Part 4
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.
100. Attach the 3 wiring harness retainers (2 shown) from the engine front cover and stud bolts.
101. NOTE: Lubricate the new coolant pump O-ring seal with clean engine coolant.
Using a new O-ring seal, install the coolant pump and the 4 bolts.
- Tighten to 20 Nm (177 lb-in) plus an additional 60 degrees.
102. Install the coolant pump pulley and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
103. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
104. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the Differential Bearing Cone Installer and Handle, install new VCT (Variable Camshaft Timing) variable force solenoid seal(s).
105. NOTE: If the valve cover is not installed and the fasteners tightened within 5 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 silicone gasket and sealant to the engine front cover-to-LH cylinder head joints.
106. Position the LH valve cover and new gasket on the cylinder head.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
107. Install the oil level indicator.
108. Install the LH intake and exhaust Camshaft Position (CMP) sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Connect the LH intake and exhaust CMP (Camshaft Position) sensor electrical connectors.
109. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the VCT (Variable Camshaft Timing) Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
110. NOTE: Installation of new seals is only required if damaged seals were removed.
Using the Differential Bearing Cone Installer and Handle, install new VCT (Variable Camshaft Timing) variable force solenoid seal(s).
111. NOTE: If the valve cover is not installed and the fasteners tightened within 5 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 silicone gasket and sealant to the engine front cover-to-RH cylinder head joints.
112. Position the RH valve cover and new gasket on the cylinder head.
- Tighten the bolts in the sequence shown to 10 Nm (89 lb-in).
113. Install the RH intake and exhaust CMP (Camshaft Position) sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Connect the RH intake and exhaust CMP (Camshaft Position) sensor electrical connectors.
114. Inspect the coil seals for rips, nicks or tears. Remove and discard any damaged coil seals.
- To install, slide the new coil seal onto the coil until it is fully seated at the top of the coil.
115. NOTE: Apply a small amount of dielectric grease to the inside of the ignition coil-on-plug boots before attaching to the spark plugs. RH shown, LH similar.
Install the 8 ignition coils and 8 bolts.
- Tighten to 6 Nm (53 lb-in).
116. NOTE: RH shown, LH similar.
Attach the 9 wiring harness retainers to the RH valve cover and the 10 wiring harness retainers to the LH valve cover.
117. NOTE: RH shown, LH similar.
Connect the 8 ignition coil electrical connectors.
118. NOTE: RH shown, LH similar.
Connect the 4 VCT (Variable Camshaft Timing) variable force solenoid electrical connectors.
119. Connect the CHT (Cylinder Head Temperature) sensor and the CKP (Crankshaft Position) sensor electrical connectors.
120. Connect the 2 KS (Knock Sensor) electrical connectors.
121. Connect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness retainers.
122. Connect the oil level sensor electrical connector and the 2 wiring harness retainers.
123. Install the Engine Lifting Bracket
124. Using the Floor Crane, remove the engine from the work stand.
125. NOTE: Lubricate the seal lips and bore with clean engine oil prior to installation.
Position the Rear Main Seal Installer onto the end of the crankshaft and slide a new crankshaft rear seal onto the tool.
126. Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
127. Install the crankshaft sensor ring.
128. NOTE: Flywheel shown, flexplate similar.
NOTE: The flywheel/flexplate bolts are torque-to-yield design and are not reusable.
Install the engine separator plate, the flywheel or flexplate and 8 new bolts.
- Tighten in the sequence shown in 2 stages.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten an additional 60 degrees.
129. NOTE: If installing the original pressure plate, align it using the index marks made during removal.
NOTE: Always install new pressure plate bolts.
If equipped, use suitable clutch aligner, position the clutch disc on the flywheel, install the pressure plate and 9 new pressure plate bolts. Turn the bolts 1-2 turns at a time in a star pattern until the clutch is fully secured.
- Tighten the pressure plate bolts in 2 stages in a star pattern.
- Stage 1: Tighten to 63 Nm (46 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
