Part 2

Engine














Engine - Upper End, Except Boss(R) 302














Engine - Lower End, Except Boss(R) 302


















Engine - Upper End, Boss(R) 302














Engine - Lower End, Boss(R) 302

















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, can cause engine failure.

NOTICE: During engine assembly do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.

NOTE: During engine assembly it may become necessary to check bearing clearances and end play.

NOTE: The Boss(R) 302 requires Motorcraft(R) SAE 5W-50 Full Synthetic Motor Oil, all other 5.0L (4V) engines require Motorcraft(R) SAE 5W-20 Premium Synthetic Blend Motor Oil.

36. NOTE: Install a new oil filter adapter gasket.
Using a new gasket, install the oil filter adapter and the 3 bolts. Tighten the bolts in 2 stages.

- Stage 1: Tighten the bolts to 20 Nm (177 lb-in).

- Stage 2: Tighten an additional 60 degrees.






Boss(R) 302 engines

37. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur.

Install a new oil cooler and the threaded fitting.
- Tighten to 58 Nm (43 lb-ft).






All engines

38. NOTE: Do not lubricate the O-ring seal.
Install a new oil filter.

- Tighten to 16 Nm (142 lb-in).


39. NOTICE: The Crankshaft Position (CKP) sensor must be positioned into the fitting on the crankshaft rear seal retainer plate and be flush against the boss on the engine block before the bolt is installed. If the CKP (Crankshaft Position) sensor is installed incorrectly, the CKP (Crankshaft Position) sensor can be damaged.

Position the CKP (Crankshaft Position) sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).






40. Install the 2 Knock Sensor (KS) and 2 bolts.
- Tighten to 20 Nm (177 lb-in).






41. Verify the crankshaft keyway is in the 9 o'clock position and install the crankshaft sprocket with the flange facing forward.





42. NOTICE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.

NOTICE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in future oil leakage.

NOTICE: The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown, RH similar.
Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.






43. Tighten the new RH cylinder head bolts in 4 stages in the sequence shown.
- Stage 1: Tighten to 25 Nm (18 lb-ft).

- Stage 2: Tighten to 40 Nm (30 lb-ft).

- Stage 3: Tighten an additional 90 degrees.

- Stage 4: Tighten an additional 90 degrees.






44. 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 which make leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.


45. Install 8 new RH exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).






46. Install new gaskets, the RH exhaust manifold and 8 new nuts.
- Tighten nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 24 Nm (18 lb-ft).

- Stage 2: Tighten to 32 Nm (24 lb-ft).






47. Install the Cylinder Head Temperature (CHT) sensor.
- Tighten to 11 Nm (97 lb-in).






48. NOTICE: Lubricate the O-ring seal with clean engine coolant prior to installing.

Using a new O-ring seal, install the coolant outlet pipe.
- Tighten to 10 Nm (89 lb-in).






49. Tighten the new LH cylinder head bolts in 4 stages in the sequence shown.
- Stage 1: Tighten to 25 Nm (18 lb-ft).

- Stage 2: Tighten to 40 Nm (30 lb-ft).

- Stage 3: Tighten an additional 90 degrees.

- Stage 4: Tighten an additional 90 degrees.






50. 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 which make leak paths. Use a plastic scraper to clean the sealing surfaces.

Clean the exhaust manifold mating surface of the cylinder head with metal surface prep. Follow the directions on the packaging.


51. Install 8 new LH exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).






52. Install new gaskets, the LH exhaust manifold and 8 new nuts.
- Tighten nuts in the sequence shown in 2 stages.
- Stage 1: Tighten to 24 Nm (18 lb-ft).

- Stage 2: Tighten to 32 Nm (24 lb-ft).






53. Using a new gasket, install the coolant outlet and 2 bolts.
- Tighten to 10 Nm (89 lb-in).






54. NOTE: Lubricate the camshaft roller follower and hydraulic lash adjuster assemblies with clean engine oil prior to installation.
Install the 16 camshaft roller follower and hydraulic lash adjuster assemblies.






55. NOTE: Lubricate the camshafts with clean engine oil prior to installation.
Install the LH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.






56. Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.

57. Install the LH front camshaft bearing mega cap and the 4 bolts. Do not tighten the bolts at this time





58. Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 6 Nm (53 lb-in).

- Stage 2: Tighten an additional 45 degrees.






59. NOTE: Intake camshaft shown, exhaust camshaft similar.
Install the Variable Camshaft Timing (VCT) system oil filter in the intake and exhaust camshafts.






60. Install the secondary timing chain onto the LH VCT (Variable Camshaft Timing) assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT (Variable Camshaft Timing) assemblies as shown in the illustration.
1. The timing mark on the intake VCT (Variable Camshaft Timing) assembly should align between the 2 consecutive colored links.

2. The timing mark on the exhaust VCT (Variable Camshaft Timing) assembly should align with the single colored link.






61. Install the LH VCT (Variable Camshaft Timing) assemblies and the secondary timing chain onto the LH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT (Variable Camshaft Timing) assembly should be in the 11 o'clock position.





62. NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the camshaft) to seat the VCT (Variable Camshaft Timing) assemblies onto the camshafts.
Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT (Variable Camshaft Timing) assemblies onto the camshafts.

- If the secondary timing chain is not centered over the tensioner, reposition the VCT (Variable Camshaft Timing) assemblies until they are fully seated on the camshafts.






63. NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT (Variable Camshaft Timing) assembly bolts.
Install the 3 LH intake VCT (Variable Camshaft Timing) assembly bolts and the 3 LH exhaust VCT (Variable Camshaft Timing) assembly bolts.

- Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.






64. Install the LH primary timing chain.
- Align the colored link on the timing chain with the timing mark on the LH VCT (Variable Camshaft Timing) assembly.






65. Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.