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Section 539 (Engine Mechanical - 5.0L (4V)): Disassembly: Engine

WARNING: This page is about a different car, the 2014 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL DESCRIPTION

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)
G06061943
 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-B		 -
Motorcraft® Silicone Gasket Remover
ZC-30-A		 -
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 in this article.
  1. Remove the engine. For additional information, refer to Engine .
  2. NOTE: The flexplate bolts are torque-to-yield design and are not reusable.

    Remove the 8 bolts and the flexplate.

    • Discard the bolts.
      G07960931
  3. Remove the engine separator plate.
    G07960932
  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.

    G09541513
  5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.
    G09541514
  6. Mount the engine on a work stand.
  7. Remove the 3 bolts and the LH engine support insulator bracket.
    G07960935
  8. Remove the 3 bolts and the RH engine support insulator.
    G07960936
  9. Remove the 3 bolts and the RH exhaust manifold heat shield.
    G07960843
  10. Remove the 8 nuts and the RH exhaust manifold.
    • Discard the gasket.
      G07960844
  11. Remove and discard the 8 RH exhaust manifold studs.
    G07960845
  12. Remove the 3 bolts and the LH exhaust manifold heat shield.
    G07960861
  13. Remove the 8 nuts and the LH exhaust manifold.
    • Discard the gasket.
      G07960862
  14. Remove and discard the 8 LH exhaust manifold studs.
    G07960863
  15. Clean and inspect the RH and LH exhaust manifolds. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
  16. NOTE: RH shown, LH similar.

    Disconnect the 8 ignition coil electrical connectors.

    G09541523
  17. NOTE: RH shown, LH similar.
    NOTE: When removing the ignition coils, a slight twisting motion will break the seal and ease removal. RH shown, LH similar.

    Remove the 8 bolts and the 8 ignition coils.

    G09541524
  18. Disconnect the 2 Variable Camshaft Timing (VCT) variable force solenoid electrical connectors.
    • Detach the 10 wiring harness retainers from the RH valve cover.
      G07960806
  19. Disconnect the 2 VCT  variable force solenoid electrical connectors.
    • Detach the 10 wiring harness retainers from the LH valve cover.
      G07960807
  20. Remove the bolt, stud bolt and heat shield from the RH cylinder head.
    G07960839
  21. 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
  22. Disconnect the Cylinder Head Temperature (CHT) sensor and the Crankshaft Position (CKP) sensor electrical connectors.
    G07960949
  23. Remove the 2 bolts and the heat shield from the LH cylinder head.
    G07960858
  24. Disconnect the LH intake and exhaust Camshaft Position (CMP) sensor electrical connectors.
    • Remove the 2 bolts and the LH intake and exhaust CMP  sensors.
      G07960859
  25. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 3 wiring harness retainers.
    G07960952
  26. Detach the wiring harness retainer from the engine front cover stud bolt.
    G08338438
  27. Remove the nut and the ground wire from the engine front cover stud bolt.
    G07960820
  28. Disconnect the 2 Knock Sensor (KS) electrical connectors.
    • Remove the wiring harness from the engine.
      G07960955
  29. 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 fasteners 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.
      G08338791
  30. Remove the oil level indicator.
  31. 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 fasteners 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.
      G08338792
  32. NOTE: RH shown, 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).
      G08338381
  33. NOTE: RH shown, 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).
      G08338382
  34. Remove the 2 bolts and position the thermostat housing and lower radiator hose aside.
    • Remove and discard the thermostat housing O-ring seal.
      G07960812
  35. Release the 2 clamps and disconnect the coolant hoses from the oil cooler.
    G07960961
  36. Loosen the 4 coolant pump pulley bolts.
    G07960813
  37. Rotate the accessory drive belt tensioner counterclockwise and remove the accessory drive belt.
    G07960814
  38. Rotate the A/C compressor belt tensioner clockwise and remove the A/C compressor belt.
    G08338798
  39. Remove the 4 bolts and the coolant pump pulley.
    G07474378
  40. Remove the 4 bolts and the coolant pump.
    • Remove and discard the O-ring seal.
      G07474379
  41. Remove the bolt and the accessory drive belt tensioner.
    G07474381
  42. Disconnect the A/C compressor electrical connector and the 2 wiring harness retainers.
    G07960968
  43. Detach the 3 wiring harness retainers.
    G07960969
  44. Remove the 2 bolts and the generator.
    G07960822
  45. Remove the crankshaft pulley bolt and washer.
    G08338806
  46. Using the 3 Jaw Puller and the crankshaft pulley bolt, remove the crankshaft pulley.
    • Discard the crankshaft pulley bolt.
      G08338807
  47. 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.

    G08339345
  48. Remove the 2 front oil pan stud bolts and 2 front oil pan bolts.
    G08338810
  49. Remove the engine front cover-to-oil filter adapter bolt.
    G08338448
  50. Using a 10 mm (0.393 in) Hex Bit loosen the engine front cover-to-oil filter adapter jack screw.
    G08338449
  51. Remove the 13 engine front cover bolts and the 2 stud bolts.
    G07960830
  52. 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.

    • 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.
      G09541558
  53. Using the crankshaft holding tool, rotate the crankshaft clockwise until the keyway is at the 12 o'clock position.
    G09541559
  54. Verify the data matrix on the camshafts is facing up, if not, rotate the crankshaft clockwise one revolution.
    G09541560
  55. Remove the 2 bolts and the RH primary timing chain tensioner.
    G09541561
  56. 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.

    G09541562
  57. 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.

    G09541563
  58. Remove the RH primary timing chain.
    G09541564
  59. Remove the 3 RH intake Variable Camshaft Timing (VCT) assembly bolts and the 3 RH exhaust VCT  assembly bolts.
    G09541565
  60. Slide the RH VCT  assemblies and secondary timing chain forward 2 mm (0.078 in).
    G09541566
  61. Depress the RH secondary timing chain tensioner and turn the tensioner 90 degrees.
    G09541567
  62. Remove the RH VCT  assemblies and the RH secondary timing chain.
    G09541568
  63. 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.

    G09541569
  64. Remove the 16 bolts and the 8 camshaft bearing caps.
    G09541570
  65. NOTE: Intake camshaft shown, exhaust camshaft similar.

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

    G09541571
  66. Remove the RH intake and exhaust camshafts.
    G09541572
  67. Remove the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
    G09541573
  68. Remove the bolt and the coolant outlet pipe from the RH cylinder head.
    • Remove and discard the O-ring seal.
      G09541574
  69. Remove the CHT  sensor.
    G07960995
  70. 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 1: Locating RH Cylinder Head Bolts
      G07474410Courtesy of FORD MOTOR CO.
  71. 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.
  72. 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 2: Locating Oil Pressure Feed Area
    G06126589Courtesy of FORD MOTOR CO.
  73. Using the crankshaft holding tool, rotate the crankshaft counterclockwise until the crankshaft keyway is at the 9 o'clock position.
    G07408947
  74. Remove the 2 bolts and the LH primary timing chain tensioner.
    G07408948
  75. 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.

    G09541580
  76. 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.

    G09541581
  77. Remove the LH primary timing chain.
    G09541582
  78. Remove the crankshaft sprocket.
    G09541583
  79. Remove the 3 LH intake Variable Camshaft Timing (VCT) assembly bolts and the 3 LH exhaust VCT  assembly bolts.
    G09541584
  80. Slide the LH VCT  assemblies and secondary timing chain forward 2 mm (0.078 in).
    G09541585
  81. Depress the LH secondary timing chain tensioner and turn the tensioner 90 degrees.
    G09541586
  82. Remove the LH VCT  assemblies and the LH secondary timing chain.
    G09541587
  83. 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.

    G09541588
  84. Remove the 16 bolts and the 8 camshaft bearing caps.
    G09541589
  85. NOTE: Intake camshaft shown, exhaust camshaft similar.

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

    G09541590
  86. Remove the LH intake and exhaust camshafts.
    G09541591
  87. Remove the 16 camshaft roller follower and hydraulic lash adjuster assemblies.
    G09541592
  88. Remove the 2 bolts and the coolant outlet from the LH cylinder head.
    • Remove and discard the gasket.
      G07474412
  89. 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 3: Locating LH Cylinder Head Bolts
      G07474431Courtesy of FORD MOTOR CO.
  90. 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.
  91. 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 4: Locating Oil Pressure Feed Area
    G06126589Courtesy of FORD MOTOR CO.
  92. Remove the 2 bolts and the 2 KS.
    G07961016
  93. Remove the bolt and the Crankshaft Position (CKP) sensor.
    G07961017
  94. NOTE: A new oil cooler must be installed or severe damage to the engine can occur.

    Remove the oil cooler threaded insert and the oil cooler.

    • Discard the oil cooler.
      G07961018
  95. Remove the 3 bolts and the oil filter adapter.
    • Discard the gasket.
      G07961019
  96. Remove the 3 bolts and the A/C compressor.
    G07961020
  97. 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.

    • Discard the gasket.
    • Clean and inspect the sealing surface.
      G09541601
  98. Remove the 3 bolts and the oil pump screen and pickup tube.
    • Discard the O-ring seal.
      G07961022
  99. Remove the oil pump screen and pickup tube spacer.
    G07961023
  100. 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
  101. Remove the 2 bolts, the 2 stud bolts and the oil pump.
    G07961025
  102. 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.
  103. 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
  104. 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
  105. Repeat the previous 2 steps for each of the remaining pistons.
  106. Disassemble the 8 pistons. For additional information, refer to PISTON .
  107. Remove the main bearing cap fasteners.
    1. Remove and discard the cross-mounted main cap bolts.
    2. Remove and discard the main bearing cap bolts and stud bolt.
      Fig 5: Identifying Main Bearing Cap Bolts And Stud Bolts
      G06392690Courtesy of FORD MOTOR CO.
  108. Remove the main bearing caps (1), the lower crankshaft main bearings (2) and the lower thrust bearing (3).
    Fig 6: Identifying Crankshaft Bearing, Cap And Thrust Bearing
    G09541609Courtesy of FORD MOTOR CO.
  109. Remove the crankshaft (1), the upper crankshaft main bearings (2) and the upper thrust washer (3) from the cylinder block.
    Fig 7: Identifying Crankshaft Bearings And Thrust Washer
    G09541610Courtesy of FORD MOTOR CO.
  110. Remove the 4 bolts and 4 piston cooling jets from the cylinder block.
    Fig 8: Locating Bolts And Piston Cooling Jets On Cylinder Block
    G07961031Courtesy of FORD MOTOR CO.
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