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Section 179 (Engine Mechanical - 5.0L (4V)): Disassembly: Engine

WARNING: This page is about a different car, the 2013 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G06061933
 3 Jaw Puller
303-D121 or equivalent
G07958493
 Handle
205-153 (T80T-4000-W)
G06126248
 Holding Tool, Crankshaft
303-448 (T93P-6303-A)
G06126594
 Installer, Connecting Rod
303-442 (T93P-6136-A)
G07397878
 Installer, Differential Bearing Cone
205-142 (T80T-4000-J)
G06061949
 Remover, Crankshaft Rear Oil Seal
303-519 (T95P-6701-EH)
G07441694
 Remover, Oil Seal
303-409 (T92C-6700-CH)
G06061916
 Remover, Spark Plug Tube Seal
303-1247/1
G06064997
 Slide Hammer
100-001 (T50T-100-A)
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® Metal Surface Prep
ZC-31-A		 -
Motorcraft® Silicone Gasket Remover
ZC-30		 -
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: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
NOTE: If the components are to be reinstalled, they must be installed in their original location. Mark the components for installation into their original location.
NOTE: For additional information, refer to the exploded view under the ASSEMBLY  procedure.
  1. Remove the engine. For additional information, refer to ENGINE - MANUAL TRANSMISSION  or ENGINE - AUTOMATIC TRANSMISSION .
  2. NOTE: Loosen the bolts evenly to prevent clutch pressure plate damage.
    NOTE: If the parts are to be reused, index-mark the pressure plate to the flywheel.

    If equipped, remove the 9 pressure plate bolts, remove the pressure plate and the clutch disc.

    • Discard the pressure plate bolts.
      G07990635
  3. NOTE: Flexplate shown in illustration, flywheel similar.
    NOTE: The flexplate/flywheel bolts are torque-to-yield design and are not reusable.

    Remove the 8 bolts and the flywheel or flexplate.

    • Discard the bolts.
    • Remove the engine separator plate.
      Fig 1: Locating Engine Separator Plate, Flexplate/Flywheel And Bolts
      G07988293Courtesy of FORD MOTOR CO.
  4. NOTE: Inspect the crankshaft sensor ring for damage. If the crankshaft sensor ring has been dropped or has any visual damage, it must be discarded.

    Remove the crankshaft sensor ring.

    G07960933
  5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.
    G07474329
  6. Mount the engine on a work stand.
  7. Disconnect the oil level sensor electrical connector and the 2 wiring harness retainers.
    G07988296
  8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness retainers.
    G07988297
  9. Disconnect the LH intake and exhaust Camshaft Position (CMP) sensor electrical connectors.
    • Remove the 2 bolts and the LH intake and exhaust CMP sensors.
      G07474413
  10. Disconnect the 2 Knock Sensor (KS) electrical connectors.
    G07960955
  11. Disconnect the RH intake and exhaust Camshaft Position (CMP) sensor electrical connectors.
    • Remove the 2 bolts and the RH intake and exhaust CMP sensors.
      G07474396
  12. Disconnect the Cylinder Head Temperature (CHT) sensor and the Crankshaft Position (CKP) sensor electrical connectors.
    G07960949
  13. NOTE: RH shown in illustration, LH similar.

    Disconnect the 4 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.

    G07474370
  14. NOTE: RH shown in illustration, LH similar.

    Disconnect the 8 ignition coil electrical connectors.

    G07474371
  15. NOTE: RH shown in illustration, LH similar.

    Detach the 9 wiring harness retainers from the RH valve cover and the 10 wiring harness retainers from the LH valve cover.

    G07474372
  16. Detach the 2 wiring harness retainers from the engine front cover and stud bolts.
    • Remove the wiring harness from the engine.
      G07474380
  17. NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease removal. RH shown in illustration, LH similar.

    Remove the 8 bolts and the 8 ignition coils.

    G07474373
  18. 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.

    Loosen the 14 bolts and remove the RH valve cover and gasket.

    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
      G07474374
  19. Remove the oil level indicator.
  20. 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.

    Loosen the 14 bolts and remove the LH valve cover and gasket.

    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
      G07474375
  21. NOTE: RH shown in illustration, LH similar.

    Inspect the 2 VCT variable force solenoid seals. Remove any damaged seals.

    • Using the Differential Bearing Cone Installer and Handle, remove the seal(s).
      G07408836
  22. NOTE: RH shown in illustration, LH similar.

    Inspect the spark plug tube seals. Remove any damaged seals.

    • Using the VCT Spark Plug Tube Seal Remover and Handle, remove the seal(s).
      G07408837
  23. Remove the 8 nuts and the RH exhaust manifold.
    • Discard the gasket.
      G07474399
  24. Clean and inspect the RH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  25. Remove and discard the 8 RH exhaust manifold studs.
    G07474400
  26. Remove the 8 nuts and the LH exhaust manifold.
    • Discard the gasket.
      G07474415
  27. Clean and inspect the LH exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  28. Remove and discard the 8 LH exhaust manifold studs.
    G07474416
  29. Remove the 4 bolts and the coolant pump pulley.
    G07474378
  30. Remove the 4 bolts and the coolant pump.
    • Remove and discard the O-ring seal.
      G07474379
  31. Remove the bolt and the accessory drive belt tensioner.
    G07474381
  32. Remove the nut, the bolt and the generator.
    G07474382
  33. Remove the crankshaft pulley bolt and washer.
    G07474383
  34. Using the 3 Jaw Puller and the crankshaft pulley bolt, remove the crankshaft pulley.
    • Discard the crankshaft pulley bolt.
      G07408866
  35. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.

    Using the Oil Seal Remover, remove the crankshaft front oil seal.

    G07408874
  36. Remove the 2 front oil pan stud bolts and 2 front oil pan bolts.
    G07474386
  37. Remove the 13 engine front cover bolts and the 2 stud bolts.
    G07474387
  38. 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.

    Remove the engine front cover from the front cover to cylinder block dowel.

    • Remove and discard the engine front cover gaskets.
    • Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the mating surfaces.
      G07474058
  39. Using the crankshaft holding tool, rotate the crankshaft clockwise until the keyway is at the 12 o'clock position.
    G07474071
  40. Verify the data matrix on the camshafts is facing up, if not, rotate the crankshaft clockwise one revolution.
    G07408938
  41. Remove the 2 bolts and the RH primary timing chain tensioner.
    G07408939
  42. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the RH timing chain tensioner arm. Return the crankshaft keyway to the 12 o'clock position after removing the RH timing chain tensioner arm.

    Remove the RH timing chain tensioner arm.

    G07408940
  43. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the RH timing chain guide. Return the crankshaft keyway to the 12 o'clock position after removing the RH timing chain guide.

    Remove the bolt and the RH timing chain guide.

    G07408941
  44. Remove the RH primary timing chain.
    G07408942
  45. Remove the 3 RH intake Variable Camshaft Timing (VCT) assembly bolts and the 3 RH exhaust VCT assembly bolts.
    G07408943
  46. Slide the RH VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
    G07408944
  47. Depress the RH secondary timing chain tensioner and turn the tensioner 90 degrees.
    G07408945
  48. Remove the RH VCT assemblies and the RH secondary timing chain.
    G07408946
  49. NOTE: The front camshaft bearing mega cap must be removed first and then the remaining camshaft bearing caps. Failure to follow this direction may result in damage to the engine.

    Remove the 4 bolts and the RH front camshaft bearing mega cap.

    G07408995
  50. Remove the 16 bolts and the 8 camshaft bearing caps.
    G08641700
  51. NOTE: Intake camshaft shown in illustration, exhaust camshaft similar.

    Remove the VCT system oil filter from the intake and exhaust camshafts.

    G07408994
  52. Remove the RH intake and exhaust camshafts.
    G07474408
  53. Remove the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
    G07474409
  54. Remove the bolt and the coolant outlet pipe from the RH cylinder head.
    • Remove and discard the O-ring seal.
      G07474395
  55. Remove the CHT sensor.
    G07960995
  56. NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
    NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
    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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

    Remove the 10 bolts and the RH cylinder head.

    • Discard the bolts and the cylinder head gasket.
      Fig 2: Locating RH Cylinder Head Mounting Bolts
      G07474410Courtesy of FORD MOTOR CO.
  57. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    NOTE: Observe all warnings or notices and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

    Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence.

    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  58. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
    NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.

    Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

    Fig 3: Locating Oil Pressure Feed Area
    G06126589Courtesy of FORD MOTOR CO.
  59. Using the crankshaft holding tool, rotate the crankshaft counterclockwise until the crankshaft keyway is at the 9 o'clock position.
    G07408947
  60. Remove the 2 bolts and the LH primary timing chain tensioner.
    G07408948
  61. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the LH timing chain tensioner arm. Return the crankshaft keyway to the 9 o'clock position after removing the LH timing chain tensioner arm.

    Remove the LH timing chain tensioner arm.

    G07408949
  62. NOTE: It may be necessary to rotate the crankshaft slightly to provide enough slack in the chain to remove the LH timing chain guide. Return the crankshaft keyway to the 9 o'clock position after removing the LH timing chain guide.

    Remove the bolt and the LH timing chain guide.

    G07408950
  63. Remove the LH primary timing chain.
    G07408951
  64. Remove the crankshaft sprocket.
    G07474090
  65. Remove the 3 LH intake Variable Camshaft Timing (VCT) assembly bolts and the 3 LH exhaust VCT assembly bolts.
    G07408952
  66. Slide the LH VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
    G07408953
  67. Depress the LH secondary timing chain tensioner and turn the tensioner 90 degrees.
    G07408954
  68. Remove the LH VCT assemblies and the LH secondary timing chain.
    G07408955
  69. NOTE: The front camshaft bearing mega cap must be removed first and then the remaining camshaft bearing caps. Failure to follow this direction may result in damage to the engine.

    Remove the 4 bolts and the LH front camshaft bearing mega cap.

    G07409031
  70. Remove the 16 bolts and the 8 camshaft bearing caps.
    G07474427
  71. NOTE: Intake camshaft shown in illustration, exhaust camshaft similar.

    Remove the VCT system oil filter from the intake and exhaust camshafts.

    G07409030
  72. Remove the LH intake and exhaust camshafts.
    G07474429
  73. Remove the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
    G07474430
  74. Remove the 2 bolts and the coolant outlet from the LH cylinder head.
    • Remove and discard the gasket.
      G07474412
  75. NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
    NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.
    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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

    Remove the 10 bolts and the LH cylinder head.

    • Discard the bolts and the cylinder head gasket.
      Fig 4: Locating LH Cylinder Head Bolts Tightening Sequence
      G07474431Courtesy of FORD MOTOR CO.
  76. 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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
    NOTE: Observe all warnings or notices and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.

    Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block in the following sequence.

    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
  77. NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
    NOTE: Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.

    Support the cylinder head on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .

    Fig 5: Locating Oil Pressure Feed Area
    G06126589Courtesy of FORD MOTOR CO.
  78. Remove the 2 bolts and the 2 KS.
    G07961016
  79. Remove the bolt and the Crankshaft Position (CKP) sensor.
    G07961017
  80. Remove and discard the oil filter.
  81. NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

    If equipped, remove the threaded fitting and the oil cooler.

    • Discard the oil cooler.
      G07988364
  82. Remove the 3 bolts and the oil filter adapter.
    • Discard the gasket.
      G07988365
  83. 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.

    Remove the bolts and the oil pan.

    • Clean and inspect the sealing surface.
      G07961021
  84. Remove the 3 bolts and the oil pump screen and pickup tube.
    • Discard the O-ring seal.
      G07988367
  85. Remove the oil pump screen and pickup tube spacer.
    G07961023
  86. Remove and discard the oil pan baffle and gasket.
    G07988369
  87. Remove the 6 bolts and the crankshaft rear seal retainer plate.
    • 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.

      Clean and inspect the sealing surfaces.

      G07961024
  88. Remove the 2 bolts, the 2 stud bolts and the oil pump.
    G07961025
  89. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following the manufacturer's instructions.
  90. NOTE: Verify that the connecting rod and rod cap have orientation numbers cast into them. If not, number the connecting rod and rod cap for correct orientation. Failure to do so can result in engine damage.

    Remove the bolts and the connecting rod cap. Discard the bolts.

    G07961026
  91. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

    Use the Connecting Rod Installer to push the piston through the top of the cylinder block.

    G07961027
  92. Repeat the previous 2 steps for each of the remaining pistons.
  93. Disassemble the 8 pistons. For additional information, refer to PISTON .
  94. Remove the fasteners.
    1. Remove and discard the cross-mounted main cap bolts.
    2. Remove and discard the main bearing cap bolts and stud bolt.
      Fig 6: Identifying Main Bearing Cap Bolts And Stud Bolts
      G06392690Courtesy of FORD MOTOR CO.
  95. Remove the main bearing caps (1), the lower crankshaft main bearings (2) and the lower thrust bearing (3).
    Fig 7: Identifying Main Bearing Caps, Lower Crankshaft Main Bearings And Lower Thrust Bearing
    G07961029Courtesy of FORD MOTOR CO.
  96. Remove the crankshaft (1), the upper crankshaft main bearings (2) and the upper thrust washer (3) from the cylinder block.
    Fig 8: Identifying Crankshaft, Upper Crankshaft Main Bearings And Upper Thrust Washer
    G07961030Courtesy of FORD MOTOR CO.
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