Engine

Disassembly

1. NOTE: Before starting disassembly, remove all wiring harnesses, emission control system, fuel system, ignition system, flywheel (6375), engine rear plate (7007) and components front end accessory drive components. For more detailed information on a particular system, refer to the specific section in the appropriate repair group.

   NOTE: All valve train components should be identified to make sure they are installed in their original positions during assembly.

   With the engine (6007) mounted on a workstand: Remove the left and right valve covers (6582) and discard the gaskets.

2. Remove the upper and lower intake manifold (9424) assemblies.

3. Remove the oil level dipstick (6750) and oil level indicator tube (6754) assembly and remove the oil filter.

4. Remove the rocker arms (6564), rocker arm seats (6A528), push rods (6565), rocker arm fulcrum guides (6A588) and valve tappets (6500) and remove the cylinder heads (6049).

   

   Item	Part Number	Description
   1	390385	Attaching Bolt
   2	6A528	Rocker Arm Seat
   3	6564	Rocker Arm
   4	6A588	Rocker Arm Fulcrum Guide
   5	—	Threaded Pedestal (Part of 6049)

5. Remove the crankshaft pulley (6312) and crankshaft vibration damper/pulse ring.

6. Remove the water pump (8501) and engine front cover (6019) as an assembly. Discard the gasket and seal.

7. Remove the oil pan (6675) and discard the gasket.

8. Remove the oil pump (6600), oil pump screen cover and tube (6622) assembly and oil pump intermediate shaft (6A618).

   

   Item	Part Number	Description
   1	33771	Nut, 3/8-16
   2	391378	Screw and Washer, 5/16-18 x 1.13
   3	6626	Oil Pump Inlet Tube Gasket
   4	6600	Oil Pump
   5	6A618	Oil Pump Intermediate Shaft
   6	6622	Oil Pump Screen Cover and Tube (Typical)
   7	—	Third Main (Part of 6010)
   8	57647	Bolt
   A	—	Tighten to 30-43 Nm (22-32 Lb-Ft)
   B	—	Tighten to 16-24 Nm (12-18 Lb-Ft)

9. Remove the crankshaft rear oil seal (6701) as described in the Crankshaft Rear Oil Seal Removal procedure in the In-Vehicle Service portion of this section.

10. Remove the camshaft sprocket, capscrew, washer and eccentric or timing flag. Slide the sprocket and timing chain/belt (6268) forward and remove the timing chain/belt and sprocket as an assembly.

11. Remove the camshaft thrust plate (6269) and remove the camshaft (6250).

12. NOTE: Pistons (6108), connecting rods and bearings should be numbered to make sure they are assembled in their original positions.

    NOTE: Before removing pistons inspect the top of the cylinder bores. If necessary, remove the ridge and/or carbon deposits from each cylinder using Cylinder Ridge Reamer T64L-6011-EA.

    Remove the connecting rod caps and remove the piston.

    

13.  CAUTION: When removing the crankshaft (6303), take care not to damage any of the bearing surfaces on the crankshaft.

    NOTE: The location of the main bearing caps and the main bearing inserts should be identified. When the engine is assembled, crankshaft main bearings (6333) which are to be reused should be installed in their original positions.

    Remove the crankshaft main bearing caps, crankshaft main bearings and crankshaft.

14. For cleaning purposes, the oil gallery and coolant drain plugs can be removed.

    Crankshaft, Disassembled View

    

    Item	Part Number	Description
    1	6333	Crankshaft Main Bearing
    2	7118	Transmission Input Shaft Pilot Bearing
    3	6375	Flywheel
    4	6701	Crankshaft Rear Oil Seal
    5	6333	Crankshaft Main Bearing
    6	6325	Main Bearing Caps
    7	384664	Bolt
    8	6306	Crankshaft Sprocket
    9	391264-S	Bolt
    10	6378	Crankshaft Pulley Retaining Washer
    11	388813	Bolt
    12	6312	Crankshaft Pulley
    13	1616	Damper
    14	6A329	Damper
    15	372890-S	Key
    16	6303	Crankshaft
    17	391546	Stud

Assembly

Before assembling cylinder block (6010), all sealing surfaces must be clean and free of chips, dirt, paint, and foreign material. Also make sure coolant and oil passages are clear.

If new piston rings are to be installed and no visible crosshatch marks remain on the cylinder wall, remove cylinder wall glaze using a spring-type tool. Follow instructions of tool manufacturer.

1. NOTE: Lightly oil all attaching bolt and stud threads with SAE 50 engine oil meeting Ford specification WSE-M2C908-A or equivalent before installation, except those specifying special sealant.

   Place crankshaft upper main bearings in position in the bores with the tang fitting in the slot provided. Lubricate bearings with SAE 50 weight oil meeting Ford specification WSE-M2C908-A or equivalent for 5.0L engine and for 5.8L engines.

2. Install the lower crankshaft main bearings in the bearing caps.

3. Carefully lower crankshaft into place. Use care to prevent damage to bearing surfaces.

4. Check clearance of each crankshaft main bearing. Refer to Section 03-00.

5. Apply a light coat of SAE 50 engine oil meeting Ford specification WSE-M2C908-A or equivalent for the 5.0L engine and 5.8L engine to the journals and crankshaft main bearings after crankshaft main bearings have been fitted.

6. NOTE: Make sure main bearing caps are installed in their original positions.

   Install all bearings and caps except thrust bearing cap (No. 3 bearing). Refer to Crankshaft Main Bearings in the In-Vehicle Service portion of this section for installation of thrust bearing cap. Tighten bearing caps to 129-142 Nm (95-105 lb-ft) for 5.8L engine and 82-95 Nm (60-70 lb-ft) for 5.0L engine.

7. Install crankshaft rear oil seal as described in this section. Install engine rear plate and flywheel and tighten bolts to specification.

   

   Item	Part Number	Description
   1	—	Dowel (2 Places)
   2	391275	Bolt, 7/16-20 x .72 (6 Places) (Apply Pipe Sealant with Teflon® D8AZ-19554-A or Equivalent Meeting Ford Specification WSK-M2G350-A2 or ESR-M18P7-A to Fasteners Prior to Assembly)
   3	—	Automatic Transmission Usage Identification
   4	6375	Flywheel
   5	7007	Engine Rear Plate
   A	—	Tighten to 102-115 Nm (75-85 Lb-Ft)

8. Coat all camshaft bearings (6261), camshaft lobes and camshaft sprocket spacer (6265) with SAE 50 engine oil meeting Ford specification WSE-M2C908-A or equivalent for 5.0L engine and for 5.8L engine.

9. Carefully slide camshaft through camshaft bearings. Install camshaft thrust plates with groove toward cylinder block. Tighten thrust plate retaining bolts. Tighten to 12-18 Nm (9-13 lb-ft).

   

10. Check camshaft end play. Refer to Section 03-00. If not within specification, replace camshaft thrust plate.

11. Install camshaft sprocket (6256) and timing chain/belt. Position camshaft sprocket and timing chain/belt on camshaft and crankshaft sprocket simultaneously. Make sure timing marks on the sprockets are aligned.

12. Install eccentric or timing flag, washers, and camshaft capscrew. Tighten camshaft capscrew to 54-61 Nm (40-45 lb-ft).

13. Oil the piston rings, pistons and cylinder walls. Be sure to install the pistons in the same cylinders from which they were removed.

14. Make sure the ring gaps are properly spaced around the circumference of the piston. (Refer to Pistons and Connecting Rods in the In-Vehicle Service portion of this section.)

15. NOTE: Install piston with indentation notch in the piston head toward front of engine.

    Install a piston ring compressor on the piston and push piston in with a hammer handle or an appropriate piston hammer until it is slightly below top of cylinder. Be sure to guide connecting rods to avoid damaging crankshaft journals (cover studs).

16. Check clearance of each connecting rod bearing (6211). Refer to procedure in Section 03-00.

17. After connecting rod bearings have been fitted, apply a light coat of engine oil to the crankshaft connecting rod journals and connecting rod bearings.

18. Turn the crankshaft throw to the bottom of its stroke. Push piston all the way down until connecting rod bearing seats on the crankshaft journal.

19. Install connecting rod cap. Install nuts and tighten to 26-33 Nm (19-24 lb-ft) for 5.0L engines, or to 54-61 Nm (40-45 lb-ft) for 5.8L engines.

20. Check side clearance between connecting rods on each crankshaft journal after piston and connecting rod assemblies have been installed.

    

21. Prime the oil pump and install oil pump, oil pump intermediate shaft, and oil pump screen cover and tube assembly. Tighten oil pump bolts to 30-43 Nm (22-32 lb-ft).

    

    Item	Part Number	Description
    1	33771	Nut, 3/8-16
    2	391378	Screw and Washer, 5/16-18 x 1.13
    3	6626	Oil Pump Inlet Tube Gasket
    4	6600	Oil Pump
    5	6A618	Oil Pump Intermediate Shaft
    6	6622	Oil Pump Screen Cover and Tube
    7	—	Third Main (Part of 6010)
    8	57647	Bolt
    A	—	Tighten to 30-43 Nm (22-32 Lb-Ft)
    B	—	Tighten to 16-24 Nm (12-18 Lb-Ft)

22. Install crankshaft front seal (6700) in engine front cover.

23. Install crankshaft front seal, gasket, timing pointer/misfire sensor assembly and engine front cover. Tighten cover bolts to specification. Refer to Engine Front Cover in the In-Vehicle Service portion of this section. Also, install crankshaft vibration damper/pulse ring and crankshaft pulley and torque bolt to 95-122 Nm (70-90 lb-ft).

24. Install new oil filter.

25. Install oil pan gasket and seal assembly. Install oil pan. Tighten oil pan bolts to specification. Tighten the four 5/16-18 x 1.12 oil pan bolts to 12-16 Nm (9-12 lb-ft) and the remaining 1/4-20 x .94 oil pan bolts to 10-14 Nm (89-124 lb-in).

    

    

    Item	Part Number	Description
    1	390657	Bolt, 5/16-18 x 1.12
    2	6730	Oil Pan Drain Plug
    3	390658	Bolt, 1/4-20 x .94
    4	6675	Oil Pan Assembly
    5	6710	Gasket, Oil Pan
    A	—	Tighten to 12-16 Nm (9-12 Lb-Ft)
    B	—	Tighten to 12-16 Nm (9-12 Lb-Ft)
    C	—	Tighten to 10-14 Nm (89-124 Lb-In)

26. Install valve tappets in their original bores.

27. Install tappet guide plate (roller tappet engines only) and tighten screws and washers to specification.

28. NOTE: If cylinder heads were completely disassembled, refer to Cylinder Head in the Disassembly and Assembly portion of this section.

    Position head gaskets (6051) on cylinder block. Install cylinder head locating dowels. Install cylinder heads.

29. Tighten cylinder head bolts to specification, in the sequence shown.

    

30. Install push rods, rocker arms, rocker arm seats, rocker arm fulcrum guides, and tighten fulcrum bolts to 24-34 Nm (18-25 lb-ft).

31. NOTE: This sealer sets up within 15 minutes after application. To assure effective sealing, assembly should proceed promptly.

    Apply 1.6mm (1/16-inch) bead of Black Silicone Rubber F4AZ-19562-B or equivalent meeting Ford specification WSE-M4G323-A1 or equivalent sealer to the end seals (junction).

    

    Item	Part Number	Description
    1	F4AZ-19562-B	Sealer (4 Joints)
    2	6049	Cylinder Head
    3	9439	Intake Manifold Gasket
    4	9A424 (LH)	Intake Manifold Seal
    5	9A425 (RH)	Intake Manifold Seal
    6	F4AZ-19562-B	Sealer (4 Seal Ends)
    7	—	Seal Mounting Surface of Cylinder Block (Part of 6010)

32. Install lower and upper intake manifolds. Use guide pins to ease installation of intake manifolds onto cylinder heads.

33. Tighten intake manifold bolts in two steps using the sequence shown.

    Step 1 — 16 Nm (12 lb-ft)

    Step 2 — 31-34 Nm (23-25 lb-ft)

    Tightening Sequence, 5.0L and 5.8L Shown

    

34. Install oil level indicator tube and oil level dipstick assembly.

35. Position valve cover gasket (6584) in each valve cover and install valve covers.

    Refer to Valve Cover and Gasket in the In-Vehicle Service portion of this section.

36. Install wiring harnesses, emission control system, fuel system, ignition system and front end accessory drive components, by referring to procedure in appropriate section.