Tool: 3031248 Camshaft holding tools.

Using a softjawed vise, compress the ratchet plunger.

95. Install the LH struttowheel knuckle nuts and bolts.

99. Install the exhaust Ypipe.

Refer to: Specifications (30301C Engine 3.5L Duratec (212kW/278PS), Specifications).

30301C Engine 3.5L Duratec (212kW/278PS) 2015 Edge

30301C Engine 3.5L Duratec (212kW/278PS) 2015 Edge

6. Install oil pantocrankshaft rear seal bolts.