Engine - 5.0L 32V Ti-VCT (359KW/486PS) (WU)/5.0L Ti-VCT V8 (343KW/466PS) (MF): Disassembly: Engine
For information on Ford Color Coded Illustrations refer to OEM COLOR CODING
Special Tool(s) / General Equipment
| 100-001 (T50T-100-A)Slide Hammer | |
|---|---|
| 205-142 (T80T-4000-J)Installer, Differential Bearing Cone | |
| 205-153 (T80T-4000-W)Handle | |
| 303-1247VCT Spark Plug Tube Seal Remover and InstallerTKIT-2006UF-FLMTKIT-2006UF-ROW | |
| 303-409 (T92C-6700-CH)Remover, Crankshaft SealTKIT-1992-FH/FMH/FLMHTKIT-1993-LMH/MH | |
| 303-448 (T93P-6303-A)Holding Tool, CrankshaftTKIT-1993-FLMTKIT-1993-LM | |
| 303-519 (T95P-6701-EH)Remover, Crankshaft Rear Oil SealTKIT-1995-FH/FLMHTKIT-1995-LMH/MH | |
| 303-F047Lifting Bracket, Engine | |
| Floor Crane | |
| Mounting Stand | |
| Puller |
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:
Unless otherwise noted, GT engine is depicted in graphics, Mach 1 engine is similar.
NOTE:
Refer to the exploded view under the Engine Component View in the Description and Operation.
- Using the special tools, remove and discard the crankshaft rear seal. Use Special Service Tool: 303-519 (T95P-6701-EH) Remover, Crankshaft Rear Oil Seal., 100-001 (T50T-100-A) Slide Hammer.
- Using a floor crane, install the engine on a mounting stand and remove the special tool. Remove Special Service Tool: 303-F047 Lifting Bracket, Engine. Use the General Equipment: Floor Crane. Use the General Equipment: Mounting Stand
- Remove the crankcase ventilation tube. Refer to: Quick Release Coupling
.
- Remove the bolt and the high-pressure fuel pump bracket.
- Disconnect the high-pressure fuel pump electrical connector.
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NOTE: When removing or installing the fuel injection pump noise insulator, spreading the openings will reduce the risk of damage.
Release the retainer, then remove the fuel injection pump noise insulator.
- Detach the wiring harness retainers from high-pressure fuel line shield.
- Remove the high-pressure fuel line shield retainers, then remove high-pressure fuel line shield.
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NOTE: To release the fuel pressure in the high-pressure fuel tube, wrap the high-pressure fuel tube flare nuts with a shop towel to absorb any residual fuel pressure during the loosening of the high-pressure fuel tube flare nuts.
Remove the high-pressure fuel tube retainers. Disconnect the high-pressure fuel tube flare nuts, then remove and discard the high-pressure fuel tube.
- Disconnect the quick release coupling and remove the high-pressure fuel tube. Refer to: Quick Release Coupling
.
- Alternately loosen the high-pressure fuel pump nuts one complete revolution at a time and remove, then remove the high-pressure fuel pump.
- Remove and discard the high-pressure fuel pump O-ring seal.
- Remove the high-pressure fuel pump roller tappet.
- Inspect the high-pressure fuel pump roller tappet. If any flat spots or scoring are found, especially in the indicated areas, then inspect the high-pressure fuel pump and the high-pressure fuel pump roller tappet drive lobe. Install new components as needed.
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- Position the wiring harness insulators aside.
- Disconnect the oil pressure sender and oil control solenoid (if equipped) electrical connector(s).
- Detach the engine wiring harness retainer.
- Detach the engine wiring harness retainer.
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- Disconnect the engine wiring harness electrical connectors.
- Detach the wiring harness retainers.
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- Remove the bolt and position the ground wire aside.
- Remove the bolt and position the capacitor aside.
- Disconnect the fuel sensor electrical connector.
- Disconnect the fuel rail electrical connector.
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- Position the wiring harness insulator aside.
- Disconnect the CKP sensor electrical connector.
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- Disconnect the fuel rail electrical connector.
- Disconnect the CHT sensor electrical connector.
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NOTE: GT engine.
Detach the wiring harness retainer and remove the nut and ground wire.
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NOTE: Mach 1 engine.
Detach the wiring harness retainers and remove the nut and ground wire.
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- Disconnect the engine wiring harness electrical connectors.
- Detach the wiring harness retainers.
- Disconnect the engine wiring harness and remove the harness from the engine.
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- Disconnect the KS electrical connectors.
- Detach the wiring harness retainers.
- Remove the KS harness from the engine.
- Remove the bolts and the KSs.
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NOTE: Use compressed air to remove any foreign material from the ignition coil-on-plugs and surrounding area before removing the ignition coil-on-plugs.NOTE: When removing the ignition coil-on-plugs, a slight twisting motion will break the seal and ease removal.
- Remove the ignition coil-on-plug retaining bolts.
- Remove the ignition coil-on-plugs.
- Inspect the ignition coil-on-plug assembly for cracks, rips, or tears. Replace any damaged coil-on-plug assemblies.
- Remove the 8 spark plugs
- Loosen the bolts and remove the valve cover.
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NOTE: Clean the valve cover gasket groove with soap and water or a suitable solvent.
Remove and discard the gaskets.
- Inspect the VCT variable force solenoid seals. Remove any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.
- Inspect the spark plug seals. Remove any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
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- Remove the oil level indicator.
- Depress the tab.
- Rotate the oil level indicator tube counterclockwise.
- Pull the oil level indicator tube from the engine.
- Loosen the bolts, the stud bolts and remove the valve cover.
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NOTE: Clean the valve cover gasket groove with soap and water or a suitable solvent.
Remove and discard the gasket.
- Inspect the VCT variable force solenoid seals. Remove any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 205-142 (T80T-4000-J) Installer, Differential Bearing Cone.
- Inspect the spark plug seals. Remove any damaged seals using the special tools. Use Special Service Tool: 205-153 (T80T-4000-W) Handle., 303-1247 VCT Spark Plug Tube Seal Remover and Installer.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Remove and discard the nuts.
- Remove the exhaust manifold.
- Clean and inspect the exhaust manifold. Refer to: Exhaust Manifold Cleaning and Inspection .
- Remove and discard the gasket and studs.
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NOTE: The pulley bolt will be used to remove the front seal and then discarded. The washer will be reused.
Remove the crankshaft pulley bolt and washer.
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NOTE: Use a universal puller (such as an OTC 6667, or equivalent).
Using a universal puller, remove the crankshaft damper pulley. Use the General Equipment: Puller
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NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.NOTE: The crankshaft bolt is a torque-to-yield design and must be discarded.
- Using the special tool, remove the crankshaft front oil seal. Use Special Service Tool: 303-409 (T92C-6700-CH) Remover, Crankshaft Seal.
- Discard the crankshaft front oil seal.
- Discard the crankshaft pulley bolt.
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- Remove the bolts and the coolant pump pulley.
- Remove the bolt and the accessory drive belt tensioner.
- Remove the fasteners and position the generator aside.
- Remove the bolts and the coolant pump.
- Remove and discard the coolant pump O-ring seal.
- Remove the bolts and stud bolts.
- Remove the bolts and stud bolts.
- Remove the engine front cover from the front cover-to-cylinder block dowels.
- Remove and discard the gaskets.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Using the special tool, rotate the crankshaft clockwise until the keyway is at the 12 o'clock position. Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.
- Verify the timing mark on the RHVCT unit is on top, if not, rotate the crankshaft clockwise one complete revolution so the keyway is at the 12 o'clock position.
- Remove the bolts and the RH primary timing chain tensioner.
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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.
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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.
- Remove the RH timing chain.
- Remove and discard the intake and exhaust VCT assembly bolts.
- Slide the VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
- Depress and turn the secondary tensioner clockwise 45 degrees.
- Remove the VCT assemblies and the secondary timing chain.
- Remove and discard the VCT system oil filter.
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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 bolts and the front camshaft bearing mega cap.
- Remove the bolts and the camshaft bearing caps.
- Remove the intake and exhaust camshafts.
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- Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
- Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
- Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.
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- Remove and discard the bolts.
- Remove the cylinder head.
- Remove and discard the cylinder head gasket.
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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.NOTE: Clean the cylinder head bolt holes in the cylinder block using compressed air. Make sure all coolant, oil or other foreign material is removed.
- Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block
- Refer to: Cylinder Head Distortion .
- Refer to: Cylinder Block Distortion .
- Using the special tool, rotate the crankshaft clockwise until the keyway is at the 5 o'clock position. Use Special Service Tool: 303-448 (T93P-6303-A) Holding Tool, Crankshaft.
- Remove the bolts and the LH primary timing chain tensioner.
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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 5 o'clock position after removing the LH timing chain tensioner arm.
Remove the LH timing chain tensioner arm.
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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 5 o'clock position after removing the LH timing chain guide.
Remove the bolt and the LH timing chain guide.
- Remove the LH timing chain.
- Remove and discard the intake and exhaust VCT assembly bolts.
- Slide the Variable Camshaft Timing VCT assemblies and secondary timing chain forward 2 mm (0.078 in).
- Depress and turn the secondary tensioner counterclockwise 45 degrees.
- Remove the VCT assemblies and the secondary timing chain.
- Remove and discard the VCT system oil filter.
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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 bolts and the front camshaft bearing mega cap.
- Remove the bolts and the camshaft bearing caps.
- Remove the intake and exhaust camshafts.
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- Remove the camshaft roller follower and hydraulic lash adjuster assemblies.
- Separate the hydraulic lash adjusters from the spring clips on the camshaft roller followers.
- Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.
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- Remove and discard the bolts.
- Remove the cylinder head.
- Discard the cylinder head gasket.
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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.NOTE: Clean the cylinder head bolt holes in the cylinder block using compressed air. Make sure all coolant, oil or other foreign material is removed.
- Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block
- Refer to: Cylinder Head Distortion .
- Refer to: Cylinder Block Distortion .
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- GT engine: Remove the bolts and the oil filter adapter.
- Mach 1 engine: Remove the bolts and the oil filter adapter.
- Discard the oil filter adapter gasket.
- Remove the bolts, the stud bolt and the oil pan.
- Remove and discard the oil pan gasket.
- Remove and discard the oil pump pickup seal.
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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.
Make sure that the mating faces are clean and free of foreign material.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Remove the bolt and the CKP sensor.
- Remove the bolts and the crankshaft rear seal retainer plate.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Remove the crankshaft sprocket.
- Remove the bolts, stud bolts and the oil pump.
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- 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.
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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.
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NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.
Remove the piston through the top of the cylinder block
- Repeat the previous 2 steps for each of the remaining pistons.
- Disassemble the 8 pistons. Refer to: Piston .
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- Remove and discard the cross-mounted main cap bolts.
- Remove and discard the main bearing cap bolts and stud bolt.
- Remove the main bearing caps (1), the lower crankshaft main bearings (2) and the lower thrust bearing (3).
- Remove the crankshaft (1), the upper crankshaft main bearings (2) and the upper thrust washer (3) from the cylinder block.
- Remove the bolts and the piston cooling jets from the cylinder block.