Engine - Lower End, Boss® 302

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Fig 1: Exploded View Of Engine (Lower End, Boss® 302)

Courtesy of FORD MOTOR CO.

Item	Part Number	Description
1	6A340	Crankshaft pulley bolt
2	N807033	Crankshaft pulley washer
3	6316	Crankshaft pulley
4	6700	Crankshaft front oil seal
5	W707288	Accessory drive belt idler pulley bolt
6	19A216	Accessory drive belt idler pulley
7	W714925	Engine front cover bolt (8 required)
8	W704920	Engine front cover bolt (5 required)
9	W704919	Engine front cover stud bolt (2 required)
10	6019	Engine front cover
11	6B297	Variable Camshaft Timing (VCT) variable force solenoid (4 required)
12	6K255	RH timing chain tensioner arm
13	W714258	RH timing chain tensioner arm pin
14	6268	RH primary timing chain
15	6K255	LH timing chain tensioner arm
16	W701501	LH timing chain tensioner arm pin
17	6268	LH primary timing chain
18	6306	Crankshaft sprocket
19	N807352	LH timing chain guide bolt
20	6B274	LH timing chain guide
21	W714258	LH timing chain guide pin
22	N807352	RH timing chain guide bolt
23	6M256	RH timing chain guide
24	W714258	RH timing chain guide pin
25	8566	Coolant bypass tee
26	W713197	Thermostat housing bolt (2 required)
27	8A586	Thermostat housing
28	W503277	Heater outlet tube bolt
29	18663	Heater outlet tube
30	N806282	Coolant pump pulley bolt (4 required)
31	8509	Coolant pump pulley
32	W714925	Coolant pump bolt
33	8501	Coolant pump
34	N806183	Oil pump bolt (2 required)
35	W714252	Oil pump stud bolt
36	W714251	Oil pump stud bolt
37	6600	Oil pump
38	6C315	Crankshaft Position (CKP) sensor
39	W500110	Knock Sensor (KS) bolt (2 required)
40	12A699	KS (2 required)
41	14A411	KS wiring harness
42	6214	Connecting rod cap bolt (16 required)
43	-	Connecting rod cap (part of 6200) (8 required)
44	6211	Connecting rod bearing (16 required)
45	6200	Connecting rod (8 required)
46	6140	Piston pin retainer (16 required)
47	6135	Piston pin (8 required)
48	6110	Piston (8 required)
49	-	Outer oil control ring (part of 6148) (16 required)
50	-	Lower compression ring (part of 6148) (8 required)
51	-	Upper compression ring (part of 6148) (8 required)
52	W714962	Oil pump screen and pickup tube bolt (2 required)
53	6622	Oil pump screen and pickup tube
54	N806180	Oil pump screen and pickup tube spacer
55	N605904	Oil pump screen and pickup tube bolt
56	W714963	Oil pan stud bolt (3 required)
57	6675	Oil pan
58	W714962	Oil pan bolt (13 required)
59	6C878	Oil pan baffle and gasket
60	6345	Crankshaft main bearing cap bolt (9 required)
61	6K258	Crankshaft main bearing cap stud bolt
62	6345	Crankshaft main bearing cap bolt (10 required)
63	-	Crankshaft main bearing cap (part of 6010) (5 required)
64	6D309	Crankshaft lower main bearing
65	6D309	Crankshaft lower main bearing (4 required)
66	N806201	Woodruff key
67	6303	Crankshaft
68	6D309	Crankshaft upper main bearing (5 required)
69	6A341	Thrust washer
70	6C358	Crankshaft main bearing cap side bolt (10 required)
71	6010	Engine block
72	6K318	Crankshaft rear seal retainer plate
73	6701	Crankshaft rear seal
74	W714962	Crankshaft rear seal retainer plate bolt (6 required)
75	12A227	Crankshaft sensor ring
76	6375	Flywheel
77	6379	Flywheel bolt (8 required)
78	7120	Input shaft bearing
79	6881	Oil filter adapter
80	6A642	Oil cooler
81	6890	Oil cooler threaded fitting (part of 6A642)
82	6731	Oil filter
83	W714974	Oil filter adapter bolt (2 required)
84	W503306	Oil filter adapter bolt
85	9278	Engine Oil Pressure (EOP) switch

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: 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. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

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

Record the main bearing code found on the front of the engine block.

Fig 2: Locating Main Bearing Code On Front Of Engine Block
Courtesy of FORD MOTOR CO.
Record the main bearing code found on the rear of the crankshaft.

Fig 3: Locating Main Bearing Code On Rear Of Crankshaft
Courtesy of FORD MOTOR CO.
NOTE: This chart is for selecting main bearings 1 and 5 only, the remaining bearings will be selected using a different chart in the next step.

Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 1 and 5.
- 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 "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing.
- Repeat the above steps using the fifth letter of the block and crankshaft codes to select the No. 5 bearing.
  
  Fig 4: Bearing Select Fit Chart (Main Bearings 1 And 5 Only)
  Courtesy of FORD MOTOR CO.
NOTE: This chart is for selecting main bearings 2, 3 and 4 only.

Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for main bearings 2, 3 and 4.
- 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(s) for the No. 2 crankshaft main bearing.
- As an example, if the engine block code letter is "F" and the crankshaft code letter is "P", the correct bearing grade for this main bearing is a "1" for the upper bearing and a "2" for the lower bearing.
- Repeat the above steps using the third and fourth letters of the block and crankshaft codes to select the No. 3 and No. 4 bearings.
  
  Fig 5: Bearing Select Fit Chart (Main Bearings 2, 3 And 4 Only)
  Courtesy of FORD MOTOR CO.
Install the crankshaft main bearings.
- Install the crankshaft upper main bearings into the cylinder block.
- Install the crankshaft lower main bearings and thrust bearing into the bearing caps.
- Make sure all oil passages are aligned.
- Lubricate all main bearings with clean engine oil.
NOTE: Lubricate the crankshaft bearing journals with clean engine oil.

Install the crankshaft into the cylinder block.
NOTE: The oil groove on the thrust washer must face toward the rear of the engine (against the crankshaft thrust surface).

Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.

Fig 6: Pushing Crankshaft Rearward
Courtesy of FORD MOTOR CO.
Install the main bearing caps and fasteners on the cylinder block and, keeping the caps as square as possible, alternately draw the caps down evenly using the cap fasteners.

Fig 7: Installing Main Bearing Caps
Courtesy of FORD MOTOR CO.
Push the crankshaft forward to seat the crankshaft thrust washer. Hold the crankshaft in the forward position.

Fig 8: Pushing Crankshaft Forward
Courtesy of FORD MOTOR CO.
Tighten the vertical main bearing cap fasteners in the sequence shown in illustration, in 4 stages.
- Stage 1: Tighten fasteners 1 through 20 to 20 Nm (177 lb-in).
- Stage 2: Tighten fasteners 1 through 10 to 40 Nm (30 lb-ft).
- Stage 3: Tighten fasteners 11 through 20 to 65 Nm (48 lb-ft).
- Stage 4: Tighten fasteners 1 through 20 an additional 90 degrees.
  
  Fig 9: Identifying Vertical Main Bearing Cap Fasteners Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the cross-mounted main bearing cap fasteners and tighten in the sequence shown in illustration, in 3 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten to 30 Nm (22 lb-ft).
- Stage 3: Tighten an additional 60 degrees.
  
  Fig 10: Installing Cross-Mounted Main Bearing Cap Fasteners Tightening Sequence
  Courtesy of FORD MOTOR CO.
Check the crankshaft end play. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
Check that crankshaft torque-to-turn does not exceed 6 Nm (53 lb-in).
Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
Assemble the pistons. For additional information, refer to PISTON .
Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.

Fig 11: Identifying Piston Ring Gap
Courtesy of FORD MOTOR CO.
Make sure the dimple in the piston faces the front of the engine.

Fig 12: Identifying Dimple In Piston Faces
Courtesy of FORD MOTOR CO.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

NOTE: Do not allow the piston connecting rods to come in contact with the piston cooling jets or engine damage may occur.

Use the Piston Ring Compressor and the Connecting Rod Installers to install the connecting rod with the upper connecting rod bearing in place.
- Lubricate the piston and ring with clean engine oil.
- Lubricate the rod bearings with clean engine oil.
  
  Fig 13: Installing Connecting Rod With Upper Connecting Rod Bearing Using Special Tools
  Courtesy of FORD MOTOR CO.
NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installers.

Fig 14: Identifying Connecting Rod Installer
Courtesy of FORD MOTOR CO.
NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

Position the lower bearing and connecting rod and install the new bolts loosely.
Repeat the previous 5 steps for each of the remaining pistons.
NOTE: Main bearing caps are removed for clarity.

Tighten the bolts in the sequence shown in illustration in 3 stages.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 38 Nm (28 lb-ft).
- Stage 3: Tighten an additional 105 degrees.
  
  Fig 15: Identifying Main Bearing Caps Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the oil pump screen and pickup tube spacer.
- Tighten to 25 Nm (18 lb-ft).
Rotate the inner rotor of the oil pump assembly to align the flats on the crankshaft and slip the oil pump over the crankshaft until seated against the block.
- Rotate the oil pump until the bolt holes are aligned to the block and install the fasteners.
NOTE: Oil pump must be held against the cylinder block until all bolts are tightened.

Tighten the fasteners in the sequence shown in illustration in 3 stages:
- Stage 1: Hand tighten.
- Stage 2: Tighten the bolt (1) to 10 Nm (89 lb-in), the stud bolt (2) to 25 Nm (18 lb-ft), the bolt (3) to 10 Nm (89 lb-in) and the stud bolt (4) to 20 Nm (177 lb-in).
- Stage 3: Tighten the bolt (1) an additional 45 degrees, the stud bolt (2) an additional 75 degrees, the bolt (3) an additional 45 degrees and the stud bolt (4) an additional 60 degrees.
  
  Fig 16: Identifying Oil Pump Fasteners Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 5 minutes, whichever is longer. Failure to follow this procedure may cause future oil leaks.

Apply a 3.75 mm (0.147 in) bead of silicone gasket and sealant to the rear crankshaft seal retainer mating surface on the engine block.

Fig 17: Locating Bead Of Silicone Gasket And Sealant Applying Areas On Rear Crankshaft Seal Retainer Mating Surface
Courtesy of FORD MOTOR CO.
Install the crankshaft rear seal retainer plate and the 6 bolts, tighten in the sequence shown in illustration in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
  
  Fig 18: Identifying Crankshaft Rear Seal Retainer Plate Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: 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 scraping tool to remove all traces of old sealant.

Inspect the oil pan and engine sealing surfaces. Clean the mating surfaces of the engine and oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
NOTE: If the oil pan 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. If this timing cannot be met, tighten fasteners 7, 8, 9 and 10 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer and final torque all of the fasteners within 1 hour of applying the sealer.

NOTE: If the engine front cover has been removed, it is only necessary to apply sealant to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces.

Apply an 8 mm (0.31 in) bead of silicone gasket and sealant to the crankshaft rear seal retainer plate-to-cylinder block sealing surfaces and the engine front cover-to-cylinder block sealing surfaces.

Fig 19: Locating Sealant Applying Areas On Crankshaft Rear Seal Retainer Plate-To-Cylinder Block Sealing Surfaces
Courtesy of FORD MOTOR CO.
Position the oil pan baffle and gasket.
NOTE: The 2 oil pump screen and pickup tube-to-oil pump bolts must be tightened prior to tightening the oil pump screen and pickup tube-to-spacer bolt.

Using a new O-ring seal, install the oil pump screen and pickup tube and the 3 bolts. Tighten the 2 oil pump screen and pickup tube-to-oil pump bolts in 2 stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 45 degrees.
Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
NOTE: Fastener location 7 is a stud bolt.

Install the oil pan and tighten the fasteners in sequence in 3 stages.
- Stage 1: Tighten to 2 Nm (18 lb-in)
- Stage 2: Tighten to 10 Nm (89 lb-in).
- Stage 3: Tighten an additional 45 degrees.
  
  Fig 20: Identifying Oil Pan Fasteners Tightening Sequence
  Courtesy of FORD MOTOR CO.
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.
NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

If equipped, install a new oil cooler and the threaded fitting.
- Tighten to 58 Nm (43 lb-ft).
NOTE: Do not lubricate the O-ring seal.

Install a new oil filter.
- Tighten to 16 Nm (142 lb-in).
NOTE: 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 sensor is installed incorrectly, the CKP sensor can be damaged.

Position the CKP sensor and install the bolt.
- Tighten to 10 Nm (89 lb-in).
Install the 2 Knock Sensor (KS) and 2 bolts.
- Tighten to 20 Nm (177 lb-in).
Verify the crankshaft keyway is in the 9 o'clock position and install the crankshaft sprocket with the flange facing forward.
NOTE: 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.

NOTE: 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.

NOTE: 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 in illustration, 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.

Fig 21: Positioning Cylinder Head Gaskets And Cylinder Heads Over Dowels Using Cylinder Head Alignment Pins
Courtesy of FORD MOTOR CO.
Tighten the new RH cylinder head bolts in 4 stages in the sequence shown in illustration.
- 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.
  
  Fig 22: Identifying RH Cylinder Head Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: 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.
Install 8 new RH exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).
Install new gaskets, the RH exhaust manifold and 8 new nuts.
- Tighten nuts in the sequence shown in illustration in 2 stages.
  - Stage 1: Tighten to 24 Nm (18 lb-ft).
  - Stage 2: Tighten to 32 Nm (24 lb-ft).
    
    Fig 23: Identifying RH Exhaust Manifold Nuts Tightening Sequence
    Courtesy of FORD MOTOR CO.
Install the Cylinder Head Temperature (CHT) sensor.
- Tighten to 11 Nm (97 lb-in).
NOTE: 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).
Tighten the new LH cylinder head bolts in 4 stages in the sequence shown in illustration.
- 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.
  
  Fig 24: Identifying LH Cylinder Head Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: 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.
Install 8 new LH exhaust manifold studs.
- Tighten to 25 Nm (18 lb-ft).
Install new gaskets, the LH exhaust manifold and 8 new nuts.
- Tighten nuts in the sequence shown in illustration in 2 stages.
  - Stage 1: Tighten to 24 Nm (18 lb-ft).
  - Stage 2: Tighten to 32 Nm (24 lb-ft).
    
    Fig 25: Identifying LH Exhaust Manifold Nuts Tightening Sequence
    Courtesy of FORD MOTOR CO.
Using a new gasket, install the coolant outlet and 2 bolts.
- Tighten to 10 Nm (89 lb-in).
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.
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.
Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.
Install the LH front camshaft bearing mega cap and the 4 bolts. Do not tighten the bolts at this time
Tighten the bolts in the sequence shown in illustration in 2 stages.
- Stage 1: Tighten to 6 Nm (53 lb-in).
- Stage 2: Tighten an additional 45 degrees.
  
  Fig 26: Identifying Camshaft Bearing Caps Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: Intake camshaft shown in illustration, exhaust camshaft similar.

Install the Variable Camshaft Timing (VCT) system oil filter in the intake and exhaust camshafts.
Install the secondary timing chain onto the LH VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
1. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
2. The timing mark on the exhaust VCT assembly should align with the single colored link.
Install the LH VCT 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 assembly should be in the 11 o'clock position.
NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the camshaft) to seat the VCT assemblies onto the camshafts.

Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT assemblies onto the camshafts.
- If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until they are fully seated on the camshafts.
NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.

Install the 3 LH intake VCT assembly bolts and the 3 LH exhaust VCT assembly bolts.
- Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.
Install the LH primary timing chain.
- Align the colored link on the timing chain with the timing mark on the LH VCT assembly.
Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.
NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain guide. Return the crankshaft keyway to the 9 o'clock position after installing the LH timing chain guide.

Install the LH timing chain guide and bolt.
- Tighten to 10 Nm (89 lb-in).
NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the LH timing chain tensioner arm. Return the crankshaft keyway to the 9 o'clock position after installing the LH timing chain tensioner arm.

Install the LH timing chain tensioner arm.

NOTE: Complete the following 3 steps on both the LH and RH primary timing chain tensioners.
NOTE: Do not compress the ratchet assembly or damage to the tensioner will occur.

Compress the primary timing chain tensioner plunger, using an edge of a vise.
Using a small screwdriver or pick, push back and hold the ratchet mechanism, then push the ratchet arm back into the tensioner housing.
Install a suitable pin into the hole of the tensioner housing to hold the ratchet assembly and plunger in place during installation.
Install the LH primary timing chain tensioner and 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Remove the holding pin from the tensioner.
  
  Fig 27: Locating LH Primary Timing Chain Tensioner And Bolts
  Courtesy of FORD MOTOR CO.
Using the crankshaft holding tool, rotate the crankshaft clockwise until the crankshaft keyway is at the 12 o'clock position.
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.
NOTE: Lubricate the camshafts with clean engine oil prior to installation.

Install the RH intake and exhaust camshafts in the neutral position. Align the D-slots as shown in the illustration.
Install the 8 camshaft bearing caps and the 16 bolts. Do not tighten the bolts at this time.
Install the RH front camshaft bearing mega cap and the 4 bolts. Do not tighten at this time
Tighten the bolts in the sequence shown in illustration in 2 stages.
- Stage 1: Tighten to 6 Nm (53 lb-in).
- Stage 2: Tighten an additional 45 degrees.
  
  Fig 28: Identifying Camshaft Bearing Cap Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: Intake camshaft shown in illustration, exhaust camshaft similar.

Install the VCT system oil filter in the intake and exhaust camshafts.
Install the secondary timing chain onto the RH VCT assemblies. Align the colored links on the secondary timing chain with the timing marks on the VCT assemblies as shown in the illustration.
1. The timing mark on the intake VCT assembly should align between the 2 consecutive colored links.
2. The timing mark on the exhaust VCT assembly should align with the single colored link.
Install the RH VCT assemblies and the secondary timing chain onto the RH camshafts to a position 2 mm (0.078 in) from fully seated. The timing mark on the exhaust VCT assembly should be in the 1 o'clock position.
NOTE: It may be necessary to rotate the exhaust camshaft slightly (using a wrench on the flats of the camshaft) to seat the VCT assemblies onto the camshafts.

Rotate the secondary timing chain tensioner 90 degrees so the ramped area is facing forward and fully seat the VCT assemblies onto the camshafts.
- If the secondary timing chain is not centered over the tensioner, reposition the VCT assemblies until they are fully seated on the camshafts.
NOTE: Use a wrench on the flats of the camshaft to hold the camshafts while tightening the VCT assembly bolts.

Install the 3 RH intake VCT assembly bolts and the 3 RH exhaust VCT assembly bolts.
- Tighten to 15 Nm (133 lb-in) plus an additional 90 degrees.
Install the RH primary timing chain.
- Align the colored link on the timing chain with the timing mark on the RH VCT assembly.
Align the remaining colored link on the timing chain with the timing mark on the crankshaft sprocket.
NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after installing the RH timing chain guide.

Install the RH timing chain guide and bolt.
- Tighten to 10 Nm (89 lb-in).
NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to install the RH timing chain tensioner arm. Return the crankshaft keyway to the 12 o'clock position after installing the RH timing chain tensioner arm.

Install the RH timing chain tensioner arm.
Install the RH primary timing chain tensioner and 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Remove the holding pin from the tensioner.
With the crankshaft keyway still at the 12 o'clock position, verify the timing mark alignment is correct.
NOTE: The Variable Camshaft Timing (VCT) variable force solenoid pins must be fully depressed to avoid interference with the VCT valve tips when installing the engine front cover. Failure to follow these instructions can result in damage to the engine.

NOTE: LH shown in illustration, RH similar.

Fully depress the VCT variable force solenoid pins.
NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Apply a bead of silicone gasket and sealant to the cylinder head-to-cylinder block joints and the oil pan-to-cylinder block joints as illustrated.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Using new gaskets, position the engine front cover onto the dowels.
- Install the 13 engine front cover bolts, 2 stud bolts, 2 oil pan-to-engine front cover bolts and the 2 oil pan-to-engine front cover stud bolts finger-tight.
NOTE: The engine front cover must be installed and all fasteners final tightened within 5 minutes of applying the sealer. If this cannot be accomplished, install the engine front cover and tighten fasteners 6, 7, 8, 9, 10 and 11 to 8 Nm (71 lb-in) within 5 minutes of applying the sealer. All of the fasteners must then be final tightened within 1 hour of applying the sealer. If this time limit is exceeded, all sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Tighten the bolts in the sequence shown in illustration in 2 stages.
- Stage 1: Tighten bolts 1-15 to 25 Nm (18 lb-ft) and bolts 16-19 to 10 Nm (89 lb-in).
- Stage 2: Tighten bolts 1-15 an additional 60 degrees and bolts 16-19 an additional 45 degrees.
  
  Fig 29: Identifying Engine Front Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: Lubricate the engine front cover bore and the crankshaft front oil seal inner lip with clean engine oil.

Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft front oil seal.
NOTE: If not secured within 5 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot in the crankshaft pulley.
Lubricate the crankshaft pulley sealing surface with clean engine oil prior to installation.
Using the Front Crank Seal and Damper Installer and the Front Cover Oil Seal Installer (plate only), install the crankshaft pulley.
Using the Strap Wrench, install a new crankshaft pulley bolt and the original washer, tighten the bolt in 4 stages:
- Stage 1: Tighten to 140 Nm (103 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 100 Nm (74 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
  
  Fig 30: Installing Crankshaft Pulley Bolt And Original Washer Using Strap Wrench
  Courtesy of FORD MOTOR CO.
Install the generator, the bolt and the nut.
- Tighten to 48 Nm (35 lb-ft).
Install the accessory drive belt tensioner and the bolt.
- Tighten to 48 Nm (35 lb-ft).
Attach the 3 wiring harness retainers (2 shown in illustration) from the engine front cover and stud bolts.
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.
Install the coolant pump pulley and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
NOTE: Installation of new seals is only required if damaged seals were removed.

Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
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 force solenoid seal(s).
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.
Position the LH valve cover and new gasket on the cylinder head.
- Tighten the bolts in the sequence shown in illustration to 10 Nm (89 lb-in).
  
  Fig 31: Identifying LH Valve Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the oil level indicator.
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 sensor electrical connectors.
NOTE: Installation of new seals is only required if damaged seals were removed.

Using the VCT Spark Plug Tube Seal Installer and Handle, install new spark plug tube seals.
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 force solenoid seal(s).
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.
Position the RH valve cover and new gasket on the cylinder head.
- Tighten the bolts in the sequence shown in illustration to 10 Nm (89 lb-in).
  
  Fig 32: Identifying RH Valve Cover Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the RH intake and exhaust CMP sensors and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Connect the RH intake and exhaust CMP sensor electrical connectors.
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.
  
  Fig 33: Locating Coil Seal
  Courtesy of FORD MOTOR CO.
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 in illustration, LH similar.

Install the 8 ignition coils and 8 bolts.
- Tighten to 6 Nm (53 lb-in).
NOTE: RH shown in illustration, LH similar.

Attach the 9 wiring harness retainers to the RH valve cover and the 10 wiring harness retainers to the LH valve cover.
NOTE: RH shown in illustration, LH similar.

Connect the 8 ignition coil electrical connectors.
NOTE: RH shown in illustration, LH similar.

Connect the 4 VCT variable force solenoid electrical connectors.
Connect the CHT sensor and the CKP sensor electrical connectors.
Connect the 2 KS electrical connectors.
Connect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness retainers.
Connect the oil level sensor electrical connector and the 2 wiring harness retainers.
Install the Engine Lifting Bracket

Fig 34: Identifying Engine Lifting Bracket
Courtesy of FORD MOTOR CO.
Using the Floor Crane, remove the engine from the work stand.
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.
Using the Rear Main Seal Installer and Handle, install the new crankshaft rear seal.
Install the crankshaft sensor ring.

NOTE: Flywheel shown in illustration, 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 illustration in 2 stages.

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

Stage 2: Tighten an additional 60 degrees.

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.