303-01B
Engine -- 5.0L (4V)
303-01B
SECTION 303-01B Engine -- 5.0L (4V) Ti-VCT
CONTENTS
SPECIFICATIONS
General Specifications ..................................................................................................................................... 1
DESCRIPTION AND OPERATION
Engine ............................................................................................................................................................... 6
Engine Identification ........................................................................................................................................ 6
Engine Code Information Label .................................................................................................................... 6
Engine Cylinder Identification ........................................................................................................................ 6
Induction System ............................................................................................................................................. 6
Crankshaft ........................................................................................................................................................ 6
Camshafts ........................................................................................................................................................ 7
Valve Train ......................................................................................................................................................... 7
Intake Variable Camshaft Timing (VCT) System ......................................................................................... 7
PCV System ..................................................................................................................................................... 7
Engine Lubrication System ............................................................................................................................ 7
Oil Pump ............................................................................................................................................................ 7
DIAGNOSIS AND TESTING
Engine ............................................................................................................................................................... 9
REMOVAL AND INSTALLATION
Intake Manifold ................................................................................................................................................ 11
Valve Cover -- RH .........................................................................................................................................22
Valve Cover -- LH ..........................................................................................................................................30
Crankshaft Pulley ...........................................................................................................................................36
Crankshaft Front Seal ..................................................................................................................................39
Engine Front Cover .......................................................................................................................................40
Engine Front Cover .......................................................................................................................................45
Timing Drive Components ..........................................................................................................................52
Camshaft -- RH .............................................................................................................................................64
Camshaft -- LH .............................................................................................................................................. 74
Camshaft Roller Follower ............................................................................................................................86
Hydraulic Lash Adjuster ................................................................................................................................86
Valve Springs ................................................................................................................................................. 87
Valve Seals ......................................................................................................................................................88
Exhaust Manifold - RH ..................................................................................................................................90
Exhaust Manifold -- LH..................................................................................................................................91
Oil Filter Adapter.............................................................................................................................................96
Oil Pan.............................................................................................................................................................. 97
Oil Pump Screen and Pickup Tube ........................................................................................................... 100
Version: 2010 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine -- 5.0L (4V)
303-01B
CONTENTS (Continued)
Oil Pump ........................................................................................................................................................ 101
Oil Level Indicator and Tube ...................................................................................................................... 102
Flexplate ....................................................................................................................................................... 104
Flywheel ....................................................................................................................................................... 104
Crankshaft Rear Seal .................................................................................................................................. 105
Crankshaft Rear Seal with Retainer Plate................................................................................................ 107
Engine Mounts .............................................................................................................................................. 110
LH and/or RH engine mounts .................................................................................................................... 113
Cylinder Head................................................................................................................................................ 114
Engine, Subframe and Transmission Assembly ..................................................................................... 120
Engine............................................................................................................................................................ 126
Engine Accessories .................................................................................................................................... 129
DISASSEMBLY
Engine ........................................................................................................................................................... 136
ASSEMBLY
Engine............................................................................................................................................................ 148
Version:: 2010 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-1
SPECIFICATIONS
Material
Item
Specification
Fill Capacity
Silicone Gasket and Sealant
WSE-M4G323-A4
--
F7AZ-19554-EA or Loctite 5900 or equivalent
Metal Surface Cleaner F4A2-19A536-RA or equivalent
WSE-M5B392-A
--
Engine Oil IISAC GF-4 SAE 5W-20
WSS-M2C930-A
8.5 L
Motorcraft� Silicone Gasket Remover ZC-30
--
--
R133 Antifreeze/Antiboil concentrate, R135 premixed
--
13.5L
Multi-Purpose Grease XG-4 and/or XL-5, or equivalents
ESB-M1C93-B
--
Silicone Brake Calliper Grease and Dielectric Compound
ESE-M1C171-A
--
XG-3-A
General Specifications
Item
Specification
Engine
Displacement
4.957 L (302 CID)
Number of cylinders
8
Bore
92.2 mm
Stroke
92.7 mm
Firing order
1-5-4-8-6-3-7-2
Spark plug
CYFS-12YP
Spark plug gap
0.85-0.95 mm
Oil pressure at 2,000 rpm (engine at normal
--
operating temperature)
Compression ratio
9.25:1
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-2
SPECIFICATIONS (Continued)
Item
Specification
Cylinder Head and Valve Train
Combustion chamber volume
54.5-57.5 cc
Valve stem diameter -- intake
5.995-5.975 mm
Valve stem diameter -- exhaust
5.995-5.975 mm
Valve stem-to-guide clearance -- intake
0.020-0.069 mm
Valve stem-to-guide clearance -- exhaust
0.045-0.094 mm
Valve head diameter -- intake
37 � 0.13 mm
Valve head diameter -- exhaust
31 � 0.13 mm
Valve face runout
0.05 mm
Valve face angle
3 angle
Valve seat width -- intake
1.3-1.5 mm
Valve seat width -- exhaust
1.4-1.6 mm
Valve seat runout
0.04 mm
Valve seat angle
121/91/61 degrees
Valve spring free length -- intake
51.32 mm
Valve spring free length -- exhaust
51.32 mm
Valve spring perpendicularity -- intake
3 mm
Valve spring perpendicularity -- exhaust
3 mm
Valve spring compression force -- intake
650 N
Valve spring compression force -- exhaust
650 N
Valve spring installed height -- intake
40 mm
Valve spring installed height -- exhaust
40 mm
Valve spring installed force -- intake
265 � 13 N
Valve spring installed force -- exhaust
265 � 13 N
Roller follower ratio
2:1
Head gasket surface flatness
0.025 mm (0.001) in any 25 mm (1) x 25 mm (1) area;
0.050 mm (0.002) in any 150 mm (6) x 150 mm (6)
area; 0.1 mm (0.004) overall
Hydraulic Lash Adjuster
Diameter -- intake
12 mm
Diameter -- exhaust
12 mm
Clearance-to-bore
0.018-0.050 mm
Hydraulic leakdown rate -- intake
0.45-3 seconds �
Hydraulic leakdown rate -- exhaust
0.45-3 seconds �
Collapsed lash adjuster gap
0.35-0.85 mm
Camshaft
Lobe lift -- intake
5.963 mm
Lobe lift -- exhaust
5.488 mm
Journal diameter
28.620 mm
Journal bore inside diameter
28.682-28.657 mm
Journal-to-bearing clearance
0.025-0.075 mm
Runout
0.04 mm (4 places)
End play
0.15 mm
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-3
SPECIFICATIONS (Continued)
Item
Specification
Cylinder Block
Cylinder bore diameter
92.200-92.220 mm
Cylinder bore maximum taper
0.013 mm
Cylinder bore maximum out-of-round
0.010 mm
Main bearing bore inside diameter
72.400-72.424 mm
Head gasket surface flatness
0.0254 mm (0.001) across any 38.1 mm square
Crankshaft
Main bearing journal diameter
67.481-67.505 mm
Main bearing journal maximum taper
0.004 mm
Main bearing journal maximum out-of-round
0.006 mm between cross sections
(circularity)
Main bearing journal-to-main bearing clearance
0.025-0.045 mm
Connecting rod journal diameter
52.983-53.003 mm
Connecting rod journal maximum taper
0.004 mm
Crankshaft maximum end play
0.28 mm
Piston and Connecting Rod
Piston diameter
92.152-92.166 mm
Piston-to-cylinder bore clearance (at grade size) b
0.025-0.059 mm
Piston ring end gap -- top
0.15-0.25 mm
Piston ring end gap -- intermediate
0.30-0.55 mm
Piston ring gap -- oil control
0.15-0.45 mm
Piston ring groove width -- top
1.220-1.250 mm
Piston ring groove width -- intermediate
1.220-1.240 mm
Piston ring groove width -- oil control
2.530-2.550 mm
Piston ring width -- top
1.17-1.19 mm
Piston ring width -- intermediate
1.17-1.19 mm
Piston ring-to-groove clearance -- top
0.030-0.080 mm
Piston ring-to-groove clearance -- intermediate
0.030-0.070 mm
Piston pin bore diameter
22.006-22.012 mm
Piston pin diameter
21.997-22.000 mm
Piston pin length
60.7-61.0 mm
Piston pin-to-piston fit (clearance)
0.004-0.013 mm
Connecting rod-to-pin clearance
0.003-0.018 mm
Connecting rod pin bore diameter
22.003-22.015 mm
Connecting rod length (centerline bore-to-bore)
150.7 mm
Connecting rod maximum allowed bend
0.038 mm
Connecting rod maximum allowed twist
0.050 mm
Connecting rod bearing-to-crankshaft clearance
0.028-0.069 mm
Connecting rod side clearance (as assembled to
0.325 mm
crank) -- standard play
Connecting rod side clearance (as assembled to
0.500 mm
crank) -- max. play
a - Time required for the plunger to leak down
1.6mm of travel with 222 N force and leakdown
fluid in the lash adjuster.
b - Before Grafal coating.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-4
SPECIFICATIONS (Continued)
Torque Specifications
Description
Nm
Accessory drive belt (supercharger, A/C) tensioner bolt
27.5
Accessory drive belt (generator, water pump) tensioner bolt
47.5
--
Camshaft bearing cap bolts a
--
Camshaft bearing mega cap bolts a
Camshaft Position (CMP) sensor bolt
10
Catalytic convertor-to-exhaust manifold nuts
40
--
Connecting rod cap bolts a
Coolant outlet bolts
10
Coolant outlet pipe bolt
10
Coolant pump bolts
25
Coolant pump pulley bolts
25
--
Crankshaft main bearing cap bolts a
Crankshaft Position (CKP) sensor bolt
10
--
Crankshaft pulley bolt a
--
Crankshaft rear seal retainer plate bolts a
--
Cylinder head bolts a
Cylinder Head Temperature (CHT) sensor
11
--
Engine front cover bolts a
--
Engine oil filter b
--
Engine Oil Pressure (EOP) c
Exhaust manifold nuts
--
--
Exhaust manifold studs a
--
Flexplate a
Flexplate inspection cover bolts
35
--
Flywheel a
--
Fuel rail bolts a
Heater hose support nuts
7
Ignition coil-on-plug bolt
6
--
Intake manifold assembly bolts a
Knock Sensor (KS)
20
Lower underbody shield bolts
10
--
Oil filter adapter bolts a
--
Oil pan bolts a
Oil pan drain plug
26
--
Oil pan stud bolts a
--
Oil pump bolts and stud bolts a
--
Oil pump screen and pickup tube bolts a
Oil pump screen and pickup tube spacer
25
--
Piston oil cooler bolts a
Primary timing chain tensioner bolts
10
Spark plugs
15
Thermostat housing bolts
10
Timing chain guide bolts
10
--
Valve cover bolts a
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-5
SPECIFICATIONS (Continued)
Description
Nm
--
VCT assembly bolts a
a - Refer to the procedure in this section.
b - Do not lubricate O-ring seal, tighten to 16 Nm.
c - Tighten to 14 Nm plus an additional 180
degrees.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-6
DESCRIPTION AND OPERATION
Engine
Engine Cylinder Identification
The 5.0L (302 CID) is a V-8 engine with the following
features:
�
Dual overhead camshafts
�
Four valves per cylinder
�
Sequential Multi-Port Fuel Injection (SFI)
�
Aluminium cylinder heads
�
Aluminium, 90-degree V-cylinder block
�
Individually chain-driven camshafts with a
hydraulic timing chain tensioner on each
timing chain
�
Electronic ignition system with 8 ignition coils
Engine Identification
Always refer to these labels when installation of
new parts is necessary or when checking engine
calibrations. The engine parts often differ within a
CID family. Verification of the identification codes will
make sure that the correct parts are obtained. These
codes contain all the pertinent information relating
to the dates, optional equipment and revisions. The
Ford Master Parts Catalogue contains a complete
listing of the codes and their applications.
Engine Code Information Label
The engine code information label, located on the LH
side of the Cylinder block in the front, contains the
engine number.
Induction System
The SFI provides the fuel/air mixture needed
for combustion in the cylinders. The 8 solenoid-
operated fuel injectors:
FPVAM
�
are mounted in the fuel injection supply
04441
manifold and the intake manifold above the
cylinder heads.
�
meter fuel into the air intake stream in
accordance with engine demand.
�
are positioned so that their tips direct fuel just
ahead of the engine intake valves.
�
supply fuel from the fuel tank by a fuel pump
AUS08886
mounted in the fuel tank.
Crankshaft
The crankshaft is supported on the bottom of the
cylinder block by 5 crankshaft main bearings.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-7
DESCRIPTION AND OPERATION (Continued)
Camshafts
Oil Pump
The lubrication system of the 5.0L (4V) engine is
The camshafts:
designed to provide optimum oil flow to critical
�
are arranged in pairs, one each (intake and
components of the engine through its entire
exhaust) on each cylinder head.
operating range. The heart of the system is a positive
displacement internal gear oil pump using top seal
�
are synchronized through a secondary timing
rotors.
chain.
Generically, this design is known as a gerotor pump,
�
depress the roller followers to actuate the
which operates as follows:
valves.
� The oil pump is mounted on the front face of
Valve Train
the cylinder block.
� The inner rotor is piloted on the crankshaft
The valves are actuated by a hydraulic lash adjuster
post and is driven through flats on the
and roller follower. The hydraulic lash adjusters and
crankshaft.
roller followers:
� System pressure is limited by an integral,
� provide hydraulic lash adjustment.
internally-vented relief valve which directs the
� ride on the camshaft lobes.
bypassed oil back to the inlet side of the oil
Intake Variable Camshaft Timing (VCT)
pump.
System
� Oil pump displacement has been selected
The independent VCT system allows variable control
to provide adequate volume to make sure
of intake valve closing, which optimises combustion
of correct oil pressure both at hot idle and
at full load providing improved power and low speed
maximum speed.
torque (broadening the torque curve). This enables
� The relief valve calibration protects the
variable valve overlap which provides better fuel
system from excessive pressure during high
economy and optimised cold start operation with
viscosity conditions.
improved exhaust emissions.
� The relief valve is designed to provide
PCV System
adequate connecting rod bearing lubrication
All engines are equipped with a closed-type PCV
under high- temperature and high-speed
system recycling the crankcase vapours to the upper
conditions.
intake manifold.
Engine Lubrication System
The engine lubrication system is of the force-feed
type in which oil is supplied under full pressure to the:
� crankshaft main bearings.
� crankshaft thrust main bearing.
� connecting rod bearings.
� oil galleries.
� piston cooling jets.
All other parts are lubricated by splash of the oil.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-8
DESCRIPTION AND OPERATION (Continued)
Engine Oil Flow Illustration
Engine Assembly
12
11
1
2
10
3
9
8
7
4
6
5
AUS07373
Item
Description
1
Valve cover
2
Cylinder head - LH
3
Exhaust camshaft assembly
4
Oil cooler and oil cooler adapter
5
Oil filter
6
Oil pan
7
Oil pan baffle and gasket
8
Oil pump screen and pickup tube
9
Oil pump
10
Timing chain tensioner - RH
11
Cylinder block
12
Inlet camshaft assembly
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-9
DIAGNOSIS AND TESTING
Engine
For basic engine mechanical concerns, refer to
Section 303-00. For driveability concerns, refer to
the Powertrain Control/Emissions Diagnosis (PC/ED)
manual.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-10
REMOVAL AND INSTALLATION
Fuel Rail Insulators, Intake Manifold and
Gaskets
2
3
1
4
AUS07344
Item
Description
1
RH fuel rail
2
Intake manifold bolt
3
LH fuel rail
4
Intake manifold gasket
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-11
REMOVAL AND INSTALLATION (Continued)
Intake Manifold
6.
Remove the throttle body bracket bolts and
remove the bracket.
Removal
Special Tool(s)
Alignment Pins,Blower
x4
303-1610
WARNING
AUS08778
Do not smoke, carry lighted tobacco or have
an open flame of any type when working on or
7.
Remove the LH and RH fuel rails. For additional
near any fuel-related component. Highly flammable
information, refer to Section 303-04D of the 2010
mixtures are always present and may be ignited.
FPV 5.0L 4V Ti-VCT V8 Supplement.
Failure to follow these instructions may result in
serious personal injury.
8.
Push in and remove the active exhaust valve
vacuum hose from the supercharger intake
WARNING
snorkel.
Before working on or disconnecting any of the
fuel tubes or fuel system components, relieve
the fuel system pressure to prevent accidental
spraying of fuel. Fuel in the fuel system remains under
high pressure, even when the engine is not running.
Failure to follow this instruction may result in serious
personal injury.
1.
Release the fuel system pressure. For additional
information, refer to Section 303-04D of the 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
2.
Disconnect the negative battery terminal. For
additional information, refer to Section 414-01B of
the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
AUS08731
3.
Remove the air filter box and air intake duct
9.
Disconnect the brake booster vacuum hose from
assembly. For additional information, refer to
the brake booster.
Section 303-12 of the 2010 FPV 5.0L 4V Ti-VCT
V8 Supplement.
4.
Release the accessory drive belt - A/C
compressor/ power steering pump /
supercharger from the supercharger pulley. For
additional information, refer to Section 303-05B
of the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
5.
Remove the throttle body. For additional
information, refer to Section 303-04D of the 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
AUS08693
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-12
REMOVAL AND INSTALLATION (Continued)
10. Disconnect the supercharger boost vacuum
13. Remove the rubber insulator beneath the engine
hoses from the intake manifold and supercharger
appearance plate.
actuator.
AUS08696
AUS08692
14. Disconnect the manifold boost pressure sensor
11. Release the fuel evaporator hose running across
(BPS) connector and disconnect the BPS wiring
rear of LH valve cover.
retaining clip from the inlet manifold.
AUS08695
AUS08699
12. Remove the retaining screws securing the
CAUTION
engine appearance plate and remove the
appearance plate from the vehicle.
The intake manifold to cylinder head retaining
bolts are thread locked. Extra care should be taken
during removal.
15. Remove and discard the retaining bolts securing
the intake manifold assembly to the right hand
0
x1
cylinder head.
AUS08694
x5
AUS08697
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-13
REMOVAL AND INSTALLATION (Continued)
16. Remove and discard the retaining bolts securing
20. Remove the retaining bolts securing the intake
the intake manifold assembly to the left hand
manifold top cover and remove the intake
cylinder head.
manifold top cover.
x18
x5
AUS08698
AUS08707
17. Carefully remove the intake manifold and super
21. Remove and discard the gasket from the cover.
charger assembly from the vehicle. After lifting
the assembly from the vehicle, release the wiring
harness retaining clip from the rear of the intake
manifold assembly.
18. Place the supercharger and intake manifold
assembly on a suitable clean work bench.
x2
AUS08714
22. Remove the intake matrix retaining bolts.
AUS08706
19. Remove and discard the intake manifold to
x6
cylinder head gaskets.
AUS08709
x8
AUS08705
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-14
REMOVAL AND INSTALLATION (Continued)
CAUTION
CAUTION
Once the intake matrix is removed, the
The intake manifold to supercharger retaining
supercharger rotors will be exposed. Use extreme
bolts are thread locked. Extra care should be taken
care not to allow foreign objects to fall into the
during removal.
supercharger. Failure to do so could cause severe
25. Remove and discard the intake manifold to
damage to the supercharger and engine.
supercharger retaining bolts.
23. Remove the intake matrix from the intake
manifold.
x12
AUS08711
AUS08715
CAUTION
24. Remove and discard the intake manifold top
The supercharger intake snorkel to
cover to intake manifold gasket.
supercharger retaining bolts are thread locked. Extra
care should be taken during removal.
26. Remove and discard the supercharger intake
snorkel retaining bolts and remove the intake
snorkel.
AUS08710
x8
AUS08712
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-15
REMOVAL AND INSTALLATION (Continued)
Installation
3.
Install the intake manifold to the supercharger.
Note: Ensure the gaskets are seated correctly into
CAUTION
the grooves.
Use extreme care not to allow foreign objects
1.
Press fit the new gaskets into the manifold intake
to fall into the supercharger. Failure to do so could
ports.
cause severe damage to the supercharger and
engine.
Note: Use new supercharger to intake manifold
retaining bolts.
�
Install retaining bolts and torque to 8-12 Nm.
x12
AUS08732
Note: Check the O-ring is fitted to supercharger inlet
(supplier fit item).
Note: Use new supercharger intake snorkel
retaining bolts.
AUS08711
2.
Install the supercharger intake snorkel to the
4.
Finger press the gasket in to position around
supercharger.
intake manifold.
�
Install retaining bolts and torque to 8-12 Nm.
Note: Complete installation by using a roller to push
the gasket in to position.
x8
AUS08712
AUS08710
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-16
REMOVAL AND INSTALLATION (Continued)
5.
Position the intake matrix on to the top of the
8.
Install the intake manifold top cover on to the
intake manifold.
intake manifold, and torque the retaining bolts to
8-12 Nm.
x18
AUS08715
AUS08707
6.
Install the retaining bolts and torque to 8-12 Nm.
CAUTION
The alignment of the supercharger and intake
manifold assembly relative to the cylinder heads
and accessory drive belt is critical. Ensure that an
appropriate method of alignment is used.
x6
Note: Use new intake manifold retaining bolts.
9.
Install the supercharger and intake manifold
assembly to the engine.
�
Carefully lift and place the supercharger and
intake manifold assembly to the engine.
�
Fit the 2x alignment pins ( Special tool 303-
AUS08735
1610) finger tight in the LH and RH front intake
manifold retaining bolt holes. Hand tighten
7.
Finger press a new gasket in to the cavity of the
the bolts to align the supercharger and intake
intake manifold top cover.
manifold assembly.
�
Install and the other 8x retaining bolts finger
tight.
x8
x2
AUS08714
AUS08733
�
Torque the middle 2x retaining bolts to 8-12
Nm.
�
Remove the alignment bolts from the LH and
RH front intake manifold retaining bolt holes.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-17
REMOVAL AND INSTALLATION (Continued)
10. Install the front 2x retaining bolts.
13. Install the engine appearance plate and tighten
the retaining screws to 5 Nm.
�
Torque all the bolts in sequence to 8-12 Nm.
8
7
0
x1
4
3
2
1
6
5
10
9
AUS08694
AUS08734
14. Connect the fuel evaporator hose.
11. Connect the boost pressure sensor (BPS) and
connect the wiring harness retaining clip.
AUS08695
AUS08699
15. Connect the supercharger boost vacuum hoses
to the intake manifold and supercharger actuator.
12. Place the rubber insulator on the intake manifold
top cover.
AUS08692
AUS08696
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-18
REMOVAL AND INSTALLATION (Continued)
16. Connect the brake booster vacuum hose.
4.
Install the throttle body. For additional information,
refer to Section 303-04D of the 2010 FPV 5.0L
4V Ti-VCT V8 Supplement.
5.
Install the accessory drive belt - A/C compressor/
power steering pump / Supercharger. For
additional information, refer to Section 303-05B
of the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
6.
Install the air filter box and air intake duct
assembly. For additional information, refer to
Section 303-12 of the 2010 FPV 5.0L 4V Ti-VCT
V8 Supplement.
7.
Connect the negative battery terminal. For
additional information, refer to Section 414-01B of
the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
AUS08693
1.
Push and refit the active exhaust valve vacuum
hose .
AUS08736
2.
Install the LH & RH fuel rails. For additional
information, refer to Section 303-04D of the 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
3.
Install the throttle body bracket.
x4
AUS08778
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-19
REMOVAL AND INSTALLATION (Continued)
Valve Cover -- RH- components
1
2
AUS07357
Item
Description
1
Variable Camshaft Timing (VCT) variable force solenoid electrical connector
2
Wiring harness retainer
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-20
REMOVAL AND INSTALLATION (Continued)
Valve Cover and Gasket
5
1
2
3
4
AUS08764
Item
Description
1
Engine oil cap
2
RH valve cover (12) Bolts.
3
RH valve cover (2) Studs.
4
RH valve cover Gasket
5
PCV Hose
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-21
REMOVAL AND INSTALLATION (Continued)
Spark Plug Tube Seals and Variable Camshaft Timing (VCT) Solenoid Seals
Item
Description
1
Variable Camshaft Timing (VCT)
variable force solenoid seal (2 required)
2
Spark plug tube seal (4 required)
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-22
REMOVAL AND INSTALLATION (Continued)
Valve Cover -- RH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Differential
Bearing Cone
205-142 (T80T-4000-J)
Installer, Spark Plug Tube
Seal
303-1247/2
Remover, Spark Plug
Tube Seal
303-1247/1
Material
Item
Specification
Silicone Gasket and Sealant
WSE-M4G323-A4
F7AZ-19554-EA or LOCTITE
5900 or equivalent
Metal Surface Cleaner F4AZ-
WSE-M5B392-A
19A536-RA or equivalent
Motorcraft� Silicone Gasket
--
Remover ZC-30
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-23
REMOVAL AND INSTALLATION (Continued)
Removal
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.
1.
Disconnect the battery ground cable. For
additional information, refer to Section 414-01 of
2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
2.
Remove the 2 bolts retaining the coolant
reservoir tank and position aside. For additional
information, refer to Section 303-03A of 2010
AUS08765
FPV 5.0L 4V Ti-VCT V8 Supplement
3.
Disconnect the RH ignition coil connectors and
7.
Remove the A/C suction pipe bracket retaining
disconnect the RH Variable Camshaft Timing
nut and position the bracket aside.
(VCT) variable force solenoid electrical connector.
AUS08770
AUS08769
Note: Do not use metal scrapers, wire brushes,
4.
Remove the RH ignition coils. For additional
power abrasive discs or other abrasive means
information, refer to Section 303-07B of 2010
to clean the sealing surfaces. These tools cause
FPV 5.0L 4V Ti-VCT V8 Supplement.
scratches and gouges which make leak paths. Use
a plastic scraping tool to remove all traces of old
5.
Slide the electrical connector from the clip at rear
sealant.
of the RH cylinder head.
8.
Loosen the 12 bolts and 2 studs, and remove the
RH valve cover and gasket.
AUS08766
6.
Detach the 10 wiring harness retainers.
AUS08768
�
Clean the valve cover mating surface of the
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-24
REMOVAL AND INSTALLATION (Continued)
RH Spark Plug Tube Seals and Variable
cylinder head with silicone gasket remover
Camshaft Timing (VCT) Solenoid Seals
and metal surface prep. Follow the directions
on the packaging.
Removal
�
Discard the valve cover gasket. Clean the
1.
Remove RH valve cover. For additional
valve cover gasket groove with soap and
information, refer to RH valve cover procedure in
water or a suitable solvent.
this section.
2.
Inspect the 2 VCT variable force solenoid seals.
Remove any damaged seals.
�
Using the Differential Bearing Cone Installer
and Handle, remove the seal(s).
3.
Inspect the spark plug tube seals. Remove any
damaged seals.
�
Using the VCT Spark Plug Tube Seal
Remover and Handle, remove the seal(s).
4.
Clean the valve cover, cylinder head and engine
front cover sealing surfaces with metal surface
prep.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-25
REMOVAL AND INSTALLATION (Continued)
Spark Plug Tube Seals and Variable
Note: Apply an 8 mm bead of silicone Gasket and
Camshaft Timing (VCT) Solenoid Seals
sealant to the engine front cover-to-RH cylinder head
joints.
Installation
Note: Installation of new seals is only required if
damaged seals were removed.
1.
Using the VCT Spark Plug Tube Seal Installer and
Handle, install new spark plug tube seals.
Installation - RH Valve cover
1.
Installation is reversal of the removal procedure.
2.
Position the RH valve cover and new gasket on
Note: Installation of new seals is only required if
the cylinder head.
damaged seals were removed.
�
Tighten the stud and bolts in the sequence
shown to 10 Nm.
2.
Using the Differential Bearing Cone Installer and
Handle, install new VCT variable force solenoid
seal(s).
Note: Failure to use silicone Gasket and sealant may
cause the engine oil to foam excessively and result in
serious engine damage.
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.
3.
Attach the 10 wiring harness retainers.
4.
Install the A/C suction pipe mounting bracket on
the stud (6).
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-26
REMOVAL AND INSTALLATION (Continued)
5.
Connect the RH VCT variable force solenoid
electrical connector.
6.
Fasten the electrical connector on to the wiring
retainer at the rear of the cylinder head.
7.
Install the RH ignition coils. For additional
information, refer to Section 303-07B.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-27
REMOVAL AND INSTALLATION (Continued)
Valve Cover - LH - components
1
2
AUS07358
Item
Description
1
Wiring harness retainer
2
Variable Camshaft Timing (VCT) variable force solenoid electrical connector
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-28
REMOVAL AND INSTALLATION (Continued)
Valve Cover, Gasket, Oil level Indicator and Tube
1
2
3
4
5
AUS07345
Item
Description
1
LH valve cover gasket
2
LH valve cover
3
Oil level indicator tube
4
Oil level indicator
5
Valve cover bolt
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-29
REMOVAL AND INSTALLATION (Continued)
Spark Plug Tube Seals and Variable
Camshaft Timing (VCT) Solenoid Seals
Item
Description
1
Variable Camshaft Timing (VCT) variable force solenoid seal (2 required)
2
Spark plug tube seal (4 required)
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-30
REMOVAL AND INSTALLATION (Continued)
Valve Cover -- LH
Special Tool(s)
Handle
205-153 (T80T-4000-W)
Installer, Differential
Bearing Cone
205-142 (T80T-4000-J)
Installer, Spark Plug Tube
Seal
303-1247/2
Remover, Spark Plug
Tube Seal
303-1247/1
Material
Item
Specification
Silicone Gasket and Sealant
WSE-M4G323-A4
F7AZ-19554-EA or LOCTITE
5900 or equivalent
Metal Surface Cleaner F4AZ-
WSE-M5B392-A
19A536-RA or equivalent
Motorcraft� Silicone Gasket
--
Remover ZC-30
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-31
REMOVAL AND INSTALLATION (Continued)
Removal
bracket to the valve cover stud and on the rear
LH side of the valve cover, and remove the
Note: During engine repair procedures, cleanliness
bracket.
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.
1.
Disconnect the battery ground cable. For
additional information, refer to Section 414-01 of
2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
2.
Remove the oil level indicator tube.
�
Remove the retaining bolt on the throttle
body bracket.
�
Remove 2 retaining nuts on the Valve cover.
AUS08785
7.
Disconnect the 4 electrical connectors from the
LH ignition coils and the electrical connector from
the VCT solenoid.
AUS08789
3.
Remove the intake manifold and supercharger
assembly. For additional information, refer to the
Intake Manifold procedure in this section.
4.
Remove the nut from the fuel line retaining clamp
AUS08787
on the LH valve cover and release the fuel lines,
placing them out of the way.
8.
Remove the LH ignition coils. For additional
information, refer to Section 303-07B of 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
9.
Detach the 6 fuel injection wiring harness
retainers from the LH valve cover.
AUS08784
5.
Remove the bolt from the fuel line retaining clamp
bracket to the rear of the LH valve cover.
6.
Remove the nut from the fuel line retaining clamp
AUS08786
Note: Do not use metal scrapers, wire brushes,
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-32
REMOVAL AND INSTALLATION (Continued)
Spark Plug Tube Seals and Variable
power abrasive discs or other abrasive means
Camshaft Timing (VCT) Solenoid Seals
to clean the sealing surfaces. These tools cause
scratches and gouges which make leak paths. Use
Removal
a plastic scraping tool to remove all traces of old
sealant
1.
Remove LH valve cover. For additional
information, refer to LH valve cover procedure in
10. Loosen the 11 bolts and 3 studs from LH valve
this section.
cover.
2.
Inspect the 2 VCT variable force solenoid seals.
Remove any damaged seals.
�
Using the Differential Bearing Cone Installer
and Handle, remove the seal(s).
AUS08788
�
Remove 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
3.
Inspect the spark plug tube seals. Remove any
on the packaging.
damaged seals.
�
Discard the valve cover gasket. Clean the
�
Using the VCT Spark Plug Tube Seal
valve cover gasket groove with soap and
Remover and Handle, remove the seal(s).
water or a suitable solvent.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-33
REMOVAL AND INSTALLATION (Continued)
Note: If the valve cover is not installed and the
Installation
fasteners tightened within 5 minutes, the sealant
Note: Installation of new seals is only required if
must be removed and the sealing area cleaned.
damaged seals were removed.
To clean the sealing area, use silicone gasket
1.
Using the VCT Spark Plug Tube Seal Installer and
remover and metal surface prep. Failure to follow
Handle, install new spark plug tube seals.
this procedure can cause future oil leakage.
Apply an 8 mm bead of silicone Gasket and
sealant to the engine front cover-to-LH cylinder
head joints.
Note: Installation of new seals is only required if
damaged seals were removed.
2.
Using the Differential Bearing Cone Installer and
Handle, install new VCT variable force solenoid
seal(s).
Note: Failure to use silicone Gasket and sealant
may cause the engine oil to foam excessively and
result in serious engine damage.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-34
REMOVAL AND INSTALLATION (Continued)
Installation - LH Valve Cover
11. Install the LH ignition coils. For additional
information, refer to Section 303-07B of 2010
1.
To install, reverse the removal procedure.
FPV 5.0L 4V Ti-VCT V8 Supplement.
2.
Position the LH valve cover and new gasket on
12. Connect the battery ground cable. For additional
the cylinder head.
information, refer Section 414-01.
�
Tighten the bolts in the sequence shown to
10 Nm.
3.
Attach the fuel supply tube retaining clip to the LH
valve cover.
4.
Connect the fuel supply tube. For additional
information, refer to Section 310-00 of 2010 FPV
5.0L 4V Ti-VCT V8 Supplement.
5.
Install the oil level indicator tube.
�
Push the oil level indicator tube into the valve
cover until it clicks into place.
6.
Install the oil level indicator.
7.
Install the intake manifold and supercharger
assembly. For additional information, refer to the
Intake Manifold procedure in this section.
8.
Attach the 6 wiring harness retainers.
9.
Connect the LH VCT variable force solenoid
electrical connector.
10. Connect the ignition coil electrical connectors.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-35
REMOVAL AND INSTALLATION (Continued)
Crankshaft Pulley and Crankshaft Front Seal -- Exploded View
Item
Description
1
Crankshaft pulley bolt
2
Crankshaft pulley washer
3
Crankshaft pulley
4
Crankshaft front seal
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-36
REMOVAL AND INSTALLATION (Continued)
Crankshaft Pulley
Special Tool(s)
3 Jaw Puller
303-D121 or equivalent
Installer, Front Cover Oil
Seal
303-335 (T88T-6701-A2
plate only)
Installer, Front Crank
Seal and Damper
303-1531
Strap Wrench
303-D055 (D85L-
6000-A) or equivalen
Vehicle Communication
Module (VCM) and
Integrated Diagnostic
System (IDS) software
with appropriate
hardware, or equivalent
scan tool
Material
Item
Specification
Silicone Gasket and Sealant
WSE-M4G323-A4
F7AZ-19554-EA or Loctite
5900 or equivalent
Engine Oil IISAC GF-4 SAE
WSS-M2C930-A
5W-20
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-37
REMOVAL AND INSTALLATION (Continued)
Removal
Installation
1.
Note: If not secured within 5 minutes, the
Note: During engine repair procedures, cleanliness
sealant must be removed and the sealing area
is extremely important. Any foreign material, including
cleaned with silicone gasket remover and metal
any material created while cleaning gasket surfaces,
surface prep. Failure to follow this procedure can
that enters the oil passages, coolant passages or the
cause future oil leakage.
oil pan, can cause engine failure.
1.
With the vehicle in NEUTRAL, position it on a
Apply silicone sealer to the Woodruff key slot in
hoist. For additional information, refer to Section
the crankshaft pulley.
100-02 of the FG Falcon Workshop Manual.
2.
Remove the cooling fan motor and shroud. For
additional information, refer to Section 303-03A
of 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
3.
Remove the accessory drive belt (A/C
compressor and power steering pump). . For
additional information, refer to Section 303-05 of
2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
4.
Remove accessory drive belt (Alternator and
Water pump). For additional information, refer to
Section 303-05 of 2010 FPV 5.0L 4V Ti-VCT V8
Supplement.
5.
Remove the crankshaft pulley bolt and washer.
6.
Using the 3 Jaw Puller and the crankshaft pulley
2.
Lubricate the crankshaft pulley sealing surface
bolt, remove the crankshaft pulley.
with clean engine oil prior to installation.
�
Discard the crankshaft pulley bolt.
3.
Using the Front Crank Seal and Damper Installer
and the Front Cover Oil Seal Installer (plate only),
install the crankshaft pulley.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-38
REMOVAL AND INSTALLATION (Continued)
4.
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.
�
Stage 2: Loosen 360 degrees.
�
Stage 3: Tighten to 100 Nm.
�
Stage 4: Tighten an additional 90 degrees.
5.
Remove the accessory drive belt (A/C
compressor and power steering pump). . For
additional information, refer to Section 303-05 of
2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
6.
Remove accessory drive belt (Alternator and
Water pump). For additional information, refer to
Section 303-05 of 2010 FPV 5.0L 4V Ti-VCT V8
Supplement.
7.
Install the cooling fan motor and shroud. For
additional information, refer to Section 303-03A
of 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-39
REMOVAL AND INSTALLATION (Continued)
Crankshaft Front Seal
CAUTION
Removal
Take care not to damage the engine front
cover or the crankshaft when removing the seal.
Special Tool(s)
3.
Using the Oil Seal Remover, remove the
Installer, Front Cover Oil
crankshaft front oil seal.
Seal
303-335 (T88T-6701-A2
plate only)
Installer, Front Crank
Seal and Damper
303-1531
Installation
Note: Lubricate the engine front cover bore and the
Remover, Oil Seal
crankshaft front oil seal inner lip with clean engine oil.
303-409 (T92C-6700-
CH)
1.
Using the Front Crank Seal and Damper Installer
and the Front Cover Oil Seal Installer (plate only),
install the crankshaft front oil seal.
Material
Item
Specification
Engine Oil IISAC GF-4 SAE
WSS-M2C930-A
5W-20
Removal
Note: During engine repair procedures, cleanliness
is extremely important. Any foreign material, including
any material created while cleaning gasket surfaces,
2.
Install the crankshaft pulley. For additional
that enters the oil passages, coolant passages or the
information, refer to Crankshaft Pulley procedure
oil pan, can cause engine failure.
in this section.
1.
With the vehicle in NEUTRAL, position it on a
hoist. For additional information, refer to Section
100-02 of FG Falcon Workshop manual.
2.
Remove the crankshaft pulley. For additional
information, refer to Crankshaft Pulley procedure
in this section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-40
REMOVAL AND INSTALLATION (Continued)
Engine Front Cover
Remover, Power Steering
Pump Pulley
Removal
A7185
Special Tool(s)
BA / BF / FG
3 Jaw Puller
303-D121 or equivalent
SST888-000
Installer, Power Steering
Pump Pulley
A7005
BA / BF / FG
Installer, Front Cover Oil
Seal
SST416-D001
303-335 (T88T-6701-A2
plate only)
Material
Item
Specification
Silicone Gasket and Sealant
WSE-M4G323-A4
Installer, Front Crank Seal
F7AZ-19554-EA or Loctite
and Damper
5900 or equivalent
303-1531
Metal Surface Cleaner F4A2-
WSE-M5B392-A
19A536-RA or equivalent
Engine Oil IISAC GF-4 SAE
WSS-M2C930-A
5W-20
Motorcraft� Silicone Gasket
--
Remover ZC-30
Motorcraft� Specialty Orange
WSS-M97B44-D
Engine Coolant VC-3-B
Remover, Oil Seal
(US); CVC-3-B (Canada); or
303-409 (T92C-6700-
equivalent
CH)
Strap Wrench
303-D055 (D85L-
6000-A) or equivalent
Vehicle Communication
Module (VCM) and
Integrated Diagnostic
System (IDS) software
with appropriate
hardware, or equivalent
scan tool
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-41
REMOVAL AND INSTALLATION (Continued)
Engine Front Cover (View 1 of 4)
1
2
4
3
5
AUS07354
Item
Description
1
Engine to radiator tank supply hose
2
Radiator tank overflow hose
3
Thermostat housing bolt (2 required)
4
Upper radiator hose T-connector/thermostat housing assembly
5
Lower radiator hose
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-42
REMOVAL AND INSTALLATION (Continued)
Engine Front Cover (View 2 of 4)
4
3
2
1
5
6
7
AUS07356
Item
Description
1
Coolant pump pulley bolt (4 required)
2
Coolant pump pulley
3
Coolant pump bolt (4 required)
4
Coolant pump
5
Crankshaft front oil seal
6
Crankshaft pulley
7
Crankshaft pulley bolt
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-43
REMOVAL AND INSTALLATION (Continued)
Engine Front Cover (View 3 of 4)
2
1
3
5
4
AUS07372
Item
Description
1
Accessory drive belt tensioner bolt
2
Accessory drive belt tensioner
3
Alternator
4
Alternator nut
5
Alternator bolt
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-44
REMOVAL AND INSTALLATION (Continued)
Engine Front Cover (View 4 of 4)
2
1
3
4
6
5
AUS07355
Item
Description
1
Engine front cover stud (2 required)
2
Engine front cover gasket
3
Oil pan bolt
4
Engine front cover stud (2 required)
5
Engine front cover bolt (2 required)
6
Engine front cover bolt (8 required)
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-45
REMOVAL AND INSTALLATION (Continued)
Engine Front Cover
VCT V8 Supplement.
9.
Remove lower RH Tensioner and pulley
Removal
assembly.
1.
Disconnect the battery ground cable. For
additional information, refer to Section 414-01 of
2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
2.
Remove the air deflector. For additional
information, refer to section 501-02 of the FG
Falcon Workshop Manual.
AUS08799
x14
10. Using the special tool A7185, remove power
steering pump pulley.
AUS08577
3.
Drain the cooling system. For additional
A7185
information, refer to Section 303-03A of 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
4.
Remove cooling Fan motor and shroud
assembly. For additional information, refer to
Section 303-03A of 2010 FPV 5.0L 4V Ti-VCT V8
Supplement.
5.
Remove battery and battery tray. For additional
information, refer to Section 414-01 of 2010 FPV
AUS08839
5.0L 4V Ti-VCT V8 Supplement.
11. Remove the crankshaft pulley bolt and washer.
6.
Remove LH and RH Valve covers. For additional
information, refer to LH and RH Valve covers in
12. Using the 3 Jaw Puller and the crankshaft pulley
this Section.
bolt, remove the crankshaft pulley.
7.
Remove Coolant pump. For additional
�
Discard the crankshaft pulley bolt.
information, refer to Section 303-03A of 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
8.
Remove alternator. For additional information,
refer to Section 414-02B of 2010 FPV 5.0L 4V Ti-
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-46
REMOVAL AND INSTALLATION (Continued)
Note: Use care not to damage the engine front
16. Remove the 19x Front cover retaining studs and
bolts.
cover or the crankshaft when removing the seal.
13. Using the Oil Seal Remover tool, remove the
crankshaft front oil seal.
x19
AUS08791
17. Carefully remove the front cover.
Note: Do not use metal scrapers, wire brushes,
power abrasive discs or other abrasive means
14. Remove the power steering pump bracket bolts
to clean the sealing surfaces. These tools cause
and remove the bracket.
scratches and gouges which make leak paths. Use
a plastic scraping tool to remove all races of old
sealant.
�
Remove and discard the engine front cover
gaskets.
x4
�
Clean the mating surfaces with silicone
gasket remover and metal surface prep.
Follow the directions on the packaging.
�
Inspect the mating surfaces.
AUS08807
15. Carefully manoeuvre the power steering pump
and bracket to gain access to the front cover
mounting bolts.
AUS08795
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-47
REMOVAL AND INSTALLATION (Continued)
Installation
Note: Make sure that the engine front cover
gaskets are in place on the engine front cover before
Note: The Variable Camshaft Timing (VCT) variable
installation.
force solenoid pins must be fully depressed to avoid
3.
Using new gaskets, position the engine front
interference with the VCT valve tips when installing
cover onto the dowels.
the engine front cover. Failure to follow these
instructions can result in damage to the engine.
�
Install the 13 engine front cover bolts, 2 stud
Note: LH shown, RH similar.
bolts and the 4 oil pan-to-engine front cover
bolts finger-tight.
1.
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 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.
2.
Apply a bead of silicone sealer to the cylinder
head-to-cylinder block joints and the oil pan-to-
cylinder block joints as illustrated.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-48
REMOVAL AND INSTALLATION (Continued)
Note: Lubricate the engine front cover bore and the
Note: The engine front cover must be installed
crankshaft front oil seal inner lip with clean engine oil.
and all fasteners final tightened within 5 minutes of
applying the sealer. If this cannot be accomplished,
6.
Using the Front Crank Seal and Damper Installer
install the engine front cover and tighten fasteners 6,
and the Front Cover Oil Seal Installer (plate only),
7, 8, 9, 10 and 11 to 8 Nm within 5 minutes of applying
install the crankshaft front oil seal.
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.
4.
Tighten the bolts in the sequence shown in 2
stages.
�
Stage 1: Tighten bolts 1-15 to 25 Nm and bolts
16-19 to 10 Nm.
�
Stage 2: Tighten bolts 1-15 an additional 60
degrees and bolts 16-19 an additional 45
degrees.
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.
7.
Apply silicone sealer to the Woodruff key slot in
the crankshaft pulley.
14
13
10
9
12
5
4
3
15
8
11
11
2
1
6
7
8.
Lubricate the crankshaft pulley sealing surface
17
with clean engine oil prior to installation.
18
19
16
AUS08796
5.
Position the wiring harness and install the 2 wiring
harness retainer nuts to the front oil pan stud
bolts.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-49
REMOVAL AND INSTALLATION (Continued)
9.
Using the Front Crank Seal and Damper Installer
12. Install all the bolts of the power steering pump
and the Front Cover Oil Seal Installer (plate only),
and bracket as shown in the sequence.
install the crankshaft pulley.
�
Torque bolts 1,2,3,4,5,6 to 30 Nm.
�
Torque bolt 7 to 35 Nm.
1
3
5
6
4
7
2
10. Using the Strap Wrench, install a new crankshaft
AUS08798
pulley bolt and the original washer, tighten the
bolt in 4 stages:
13. Using the special tool A7005, install the power
steering pump pulley.
�
Stage 1: Tighten to 140 Nm.
14. Install the lower RH Tensioner and pulley
�
Stage 2: Loosen 360 degrees.
assembly.
�
Stage 3: Tighten to 100 Nm.
�
Stage 4: Tighten an additional 90 degrees.
AUS08799
15. Install the alternator. For additional information,
refer to Section 414-02B of 2010 FPV 5.0L 4V Ti-
VCT V8 Supplement.
11. Reposition the power steering pump and bracket
16. Install the coolant pump. For additional
back in to position.
information, refer to Section 303-03A of 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
17. Install the LH and RH Valve covers. For additional
information, refer to LH and RH Valve covers in
this Section.
18. Install the battery and battery tray. For additional
information, refer to Section 414-01 of 2010 FPV
5.0L 4V Ti-VCT V8 Supplement.
19. install the cooling fan motor and shroud
assembly. For additional information, refer to
Section 303-03A of 2010 FPV 5.0L 4V Ti-VCT V8
Supplement.
AUS08797
20. Fill and bleed the cooling system. For additional
information, refer to Section 303-03A of 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-50
REMOVAL AND INSTALLATION (Continued)
21. Install the air deflector. For additional information,
refer to section 501-02 of the FG Falcon
Workshop Manual.
22. Check the engine oil and top up if necessary.
23. Connect the battery ground cable. For additional
information, refer to Section 414-01 of 2010 FPV
5.0L 4V Ti-VCT V8 Supplement.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-51
REMOVAL AND INSTALLATION (Continued)
Timing Drive Components - Overview
Item
Description
1
RH exhaust camshaft Variable Camshaft Timing (VCT)
2
RH secondary tensioner
3
RH intake camshaft VCT
4
RH secondary timing chain
5
RH timing chain guide
6
LH timing chain tensioner arm
7
LH primary tensioner
8
LH intake camshaft VCT
9
LH secondary timing chain
10
LH secondary tensioner
11
LH primary timing chain
12
LH exhaust camshaft VCT
13
LH timing chain guide
14
Crankshaft sprocket
15
RH timing chain
16
RH timing chain tensioner arm
17
RH primary tensioner
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-52
REMOVAL AND INSTALLATION (Continued)
Timing Drive Components
Special Tool(s)
Holding Tool, Crankshaft
303-448 (T93P-6303-A)
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-53
REMOVAL AND INSTALLATION (Continued)
Removal
chain tensioner.
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.
1.
Remove the engine front cover. For additional
information, refer to Engine Front Cover in this
section.
2.
Using the crankshaft holding tool, rotate the
crankshaft clockwise until the keyway is at the 12
o'clock position.
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.
5.
Remove the RH timing chain tensioner arm.
3.
Verify the data matrix on the camshafts is facing
up, if not, rotate the crankshaft clockwise one
revolution.
4.
Remove the 2 bolts and the RH primary timing
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-54
REMOVAL AND INSTALLATION (Continued)
Note: It may be necessary to rotate the crankshaft
9.
Slide the RH VCT assemblies and secondary
timing chain forward 2 mm.
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.
6.
Remove the bolt and the RH timing chain guide.
10. Depress the RH secondary timing chain tensioner
and turn the tensioner 90 degrees.
7.
Remove the RH primary timing chain.
11. Remove the RH VCT assemblies and the RH
secondary timing chain.
8.
Remove the 3 RH intake Variable Camshaft
Timing (VCT) assembly bolts and the 3 RH
exhaust VCT assembly bolts.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-55
REMOVAL AND INSTALLATION (Continued)
Note: It may be necessary to rotate the crankshaft
12. Using the crankshaft holding tool, rotate the
crankshaft counterclockwise until the crankshaft
slightly to provide enough slack in the chain to
keyway is at the 9 o'clock position.
remove the LH timing chain guide. Return the
crankshaft keyway to the 9 o'clock position after
removing the LH timing chain guide.
15. Remove the bolt and the LH timing chain guide.
13. Remove the 2 bolts and the LH primary timing
chain tensioner.
16. Remove the LH primary timing chain.
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
17. Remove the 3 LH intake Variable Camshaft
the crankshaft keyway to the 9 o'clock position after
Timing (VCT) assembly bolts and the 3 LH
removing the LH timing chain tensioner arm.
exhaust VCT assembly bolts.
14. Remove the LH timing chain tensioner arm.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-56
REMOVAL AND INSTALLATION (Continued)
18. Slide the LH VCT assemblies and secondary
21. Remove the crankshaft sprocket.
timing chain forward 2 mm.
19. Depress the LH secondary timing chain tensioner
and turn the tensioner 90 degrees.
20. Remove the LH VCT assemblies and the LH
secondary timing chain.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-57
REMOVAL AND INSTALLATION (Continued)
Installation
3.
Install the LH VCT assemblies and the secondary
timing chain onto the LH camshafts to a position
1.
Install the crankshaft sprocket with the flange
2 mm from fully seated. The timing mark on the
facing forward.
exhaust VCT assembly should be in the 11 o'clock
position.
2.
Install the secondary timing chain onto the LH
VCT assemblies. Align the coloured links on the
Note: It may be necessary to rotate the exhaust
secondary timing chain with the timing marks on
camshaft slightly (using a wrench on the flats of
the VCT assemblies as shown in the illustration.
the camshaft) to seat the VCT assemblies onto the
camshafts.
�
The timing mark on the intake VCT assembly
should align between the 2 consecutive
4.
Rotate the secondary timing chain tensioner 90
coloured links.
degrees so the ramped area is facing forward
and fully seat the VCT assemblies onto the
�
The timing mark on the exhaust VCT
camshafts.
assembly should align with the single
coloured link.
�
If the secondary timing chain is not centred
over the tensioner, reposition the VCT
assemblies until they are fully seated on the
camshafts.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-58
REMOVAL AND INSTALLATION (Continued)
Note: Use a wrench on the flats of the camshaft
Note: It may be necessary to rotate the crankshaft
to hold the camshafts while tightening the VCT
slightly to provide enough slack in the chain to install
assembly bolts.
the LH timing chain guide. Return the crankshaft
keyway to the 9 o'clock position after installing the LH
5.
Install the 3 LH intake VCT assembly bolts and
timing chain guide.
the 3 LH exhaust VCT assembly bolts.
8.
Install the LH timing chain guide and bolt.
�
Tighten to 15 Nm plus an additional 90
degrees.
�
Tighten to 10 Nm.
Note: It may be necessary to rotate the crankshaft
6.
Install the LH primary timing chain.
slightly to provide enough slack in the chain to
�
Align the coloured link on the timing chain
install the LH timing chain tensioner arm. Return the
with the timing mark on the LH VCT
crankshaft keyway to the 9 o'clock position after
assembly.
installing the LH timing chain tensioner arm.
9.
Install the LH timing chain tensioner arm.
7.
Align the remaining coloured link on the timing
chain with the timing mark on the crankshaft
sprocket.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-59
REMOVAL AND INSTALLATION (Continued)
Note: Complete the following 3 steps on both the
13. Install the LH primary timing chain tensioner and
2 bolts.
LH and RH primary timing chain tensioners.
� Tighten to 10 Nm.
Note: Do not compress the ratchet assembly or
� Remove the holding pin from the tensioner.
damage to the tensioner will occur.
10. Compress the primary timing chain tensioner
plunger, using an edge of a vise.
14. Using the crankshaft holding tool, rotate the
crankshaft clockwise until the crankshaft keyway
is at the 12 o'clock position.
11. Using a small screwdriver or pick, push back
and hold the ratchet mechanism, then push the
ratchet arm back into the tensioner housing.
15. Install the secondary timing chain onto the RH
VCT assemblies. Align the coloured links on the
secondary timing chain with the timing marks on
the VCT assemblies as shown in the illustration.
� The timing mark on the intake VCT assembly
12. Install a suitable pin into the hole of the tensioner
should align between the 2 consecutive
housing to hold the ratchet assembly and plunger
coloured links.
in place during installation.
� The timing mark on the exhaust VCT
assembly should align with the single
coloured link.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-60
REMOVAL AND INSTALLATION (Continued)
Note: Use a wrench on the flats of the camshaft
16. Install the RH VCT assemblies and the secondary
timing chain onto the RH camshafts to a position
to hold the camshafts while tightening the VCT
2 mm from fully seated. The timing mark on the
assembly bolts.
exhaust VCT assembly should be in the 1 o'clock
18. Install the 3 RH intake VCT assembly bolts and
position.
the 3 RH exhaust VCT assembly bolts.
�
Tighten to 15 Nm plus an additional 90
degrees.
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.
19. Install the RH primary timing chain.
17. Rotate the secondary timing chain tensioner 90
�
Align the coloured link on the timing chain
degrees so the ramped area is facing forward
with the timing mark on the RH VCT
and fully seat the VCT assemblies onto the
assembly.
camshafts.
�
If the secondary timing chain is not centred
over the tensioner, reposition the VCT
assemblies until they are fully seated on the
camshafts.
20. Align the remaining coloured link on the timing
chain with the timing mark on the crankshaft
sprocket.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-61
REMOVAL AND INSTALLATION (Continued)
Note: It may be necessary to rotate the crankshaft
23. Install the RH primary timing chain tensioner and
2 bolts.
slightly to provide enough slack in the chain to install
the RH timing chain guide. Return the crankshaft
�
Tighten to 10 Nm.
keyway to the 12 o'clock position after installing the
RH timing chain guide.
�
Remove the holding pin from the tensioner.
21. Install the RH timing chain guide and bolt.
�
Tighten to 10 Nm.
24. With the crankshaft keyway still at the 12 o'clock
position, verify the timing mark alignment is
correct.
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.
22. Install the RH timing chain tensioner arm.
25. Install the engine front cover. For additional
information, refer to Engine Front Cover in this
section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-62
REMOVAL
REMOVAL AND INSTALLATION (Continued)
Timing Drive Components - Overview
Item
Description
1
RH exhaust Variable Camshaft Timing (VCT) assembly
2
RH secondary timing chain tensioner
3
RH intake VCT assembly
4
RH secondary timing chain
5
RH timing chain guide
6
Crankshaft sprocket
7
RH primary timing chain
8
RH timing chain tensioner arm
9
RH primary timing chain tensioner
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-63
REMOVAL AND INSTALLATION (Continued)
Camshafts
Item
Description
1
RH intake camshaft
2
Intake camshaft bearing cap (4 required)
3
Front camshaft bearing mega cap
4
Front camshaft bearing mega cap bolt
5
Intake/exhaust camshaft bearing cap bolt (16 required)
6
Exhaust camshaft bearing cap (4 required)
7
RH exhaust camshaft
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-64
REMOVAL AND INSTALLATION (Continued)
Camshaft -- RH
Special Tool(s)
Holding Tool, Crankshaft
303-448 (T93P-6303-A)
Material
Item
Specification
Engine Oil IISAC GF-4 SAE
WSS-M2C930-A
5W-20
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-65
REMOVAL AND INSTALLATION (Continued)
Removal
5.
Remove the 2 bolts and the RH primary timing
chain tensioner.
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: If the components are to be reinstalled, they
must be installed in their original location. Mark the
components for installation into their original location.
1.
Remove the engine front cover. For additional
information, refer to Engine Front Cover in this
section.
2.
Remove the RH intake and exhaust Camshaft
Position (CMP) sensors. For additional
information, refer to Section 303-14B of 2010 FPV
5.0L 4V Ti-VCT V8 Supplement.
Note: It may be necessary to rotate the crankshaft
3.
Using the crankshaft holding tool, rotate the
slightly to provide enough slack in the chain to
crankshaft clockwise until the crankshaft keyway
remove the RH timing chain tensioner arm. Return
is at the 12 o'clock position.
the crankshaft keyway to the 12 o'clock position after
removing the RH timing chain tensioner arm.
6.
Remove the RH timing chain tensioner arm.
4.
Verify the data matrix on the camshafts is facing
up, if not, rotate the crankshaft clockwise one
revolution.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-66
REMOVAL AND INSTALLATION (Continued)
Note: It may be necessary to rotate the crankshaft
10. Slide the RH VCT assemblies and secondary
timing chain forward 2 mm.
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.
7.
Remove the bolt and the RH timing chain guide.
11. Depress the RH secondary timing chain tensioner
and turn the tensioner 90 degrees.
8.
Remove the RH primary timing chain.
12. Remove the RH VCT assemblies and the RH
secondary timing chain.
9.
Remove the 3 RH intake Variable Camshaft
Timing (VCT) assembly bolts and the 3 RH
exhaust VCT assembly bolts.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-67
REMOVAL AND INSTALLATION (Continued)
Note: Intake camshaft shown, exhaust camshaft
similar.
13. Remove the VCT system oil filter from the intake
and exhaust camshafts.
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.
14. Remove the 4 bolts and the RH front camshaft
bearing mega cap.
15. Remove the 16 bolts and the 8 camshaft bearing
caps.
16. Remove the RH intake and exhaust camshafts.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-68
REMOVAL AND INSTALLATION (Continued)
Installation
Note: Intake camshaft shown, exhaust camshaft
similar.
Note: Lubricate the camshafts with clean engine oil
5.
Install the VCT system oil filter in the intake and
prior to installation.
exhaust camshafts.
1.
Install the RH intake and exhaust camshafts in the
neutral position. Align the D-slots as shown in the
illustration.
6.
Install the secondary timing chain onto the RH
VCT assemblies. Align the coloured links on the
secondary timing chain with the timing marks on
2.
Install the 8 camshaft bearing caps and the 16
the VCT assemblies as shown in the illustration.
bolts. Do not tighten the bolts at this time.
3.
Install the RH front camshaft bearing mega cap
�
The timing mark on the intake VCT assembly
and the 4 bolts. Do not tighten at this time
should align between the 2 consecutive
coloured links.
�
The timing mark on the exhaust VCT
assembly should align with the single
coloured link.
4.
Tighten the bolts in the sequence shown in 2
stages.
�
Stage 1: Tighten to 6 Nm.
�
Stage 2: Tighten an additional 45 degrees.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-69
REMOVAL AND INSTALLATION (Continued)
7.
Install the RH VCT assemblies and the secondary
9.
Install the 3 RH intake VCT assembly bolts and
timing chain onto the RH camshafts to a position
the 3 RH exhaust VCT assembly bolts.
2 mm from fully seated. The timing mark on the
�
Tighten to 15 Nm plus an additional 90
exhaust VCT assembly should be in the 1 o'clock
degrees.
position.
10. Install the RH primary timing chain.
Note: It may be necessary to rotate the exhaust
camshaft slightly (using a wrench on the flats of
�
Align the coloured link on the timing chain
the camshaft) to seat the VCT assemblies onto the
with the timing mark on the RH VCT
camshafts.
assembly.
8.
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 centred
over the tensioner, reposition the VCT
assemblies until they are fully seated on the
camshafts.
11. Align the remaining coloured link on the timing
chain with the timing mark on the crankshaft
sprocket.
Note: Use a wrench on the flats of the camshaft
to hold the camshafts while tightening the VCT
assembly bolts.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-70
REMOVAL AND INSTALLATION (Continued)
Note: It may be necessary to rotate the crankshaft
Note: Do not compress the ratchet assembly or
slightly to provide enough slack in the chain to install
damage to the tensioner will occur.
the RH timing chain guide. Return the crankshaft
14. Compress the primary timing chain tensioner
keyway to the 12 o'clock position after installing the
plunger, using an edge of a vise.
RH timing chain guide.
12. Install the RH timing chain guide and bolt.
�
Tighten to 10 Nm.
15. Using a small screwdriver or pick, push back
and hold the ratchet mechanism, then push the
ratchet arm back into the tensioner housing.
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.
13. Install the RH timing chain tensioner arm.
16. Install a suitable pin into the hole of the tensioner
housing to hold the ratchet assembly and plunger
in place during installation.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-71
REMOVAL AND INSTALLATION (Continued)
17. Install the RH primary timing chain tensioner and
2 bolts.
�
Tighten to 10 Nm.
�
Remove the holding pin from the tensioner.
18. Install the RH intake and exhaust CMP sensors.
For additional information, refer to Section 303-14
of 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
19. Install the engine front cover. For additional
information, refer to Engine Front Cover in this
section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-72
REMOVAL AND INSTALLATION (Continued)
Timing Drive Components - Overview
Item
Description
1
RH exhaust Variable Camshaft Timing (VCT) assembly
2
RH secondary timing chain tensioner
3
RH intake VCT assembly
4
RH secondary timing chain
5
RH timing chain guide
6
LH timing chain tensioner arm
7
LH primary timing chain tensioner
8
LH intake VCT assembly
9
LH secondary timing chain
10
LH secondary timing chain tensioner
11
LH primary timing chain
12
LH exhaust VCT assembly
13
LH timing chain guide
14
Crankshaft sprocket
15
RH primary timing chain
16
RH timing chain tensioner arm
17
RH primary timing chain tensioner
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-73
REMOVAL AND INSTALLATION (Continued)
Camshafts - LH
Item
Description
1
LH intake camshaft
2
Front camshaft bearing mega cap (part of 6049)
3
Front camshaft bearing mega cap bolt (4 required)
4
Intake camshaft bearing cap (part of 6049) (4 required)
5
Exhaust camshaft bearing cap (part of 6049) (4 required)
6
Intake/exhaust camshaft bearing cap bolt (16 required)
7
LH exhaust camshaft
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-74
REMOVAL AND INSTALLATION (Continued)
Camshaft -- LH
Special Tool(s)
Holding Tool, Crankshaft
303-448 (T93P-6303-A)
Material
Item
Specification
Engine Oil IISAC GF-4 SAE
WSS-M2C930-A
5W-20
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-75
REMOVAL AND INSTALLATION (Continued)
Removal
chain tensioner.
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: If the RH camshafts are being serviced at
the same time as the LH camshafts, remove the RH
camshafts first. For additional information, refer to
Camshaft -- RH in this section.
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.
1.
Remove the engine front cover. For additional
information, refer to Engine Front Cover in this
Note: It may be necessary to rotate the crankshaft
section.
slightly to provide enough slack in the chain to
2.
Remove the LH intake and exhaust Camshaft
remove the RH timing chain tensioner arm. Return
Position (CMP) sensors. For additional
the crankshaft keyway to the 12 o'clock position after
information, refer to Section 303-14 of 2010 FPV
removing the RH timing chain tensioner arm.
5.0L 4V Ti-VCT V8 Supplement.
6.
Remove the RH timing chain tensioner arm.
3.
Using the crankshaft holding tool, rotate the
crankshaft clockwise until the keyway is at the 12
o'clock position.
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
4.
Verify the data matrix on the camshafts is facing
crankshaft keyway to the 12 o'clock position after
up, if not, rotate the crankshaft clockwise one
removing the RH timing chain guide.
revolution.
7.
Remove the bolt and the RH timing chain guide.
5.
Remove the 2 bolts and the RH primary timing
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-76
REMOVAL AND INSTALLATION (Continued)
8.
Remove the RH primary timing chain.
11. Remove the LH timing chain tensioner arm.
Note: It may be necessary to rotate the crankshaft
9.
Using the crankshaft holding tool, rotate the
crankshaft counterclockwise until the crankshaft
slightly to provide enough slack in the chain to
keyway is at the 9 o'clock position.
remove the LH timing chain guide. Return the
crankshaft keyway to the 9 o'clock position after
removing the LH timing chain guide.
12. Remove the bolt and the LH timing chain guide.
10. Remove the 2 bolts and the LH primary timing
chain tensioner.
13. Remove the LH primary timing chain.
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.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-77
REMOVAL AND INSTALLATION (Continued)
14. Remove the 3 LH intake Variable Camshaft
17. Remove the LH VCT assemblies and the LH
Timing (VCT) assembly bolts and the 3 LH
secondary timing chain.
exhaust VCT assembly bolts.
Note: Intake camshaft shown, exhaust camshaft
15. Slide the LH VCT assemblies and secondary
similar.
timing chain forward 2 mm.
18. Remove the VCT system oil filter from the intake
and exhaust camshafts.
16. Depress the LH secondary timing chain tensioner
and turn the tensioner 90 degrees.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-78
REMOVAL AND INSTALLATION (Continued)
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.
19. Remove the 4 bolts and the LH front camshaft
bearing mega cap.
20. Remove the 16 bolts and the 8 camshaft bearing
caps.
21. Remove the LH intake and exhaust camshafts.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-79
REMOVAL AND INSTALLATION (Continued)
Installation
Note: Intake camshaft shown, exhaust camshaft
similar.
Note: Lubricate the camshafts with clean engine oil
prior to installation.
5.
Install the VCT system oil filter in the intake and
exhaust camshafts.
1.
Install the LH intake and exhaust camshafts in the
neutral position. Align the D-slots as shown in the
illustration.
6.
Install the secondary timing chain onto the LH
VCT assemblies. Align the coloured links on the
2.
Install the 8 camshaft bearing caps and the 16
secondary timing chain with the timing marks on
bolts. Do not tighten the bolts at this time.
the VCT assemblies as shown in the illustration.
3.
Install the LH front camshaft bearing mega cap
1.
The timing mark on the intake VCT
and the 4 bolts. Do not tighten the bolts at this
assembly should align between the 2
time
consecutive coloured links.
2.
The timing mark on the exhaust VCT
assembly should align with the single
coloured link.
4.
Tighten the bolts in the sequence shown in 2
stages.
�
Stage 1: Tighten to 6 Nm.
�
Stage 2: Tighten an additional 45 degrees.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-80
REMOVAL AND INSTALLATION (Continued)
7.
Install the LH VCT assemblies and the secondary
9.
Install the 3 LH intake VCT assembly bolts and
timing chain onto the LH camshafts to a position
the 3 LH exhaust VCT assembly bolts.
2 mm from fully seated. The timing mark on the
�
Tighten to 15 Nm plus an additional 90
exhaust VCT assembly should be in the 11 o'clock
degrees.
position.
10. Install the LH primary timing chain.
Note: It may be necessary to rotate the exhaust
camshaft slightly (using a wrench on the flats of
�
Align the coloured link on the timing chain
the camshaft) to seat the VCT assemblies onto the
with the timing mark on the LH VCT
camshafts.
assembly.
8.
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 centred
over the tensioner, reposition the VCT
assemblies until they are fully seated on the
camshafts.
11. Align the remaining coloured link on the timing
chain with the timing mark on the crankshaft
sprocket.
Note: Use a wrench on the flats of the camshaft
to hold the camshafts while tightening the VCT
assembly bolts.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-81
REMOVAL AND INSTALLATION (Continued)
Note: It may be necessary to rotate the crankshaft
14. Compress the primary timing chain tensioner
plunger, using an edge of a vise.
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.
12. Install the LH timing chain guide and bolt.
�
Tighten to 10 Nm.
15. Using a small screwdriver or pick, push back
and hold the ratchet mechanism, then push the
ratchet arm back into the tensioner housing.
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.
13. Install the LH timing chain tensioner arm.
16. Install a suitable pin into the hole of the tensioner
housing to hold the ratchet assembly and plunger
in place during installation.
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.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-82
REMOVAL AND INSTALLATION (Continued)
17. Install the LH primary timing chain tensioner and
2 bolts.
�
Tighten to 10 Nm.
�
Remove the holding pin from the tensioner.
20. Align the remaining coloured link on the timing
chain with the timing mark on the crankshaft
sprocket.
18. Using the crankshaft holding tool, rotate the
crankshaft clockwise until the crankshaft keyway
is at the 12 o'clock position.
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.
19. Install the RH primary timing chain.
21. Install the RH timing chain guide and bolt.
�
Align the coloured link on the timing chain
�
Tighten to 10 Nm.
with the timing mark on the RH VCT
assembly.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-83
REMOVAL AND INSTALLATION (Continued)
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.
22. Install the RH timing chain tensioner arm.
23. Install the RH primary timing chain tensioner and
2 bolts.
�
Tighten to 10 Nm.
�
Remove the holding pin from the tensioner.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-84
REMOVAL AND INSTALLATION (Continued)
24. With the crankshaft keyway still at the 12 o'clock
position, verify the timing mark alignment is
correct.
25. Install the LH intake and exhaust CMP sensors.
For additional information, refer to Section 303-14
of 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
26. Install the engine front cover. For additional
information, refer to Engine Front Cover in this
section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-85
REMOVAL AND INSTALLATION (Continued)
Valve Train Components -- Overview
Item
Description
1
Hydraulic lash adjuster (32 required)
2
Camshaft roller follower (32 required)
3
Valve spring retainer key (64 required)
4
Valve spring retainer (32 required)
5
Valve spring (32 required)
6
Valve seal (32 required)
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-86
REMOVAL AND INSTALLATION (Continued)
Camshaft Roller Follower
3.
Separate the hydraulic lash adjuster from the
spring clip on the camshaft roller follower.
Material
Installation
Item
Specification
1.
To install, reverse the removal procedure.
Engine Oil IISAC GF-4 SAE
WSS-M2C930-A
�
Lubricate the camshaft roller follower and
5W-20
hydraulic lash adjuster assembly with clean
Removal
engine oil prior to installation.
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: If the components are to be reinstalled, they
must be installed in their original locations. Mark
the components for installation into their original
locations.
1.
Remove the camshaft for the camshaft
roller follower being serviced. For additional
information, refer to Camshaft - RH or Camshaft -
LH in this section.
2.
Remove the camshaft roller follower and
hydraulic lash adjuster as an assembly.
3.
Separate the hydraulic lash adjuster from the
spring clip on the camshaft roller follower.
Installation
1.
To install, reverse the removal procedure.
�
Lubricate the camshaft roller follower and
hydraulic lash adjuster assembly with clean
engine oil prior to installation.
Hydraulic Lash Adjuster
Material
Item
Specification
Engine Oil IISAC GF-4 SAE
WSS-M2C930-A
5W-20
Removal
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: If the components are to be reinstalled, they
must be installed in their original locations. Mark
the components for installation into their original
locations.
1.
Remove the camshaft for the hydraulic
lash adjuster being serviced. For additional
information, refer to Camshaft-RH or Camshaft-
LH in this section.
2.
Remove the camshaft roller follower and
hydraulic lash adjuster as an assembly.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-87
REMOVAL AND INSTALLATION (Continued)
Valve Springs
Removal
Note: During engine repair procedures, cleanliness
Special Tool(s)
is extremely important. Any foreign material, including
Compressor, Valve
any material created while cleaning gasket surfaces,
Spring
that enters the oil passages, coolant passages or the
303-1418
oil pan, can cause engine failure.
Note: If the components are to be reinstalled, they
must be installed in their original locations. Mark
the components for installation into their original
locations.
1.
Remove the camshaft for the valve spring being
serviced. For additional information, refer to
Compressor, Valve
Camshaft-RH or Camshaft-LH in this section.
Spring
2.
Remove the roller follower and hydraulic lash
303-300 (T87C-6565-A)
adjuster assembly for the valve spring being
serviced.
Note: If air pressure must be removed, support the
valve prior to removal or engine damage may occur.
Note: If a valve drops into the cylinder, remove the
cylinder head. For additional information, refer to
Cylinder Head in this section.
Compressor, Valve
3.
Pressurize the cylinder using compressed air.
Spring
303-350 (T89P-6565-A)
4.
Using the Valve Spring Compressors, remove the
keys, retainer and spring.
Compressor, Valve
Spring
303-1249
Material
Installation
5.
To install, reverse the removal procedure.
Item
Specification
�
Lubricate the roller follower and hydraulic lash
Engine Oil IISAC GF-4 SAE
WSS-M2C930-A
adjuster assembly with clean engine oil prior
5W-20
to installation.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-88
REMOVAL AND INSTALLATION (Continued)
Valve Seals
1.
Remove the camshaft for the valve seal being
serviced. For additional information, refer to
Removal
Camshaft-RH and/or Camshaft-LH I in this
section.
Special Tool(s)
2.
Remove the roller follower and hydraulic lash
Compressor, Valve
adjuster assembly for the valve seal being
Spring
serviced.
303-1418
Note: If air pressure must be removed, support the
valve prior to removal or engine damage may occur.
Note: If a valve drops into the cylinder, remove the
cylinder head. For additional information, refer to
Cylinder Head in this section.
3.
Pressurize the cylinder using compressed air.
Compressor, Valve
Spring
4.
Using the Valve Spring Compressors, remove the
303-300 (T87C-6565-A)
keys, retainer and spring.
Compressor, Valve
Spring
303-350 (T89P-6565-A)
5.
Remove and discard the valve seal.
Compressor, Valve
Spring
303-1249
Material
Item
Specification
Engine Oil IISAC GF-4 SAE
WSS-M2C930-A
5W-20
Installation
Removal
1.
To install, reverse the removal procedure.
Notice: During engine repair procedures, cleanliness
�
Lubricate the valve seal and the roller follower
is extremely important. Any foreign material, including
and hydraulic lash adjuster assembly with
any material created while cleaning gasket surfaces,
clean engine oil prior to installation.
that enters the oil passages, coolant passages or the
oil pan, can cause engine failure.
Note: If the components are to be reinstalled, they
must be installed in their original locations. Mark
the components for installation into their original
locations.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-89
REMOVAL AND INSTALLATION (Continued)
Exhaust Manifold - RH
2
3
1
AUS07376
Item
Description
1
RH exhaust manifold bolts (early build coarse thread) (8 required)
1
RH exhaust manifold bolts (late build fine thread) (8 required)
2
RH exhaust manifold
3
RH exhaust manifold gasket
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-90
REMOVAL AND INSTALLATION (Continued)
Exhaust Manifold - RH
Installation
Note: Do not use metal scrapers, wire brushes,
Removal
power abrasive discs or other abrasive means
1.
Remove the Engine, transmission and subframe
to clean the sealing surfaces. These tools cause
assembly from the vehicle. For additional
scratches and gouges which make leak paths. Use a
information refer to Engine, Subframe and
plastic scraper to clean the sealing surfaces.
Transmission Assembly procedure in this section.
1.
Clean the exhaust manifold mating surface of the
2.
Disconnect the HEGO sensor electrical
cylinder head with metal surface prep. Follow the
connector and unscrew the HEGO sensor from
directions on the packaging.
the exhaust manifold.
Note: There are two types of exhaust manifold
bolts available for this engine, (coarse thread and
fine thread exhaust manifold bolts). Ensure that the
correct bolts are used prior to Installation.
2.
Install new gaskets, the RH exhaust manifold and
8 new bolts.
�
Tighten bolts in the sequence shown in 2
stages.
Stage 1: Tighten to 30 Nm.
n
Stage 2: Tighten to 45 Nm.
n
3
1
5
AUS08804
7
3.
Remove 8x exhaust manifold retaining bolts.
x8
6
4
2
8
AUS07347
3.
Install the HEGO sensor and torque to
specification. Connect the HEGO sensor
electrical connector.
AUS08801
�
Discard the gasket and bolts.
4.
Clean and inspect the RH exhaust manifold. For
additional information, refer to Section 303-00.
AUS08804
4.
Install the engine, transmission and subframe
assembly. For additional information refer to
Engine, Subframe and Transmission Assembly
procedure in this section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-91
REMOVAL AND INSTALLATION (Continued)
Exhaust Manifold -- LH
Material
Item
Specification
Metal Surface Cleaner F4A2-
WSE-M5B392-A
19A536-RA or equivalent
LH Exhaust Manifold
1
2
3
4
7
6
5
AUS07375
Item
Description
1
LH exhaust manifold gasket
2
LH exhaust manifold
3
LH exhaust manifold stud (early build coarse thread) (2 required)
3
LH exhaust manifold stud (late build fine thread) (2 required)
4
LH exhaust manifold heatshield nut (2 required)
5
LH exhaust manifold heatshield nut
6
LH exhaust manifold heatshield
7
LH exhaust manifold bolt (early build coarse thread) (6 required)
8
LH exhaust manifold bolt (late build fine thread) (6 required)
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-92
REMOVAL AND INSTALLATION (Continued)
Removal
Installation
Notice: Do not use metal scrapers, wire brushes,
1.
Remove the Engine, transmission and subframe
assembly from the vehicle. For additional
power abrasive discs or other abrasive means
information refer to Engine, Subframe and
to clean the sealing surfaces. These tools cause
Transmission Assembly procedure in this section.
scratches and gouges which make leak paths. Use a
plastic scraper to clean the sealing surfaces.
2.
Disconnect the HEGO sensor electrical
connector and unscrew the HEGO sensor from
1.
Clean the exhaust manifold mating surface of the
the exhaust manifold.
cylinder head with metal surface prep. Follow the
directions on the packaging.
Note: There are two types of exhaust manifold
bolts available for this engine, (coarse thread and
fine thread exhaust manifold bolts). Ensure that the
correct bolts are used prior to Installation.
2.
Install new gaskets, the LH exhaust manifold, 6
new bolts and 2 new studs.
�
Tighten bolts and studs in the sequence
shown in 2 stages.
Stage 1: Tighten to 30 Nm.
n
Stage 2: Tighten to 45 Nm.
n
AUS08803
7
1
5
3
3.
Remove 3x exhaust manifold heatshield nuts.
x3
6
8
4
2
AUS07346
3.
Install LH exhaust manifold heatshield.
�
Tighten the 2 M8 nuts to 25 Nm.
AUS08800
�
Tighten the M6 nut to 10 Nm.
4.
Remove 6x exhaust manifold retaining bolts and
2x retaining studs.
x3
x8
AUS08800
AUS08802
�
Discard the gasket and bolts.
5.
Clean and inspect the RH exhaust manifold. For
additional information, refer to Section 303-00.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-93
REMOVAL AND INSTALLATION (Continued)
4.
Install the HEGO sensor and torque to
specification. Connect the HEGO sensor
electrical connector.
AUS08803
5.
Install the engine, transmission and subframe
assembly. For additional information refer to
Engine, Subframe and Transmission Assembly
procedure in this section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-94
REMOVAL AND INSTALLATION (Continued)
Engine Lubrication Components - Overview
Oil Pan
1
2
4
3
Item
Description
AUS07353
1
Oil pan baffle and gasket
2
Oil drain plug
3
Oil pan bolt (16 required)
4
Oil pan
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-95
REMOVAL AND INSTALLATION (Continued)
Oil Pump, Oil Filter Adapter, Oil Pump Screen and Pickup Tube and Oil Level Indicator and
Tube
17
15
16
14
18
19
9
10
8
11
7
3
5
6
4
2
13
1
12
AUS07349
Item
Description
1
Oil pump
2
Oil pump bolt (2 required)
3
Oil pump stud bolt (2 required)
4
Oil filter
5
Oil cooler
6
Oil cooler adapter
7
Oil cooler adapter gasket (2 required)
8
Oil temperature sensor
9
Oil pressure switch
10
Oil cooler adapter bracket
11
Oil cooler adapter bracket bolt
12
Oil cooler adapter bolt
13
Oil cooler adapter bolt (3 required)
14
Oil pump screen and pickup tube spacer
15
Oil pump screen and pickup tube bolt
16
Oil pump screen and pickup tube
17
Oil pump screen and pickup tube bolt (2 required)
18
Oil indicator
19
Oil indicator tube
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-96
REMOVAL AND INSTALLATION (Continued)
Oil Filter Adapter
Removal
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.
1.
Remove the oil pan drain plug and drain the
engine oil.
2.
Remove the engine. For additional information
refer to Engine removal procedure in this section.
AUS08830
3.
Mount the engine on engine stand.
4.
Remove and discard the oil filter.
Installation
5.
Remove the engine oil cooler. For additional
1.
Install the Engine oil pressure switch and the
information, refer to section 303-03A of the 2010
Engine oil temperature sensor.
FPV 5.0L 4V Ti-VCT V8 Supplement.
�
Torque them to 16 Nm.
6.
Disconnect the engine oil temperature sensor
Note: Install a new oil filter adapter gasket and
and engine oil pressure switch, electrical
replace all `O'- rings.
connectors.
2.
Install the oil filter adaptor to the engine.
�
Torque bolts 1,2,3 to 30 Nm.
�
Torque bolt 4 to 45 Nm.
�
Torque bolt 5 to 12 Nm.
1
5
4
AUS08806
2
7.
Remove the 5x bolts and remove the oil filter
adaptor.
3
AUS08829
3.
To install, reverse the removal procedure.
AUS08805
�
Discard the gasket and `O'- rings.
8.
Remove Engine oil temperature sensor and oil
pressure switch from the oil filter adaptor.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-97
REMOVAL AND INSTALLATION (Continued)
Oil Pan
5.
Remove the 3 bolts and the oil pump screen and
pickup tube.
Material
�
Remove and discard the O-ring seal.
Item
Specification
Silicone Gasket and Sealant
WSE-M4G323-A4
F7AZ-19554-EA or Loctite
5900 or equivalent
x2
Metal Surface Cleaner F4A2-
WSE-M5B392-A
19A536-RA or equivalent
Engine Oil IISAC GF-4 SAE 5W- WSS-M2C930-A
20
Motorcraft� Silicone Gasket
--
Remover ZC-30
Removal
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.
1.
Disconnect the battery negative terminal. For
additional information, refer to section 414-01 of
the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement..
2.
Remove the oil pan drain plug and drain the
x1
engine oil and refit the drain plug.
3.
Remove the engine. For additional information
refer to Engine procedure in this section.
4.
Remove the oil pan from the Engine.
�
Remove the 16 bolts and the oil pan.
AUS08832
6.
Remove and inspect the oil pan baffle and
gasket.
AUS08831
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-98
REMOVAL AND INSTALLATION (Continued)
Installation
1.
Apply an 8 mm bead of silicone Gasket and
sealant to the crankshaft rear seal retainer plate-
Note: Replace the oil pan gasket, install new `O'-ring
to-cylinder block sealing surfaces and the engine
seals for the oil pick up tube.
front cover-to- cylinder block sealing surfaces.
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: Failure to use silicone Gasket and sealant
may cause the engine oil to foam excessively and
result in serious engine damage.
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 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.
AUS08833
2.
Position the oil pan baffle and gasket.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-99
REMOVAL AND INSTALLATION (Continued)
Note: The 2 oil pump screen and pickup tube-to-oil
4.
Install the oil pan hand tight the bolts and torque
the bolts in two sequence.
pump bolts must be tightened prior to tightening the
oil pump screen and pickup tube-to-spacer bolt.
�
Stage 1: Tighten to 12 Nm.
3.
Using a new O-ring seal, install the oil pump
�
Stage 2: Tighten to 12 Nm.
.screen and pickup tube and the 3 bolts.
28
27
�
Tighten the 2 oil pump screen and pickup
tube-to-oil pump bolts to 12 Nm.
11
12
�
Tighten the oil pump screen and pickup tube-
to-spacer bolt to 30 Nm.
14
16
�
the bracket holding bolt to 30 Nm.
13
15
3
2
18
1
17
2
20
19
4
3
1
22
6
21
5
24
8
23
7
9
10
26
25
AUS07348
Note: Make sure that the engine oil drain plug is
installed.
5.
Fill the Engine with clean engine oil.
6.
Install engine to the subframe. For additional
information refer Engine subframe procedure in
AUS08834
this section.
7.
Install the Engine/subframe assembly to the
vehicle. For additional information refer Engine
installtion procedure in this section.
8.
Connect the battery negative terminal. For
additional information, refer to section 414-01 of
the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-100
REMOVAL AND INSTALLATION (Continued)
Oil Pump Screen and Pickup Tube
Removal
1.
The oil pump screen and pickup tube is part
of the oil pan/gasket procedure. For additional
information refer Oil pan procedure in this
section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-101
REMOVAL AND INSTALLATION (Continued)
Oil Pump
Installation
1.
Rotate the inner rotor of the oil pump assembly
Removal
to align the flats on the crankshaft and slip the oil
Note: During engine repair procedures, cleanliness
pump over the crankshaft until seated against the
is extremely important. Any foreign material, including
block.
any material created while cleaning gasket surfaces,
�
Rotate the oil pump until the bolt holes are
that enters the oil passages, coolant passages or the
aligned to the block and install the fasteners.
oil pan, can cause engine failure.
2. Note: Oil pump must be held against the cylinder
1.
Disconnect the battery negative terminal. For
block until all bolts are tightened.
additional information, refer to section 414-01 of
Tighten the fasteners in the sequence shown in 3
the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
stages:
2.
Remove the engine front cover. For additional
�
Stage 1: Hand tighten.
information, refer to Engine Front Cover in this
section.
�
Stage 2: Tighten the bolt (1) to 10 Nm, the
stud bolt (2) to 25 Nm, the bolt (3) to 10 Nm
3.
Remove the timing chains (RH & LH) at the
and the stud bolt (4) to 20 Nm.
crankshaft end. For additional information, refer
to Timing drive components in this section.
�
Stage 3: Tighten the bolt (1) an additional
45 degrees, the stud bolt (2) an additional
4.
Remove the oil pan. For additional information,
75 degrees, the bolt (3) an additional 45
refer to Oil Pan procedure in this section.
degrees and the stud bolt (4) an additional
5.
Remove the 2 bolts, the 2 stud bolts and the oil
60 degrees.
pump.
3.
Install the oil pan. For additional information, refer
to Oil Pan procedure in this section.
4.
Install the timing chains (RH & LH). For additional
information, refer to Timing drive components in
this section.
5.
Install the engine front cover. For additional
information, refer to Engine Front Cover in this
section.
6.
Connect the battery negative terminal. For
additional information, refer to section 414-01 of
the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-102
REMOVAL AND INSTALLATION (Continued)
Oil Level Indicator and Tube
Removal
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.
1.
Remove the oil level indicator tube.
�
Remove the retaining bolt on the throttle
body bracket.
�
Remove the 2 retaining nuts on the Valve
cover.
AUS08789
2.
Remove the LH valve cover. For additional
information, refer to Valve Cover - LH in this
section.
3.
Remove the oil level indicator tube from the LH
valve cover.
Installation
1.
To install, reverse the removal procedure.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-103
REMOVAL AND INSTALLATION (Continued)
Flexplate or Flywheel and Crankshaft Rear Seal -- Exploded View
8
7
6
1
5
4
2
3
AUS07374
Item
Description
1
Crankshaft rear seal retainer plate
2
Crankshaft rear seal
3
Crankshaft sensor ring
4
Flexplate/Flywheel bolt (8 required)
5
Flexplate/Flywheel
6
Separator plate
7
Crankshaft rear seal retainer plate bolt (6 required)
8
Crankshaft Position (CKP) sensor
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-104
REMOVAL AND INSTALLATION (Continued)
Flexplate
Flywheel
Removal
Removal
Special Tool(s)
Special Tool(s)
Vehicle Communication
Vehicle Communication
Module (VCM) and
Module (VCM) and
Integrated Diagnostic
Integrated Diagnostic
System (IDS) software
System (IDS) software
with appropriate
with appropriate
hardware,or equivalent
hardware,or equivalent
scan tool
scan tool
1.
Remove the transmission. For additional
1.
Remove the clutch. For additional information,
information, refer to Section 307-01 of the FG
refer to Section 308-01 of the FG Falcon
Falcon Workshop Manual.
Workshop Manual.
Note: The flexplate bolts are torque-to-yield design
Note: The flywheel bolts are torque-to-yield design
and are not reusable.
and are not reusable.
2.
Remove the 8 bolts and the flexplate.
2.
Remove the 8 bolts and the flywheel.
�
Discard the bolts.
�
Discard the bolts.
�
To install, tighten in the sequence shown in 2
�
To install, tighten in the sequence shown in 2
stages.
stages.
Stage 1: Tighten to 20 Nm.
Stage 1: Tighten to 20 Nm.
n
n
Stage 2: Tighten an additional 60
Stage 2: Tighten an additional 60
n
n
degrees.
degrees.
Installation
Installation
1.
Installation is reversal of the removal procedure.
1.
Installation is reversal of the removal procedure
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-105
REMOVAL AND INSTALLATION (Continued)
Crankshaft Rear Seal
Removal
1.
With the vehicle in NEUTRAL, position it on a
Removal
hoist. For additional information, refer to Section
Special Tool(s)
100-02.
Handle
2.
Remove the flywheel or flexplate. For additional
205-153 (T80T-4000-W)
information, refer to Flexplate or Flywheel
procedure in this section.
3.
Remove the engine separator plate.
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.
Installer, Rear Main Seal
4.
Remove the crankshaft sensor ring.
303-1250
5.
Using the Slide Hammer and the Crankshaft
Rear Oil Seal Remover, remove and discard the
crankshaft rear seal.
�
Clean all sealing surfaces with metal surface
prep.
Remover, Crankshaft
Rear Oil Seal
303-519 (T95P-6701-
EH)
Slide Hammer
100-001 (T50T-100-A)
Material
Item
Specification
Metal Surface Cleaner F4A2-
WSE-M5B392-A
19A536-RA or equivalent
Engine Oil IISAC GF-4 SAE
WSS-M2C930-A
5W-20
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-106
REMOVAL AND INSTALLATION (Continued)
Installation
Note: Lubricate the seal lips and bore with clean
engine oil prior to installation.
1.
Position the Rear Main Seal Installer onto the end
of the crankshaft and slide a new crankshaft rear
seal onto the tool.
2.
Using the Rear Main Seal Installer and Handle,
install the new crankshaft rear seal.
3.
Install the crankshaft sensor ring.
4.
Install the engine separator plate.
5.
Install the flywheel or flexplate. For additional
information, refer to Flexplate or Flywheel
procedure in this section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-107
REMOVAL AND INSTALLATION (Continued)
Crankshaft Rear Seal with Retainer Plate
1.
Remove the flywheel or flexplate. For additional
information, refer to Flexplate or Flywheel
Removal
procedure in this section.
2.
Remove the engine separator plate.
Special Tool(s)
Handle
Note: Inspect the crankshaft sensor ring for
205-153 (T80T-4000-W)
damage. If the crankshaft sensor ring has been
dropped or has any visual damage, it must be
discarded.
3.
Remove the crankshaft sensor ring.
All vehicles
4.
Remove the oil pan. For additional information,
refer to Oil Pan procedure in this section.
Installer, Rear Main Seal
5.
Disconnect the Crankshaft Position (CKP) sensor
303-1250
electrical connector.
6.
Remove the bolt and the CKP sensor.
Remover, Crankshaft
Rear Oil Seal
303-519 (T95P-6701-
EH)
Slide Hammer
100-001 (T50T-100-A)
Material
Item
Specification
Silicone Gasket and Sealant
WSE-M4G323-A4
F7AZ-19554-EA or Loctite
5900 or equivalent
Metal Surface Cleaner F4A2-
WSE-M5B392-A
19A536-RA or equivalent
Engine Oil IISAC GF-4 SAE
WSS-M2C930-A
5W-20
Motorcraft� Silicone Gasket
--
Remover ZC-30
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-108
REMOVAL AND INSTALLATION (Continued)
Installation
7.
Using the Slide Hammer and the Crankshaft
Rear Oil Seal Remover, remove and discard the
All vehicles
crankshaft rear seal.
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.
Note: Clean the sealing surfaces with silicone
gasket remover and metal surface prep. Follow the
directions on the packaging.
1.
Clean and inspect the mating surface.
Note: Failure to use silicone Gasket and sealant
may cause the engine oil to foam excessively and
result in serious engine damage.
Note: If the rear crankshaft seal retaining plate is
8.
Remove the 6 bolts and the crankshaft rear seal
not secured within 4 minutes, the sealant must be
retainer plate.
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.
2.
Apply a 3.75 mm bead of silicone Gasket and
sealant to the rear crankshaft seal retainer
mating surface on the engine block.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-109
REMOVAL AND INSTALLATION (Continued)
Note: The Crankshaft Position (CKP) sensor must
3.
Install the crankshaft rear seal retainer plate and
the 6 bolts, tighten in the sequence shown in 2
be positioned into the fitting on the crankshaft rear
stages.
seal retainer plate and be flush against the boss on
the engine block before the bolt is installed. If the
�
Stage 1: Tighten to 12 Nm.
CKP sensor is installed incorrectly, the CKP sensor
can be damaged.
�
Stage 2: Tighten an additional 45 degrees.
6.
Position the CKP sensor and install the bolt.
�
Tighten to 12 Nm.
Note: Lubricate the seal lips and bore with clean
engine oil prior to installation.
4.
Position the Rear Main Seal Installer onto the end
of the crankshaft and slide a new crankshaft rear
seal onto the tool.
7.
Connect the CKP sensor electrical connector.
8.
Install the oil pan. For additional information, refer
5.
Using the Rear Main Seal Installer and Handle,
to Oil Pan procedure in this section.
install the new crankshaft rear seal.
9.
Install the crankshaft sensor ring.
10. Install the engine separator plate.
11. Install the flywheel or flexplate. For additional
information, refer to Flexplate or Flywheel
procedure in this section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-110
REMOVAL AND INSTALLATION (Continued)
Engine Mounts
Special Tool(s)
Special Tool(s)
Lifting Bracket, Engine
303-050 (T70P-6000)
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-111
REMOVAL AND INSTALLATION (Continued)
RH Engine Mounts
2
1
3
4
5
AUS07377
Item
Description
1
RH engine support insulator bolt
2
RH engine support insulator
3
RH engine support insulator bracket
4
RH engine support insulator bracket bolt (2 required)
5
RH engine support insulator bracket bolt (1 required)
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-112
REMOVAL AND INSTALLATION (Continued)
LH Engine Mounts
2
1
3
4
8
7
5
6
AUS07378
Item
Description
1
LH engine mount bracket
2
LH engine mount bracket bolt (3 required)
3
LH engine mount bolt
4
LH engine mount
5
LH exhaust manifold heatshield
6
LH exhaust manifold heatshield nut
7
LH exhaust manifold heatshield stud
8
Oil cooler adapter bracket
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-113
REMOVAL AND INSTALLATION (Continued)
LH and/or RH engine mounts
Removal
1.
Remove the engine. For additional information,
refer to the Engine removal procedure in this
section.
2.
Remove the LH upper engine mount bolt.
AUS08882
3.
Remove the RH upper engine mount bolt and
remove the engine mount.
AUS08883
Installation
1.
Install the LH/RH engine mount and upper engine
mount bolt and torque to 50 Nm.
2.
Install the engine. For additional information, refer
to the Engine removal procedure in this section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-114
REMOVAL AND INSTALLATION (Continued)
Cylinder Head
Item
Specification
Removal
Metal Surface Cleaner F4A2-
WSE-M5B392-A
19A536-RA or equivalent
Special Tool(s)
Motorcraft� Silicone Gasket
3 Jaw Puller
Remover
_
303-D121 or equivalent
ZC-30
Handle
205-153 (T80T-4000-W)
Holding Tool, Crankshaft
303-448 (T93P-6303-A)
Installer, Differential
Bearing Cone
205-142 (T80T-4000-J)
Remover, Oil Seal
303-409 (T92C-6700-
CH)
Remover, Spark Plug
Tube Seal
303-1247/1
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-115
REMOVAL AND INSTALLATION (Continued)
Removal
LH cylinder head
11. Remove the 16 camshaft roller follower and
Note: During engine repair procedures, cleanliness
hydraulic lash adjuster assemblies on LH cylinder
is extremely important. Any foreign material, including
head.
any material created while cleaning gasket surfaces,
that enters the oil passages, coolant passages or the
oil pan, can cause engine failure.
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.
All cylinder heads
1.
Disconnect the battery negative terminal. For
additional information, refer to section 414-01 of
the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
2.
Remove the engine, subframe and transmission
assembly. For additional information, refer to
Engine removal procedure.
3.
Disconnect engine compartment wiring electrical
connectors and remove the wiring harness from
CAUTION
the engine. For additional information, refer to
The cylinder head must be cool before
Engine Accessories in this section.
removing it from the engine. Cylinder head warpage
Note: RH shown, LH similar.
can result if a warm or hot cylinder head is removed.
4.
Disconnect the 8 ignition coil electrical
Place clean shop towels over exposed engine
connectors and remove ignition coils.
cavities. Carefully remove the towels so foreign
material is not dropped into the engine.
The cylinder head bolts must be discarded
and new bolts must be installed. They are a tighten-
to-yield design and cannot be reused.
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.
Aluminium surfaces are soft and can be
scratched easily. Never place the cylinder head
gasket surface, unprotected, on a bench surface.
5.
Remove the supercharger and intake manifold
assembly. For additional information, refer to
12. Remove 10 bolts from the LH cylinder head and
Intake Manifold in this section.
remove the cylinder head.
6.
Remove LH or RH valve cover. For additional
�
Discard the bolts and the head gasket.
information, refer to LH and RH Valve cover
Procedure in this section.
7.
Remove coolant pump. For additional
information, refer to section 303-03A of the 2010
0
x1
FPV 5.0L 4V Ti-VCT V8 Supplement.
8.
Remove the engine front cover. For additional
information, refer to Engine Front cover
procedure in this section.
9.
Remove camshafts from the cylinder head(s).
For additional information, refer to RH & LH
camshafts procedure in this section.
10. Remove RH or LH Exhaust manifold. For
additional information, refer to RH & LH Exhaust
AUS08835
manifold procedure in this section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-116
REMOVAL AND INSTALLATION (Continued)
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 Notes 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.
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 per running
foot length. For example, if the straightedge is 61 cm
long, the machined edge must be flat within 0.010
mm 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 Section 303-00 of the FG Falcon
Workshop Manual.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-117
REMOVAL AND INSTALLATION (Continued)
RH cylinder head
Note: Do not use metal scrapers, wire brushes,
power abrasive discs or other abrasive means
15. Remove the 16 camshaft roller follower and
to clean the sealing surfaces. These tools cause
hydraulic lash adjuster assemblies on LH cylinder
scratches and gouges that make leak paths. Use a
head.
plastic scraping tool to remove all traces of the head
gasket.
Note: Observe all warnings or Notes 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
CAUTION
directions and allow to set for several minutes.
The cylinder head must be cool before
3.
Remove the silicone gasket remover with a
removing it from the engine. Cylinder head warpage
plastic scraper. A second application of silicone
can result if a warm or hot cylinder head is removed.
gasket remover may be required if residual
traces of silicone or gasket material remain.
Place clean shop towels over exposed engine
4.
Apply metal surface prep, following package
cavities. Carefully remove the towels so foreign
directions, to remove any remaining traces of oil
material is not dropped into the engine.
or coolant and to prepare the surfaces to bond
The cylinder head bolts must be discarded
with the new gasket. Do not attempt to make the
and new bolts must be installed. They are a tighten-
metal shiny. Some staining of the metal surfaces
to-yield design and cannot be reused.
is normal.
Note: Make sure all cylinder head surfaces are clear
Do not use metal scrapers, wire brushes,
of any gasket material, RTV, oil and coolant. The
power abrasive discs or other abrasive means
cylinder head surface must be clean and dry before
to clean the sealing surfaces. These tools cause
running a flatness check.
scratches and gouges that make leak paths. Use a
plastic scraping tool to remove all traces of the head
Note: Use a straightedge that is calibrated by the
gasket.
manufacturer to be flat within 0.005 mm per running
foot length. For example, if the straightedge is 61 cm
Aluminium surfaces are soft and can be
long, the machined edge must be flat within 0.010
scratched easily. Never place the cylinder head
mm from end to end.
gasket surface, unprotected, on a bench surface.
Support the cylinder head on a bench with the head
16. Remove 10 bolts from the LH cylinder head and
gasket side up. Check the cylinder head distortion
remove the cylinder head.
and the cylinder block distortion, paying particular
attention to the oil pressure feed area. For additional
�
Discard the bolts and the head gasket.
information, refer to Section 303-00 of the FG Falcon
Workshop Manual.
0
x1
AUS08836
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-118
REMOVAL AND INSTALLATION (Continued)
Installation
Note: Do not use metal scrapers,wire brushes,
power abrasive discs or other abrasive means
Note: Make sure all coolant residue and foreign
to clean the sealing surfaces. These tools cause
material are cleaned from the block surface and
scratches and gouges which make leak paths. Use a
cylinder bore. Failure to follow these instructions may
plastic scraper to clean the sealing surfaces.
result in engine damage.
Clean the exhaust manifold mating surface of the
Note: The use of sealing aids (aviation cement,
cylinder head with metal surface prep. Follow the
copper spray and glue) is not permitted. The
directions on the packaging.
gasket must be installed dry. Failure to follow these
instructions may result in future oil leakage.
Note: The cylinder head bolts must be discarded
RH cylinder head
and new bolts installed. They are a tighten-to-yield
1.
Using the Cylinder Head Alignment Pins, position
design and cannot be reused.
the cylinder head gaskets and cylinder heads
Note: Do not turn the crankshaft until instructed to
over the dowels and install the cylinder head
bolts loosely.
do so.
LH cylinder head
1.
Using the Cylinder Head Alignment Pins, position
the cylinder head gaskets and cylinder heads
over the dowels and install the cylinder head
bolts loosely.
2.
Tighten the new RH cylinder head bolts in 4
stages in the sequence shown.
�
Stage 1: Tighten to 25 Nm.
�
Stage 2: Tighten to 40 Nm.
�
Stage 3: Tighten an additional 90 degrees.
2.
Tighten the new RH cylinder head bolts in 4
stages in the sequence shown.
�
Stage 4: Tighten an additional 90 degrees.
�
Stage 1: Tighten to 25 Nm.
�
Stage 2: Tighten to 40 Nm.
2
6
4
10
8
�
Stage 3: Tighten an additional 90 degrees.
�
Stage 4: Tighten an additional 90 degrees.
3
1
7
9
5
5
9
1
3
7
AUS08838
10
4
2
6
8
AUS08837
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-119
REMOVAL AND INSTALLATION (Continued)
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.
All cylinder heads
1.
Install the RH or LH Exhaust manifold. For
additional information, refer to RH & LH Exhaust
manifold procedure in this section.
2.
Install the camshafts. For additional information,
refer to RH & LH camshafts procedure in this
section.
3.
Install the engine front cover. For additional
information, refer to Engine Front cover
procedure in this section.
4.
Install the coolant pump. For additional
information, refer to section 303-03A of the 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
5.
Install the LH or RH valve cover. For additional
information, refer to LH and RH Valve cover
Procedure in this section.
6.
Install the supercharger and intake manifold
assembly. For additional information, refer to
section 303-04E of the 2010 FPV 5.0L 4V Ti-VCT
V8 Supplement.
7.
Install the ignition coils and Connect the electrical
connectors. For additional information, refer to
303-07B of the 2010 FPV 5.0L 4V Ti-VCT V8
Supplement.
8.
Install the engine compartment wiring harness
to the engine and connect engine compartment
wiring electrical connectors. For additional
information, refer to Engine Accessories in this
section.
9.
Install the engine, subframe and transmission
assembly. For additional information, refer to
Engine, subframe and transmission assembly
installation procedure in this section.
10. Connect the battery negative terminal. For
additional information, refer to section 414-01 of
the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-120
REMOVAL AND INSTALLATION (Continued)
Engine, Subframe and Transmission
For All Vehicles
Assembly
6.
Recover the air conditioning (A/C) System
refrigerant. For additional information, refer to
Removal
section 412-00 of the FG Falcon workshop
manual.
General Workshop Tool(s)
AU-687
7.
Drain the engine coolant. For additional
AU-687
information, refer to Section 303-03A of the 2010
Front and Rear Sub
FPV 5.0L 4V Ti-VCT V8 Supplement.
Frame/Engine and
Transmission support
8.
Remove the air cleaner assembly and intake
cradle.
duct. For additional information, refer to Section
303-12 of the 2010 FPV 5.0L 4V Ti-VCT V8
Supplement.
AUS07065
9.
Disconnect the brake booster vacuum hose from
the brake booster.
WARNING
Do not smoke, carry lighted tobacco or have
an open flame of any type when working on or
near any fuel-related component. Highly flammable
mixtures are always present and may be ignited.
Failure to follow these instructions may result in
serious personal injury.
WARNING
Before working on or disconnecting any of the
fuel tubes or fuel system components, relieve
the fuel system pressure to prevent accidental
spraying of fuel. Fuel in the fuel system remains under
AUS08693
high pressure, even when the engine is not running.
Failure to follow this instruction may result in serious
10. Disconnect the heater inlet/outlet hoses from the
personal injury.
heater inlet/outlet pipes at the rear of the engine.
1.
Release the system fuel pressure. For additional
information, refer to Section 303-04D of 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
2.
Remove the battery and battery tray. For
additional information, refer to Section 414-01B of
the 2010 FPV 5.0L 4V Ti-VCT V8 supplement.
For Vehicles with Manual Transmission
3.
Disconnect the hydraulic clutch line from the
firewall. Retain the metal clip. For additional
information, refer to Section 501-12 of the FG
Falcon Workshop Manual.
4.
Remove the centre console. For additional
AUS08815
information, refer to Section 501-12 of the FG
Falcon Workshop Manual.
5.
Remove the 2 nuts retaining the gear shift
lever assembly to the transmission stub lever
assembly, and disengage the stub lever.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-121
REMOVAL AND INSTALLATION (Continued)
11. Disconnect the supercharger boost vacuum
13. Remove electrical power supply cables at engine
hoses from the intake manifold and supercharger
compartment fuse box.
actuator.
�
Remove the alternator and battery cable
retaining nuts from the fusebox, and
disconnect the wiring.
�
Disconnect the electrical connector from the
fusebox
�
Remove the bolt and nut from the battery
positive cable and disconnect the wiring.
�
Release the wiring harness from the 2x wiring
harness retaining clips on the fusebox.
AUS08692
12. Remove the 2 bolts retaining the coolant
expansion tank and position on top of the intake
manifold. For additional information, refer to
Section 303-03A of 2010 FPV 5.0L 4V Ti-VCT V8
Supplement.
AUS08816
x2
14. Remove the wiring harness retaining clip from the
battery tray.
AUS06719
AUS08813
15. Remove the wiring harness retaining clip from the
body, below the battery tray.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-122
REMOVAL AND INSTALLATION (Continued)
16. Remove the A/C suction hose assembly nut
21. Release the fuel evaporator hose running across
from the pad fittings on the side of the dual tube
rear of LH valve cover, splitting it in 2 parts.
assembly. Reposition the suction hose.
AUS08695
AUS08756
22. Remove the nut from the fuel line retaining clamp
17. Remove the PCM and disconnect the main
on the LH valve cover and release the fuel lines,
wiring loom wiring connector. For additional
positioning them out of the way.
information, refer to Section 303-14B of the 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
18. Remove the throttle body. For additional
information, refer to Section 303-04D of the 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
19. Remove the Throttle body bracket retaining bolts
and remove the bracket.
x4
AUS08784
23. Raise the vehicle. For additional information, refer
to Section 100-02 of the FG Falcon Workshop
Manual.
24. Remove the front wheels. For additional
information, refer to Section 204-04 of the FG
Falcon Workshop Manual.
AUS08778
25. Remove the earth strap retaining bolt from the
20. Push in and remove the active exhaust valve
RH body rail.
vacuum hose from the supercharger intake
snorkel.
AUS08820
AUS08731
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-123
REMOVAL AND INSTALLATION (Continued)
Note: Support the calliper with a wire to avoid
26. Remove the nut attaching the liquid line pad
fitting to the bottom of the condenser. Carefully
damaging the calliper or the hose.
separate the A/C line from the condenser pad
32. Remove the brake calliper retaining bolts and
fitting.
position the calliper out of the way. For additional
information, refer to section 206-03 of the FG
Falcon Workshop Manual.
33. Remove the LH and RH brake discs. For
additional information, refer to section 206-03 of
the FG Falcon Workshop Manual.
Note: Ensure that the area around the ABS sensor is
clean so that no dirt or foreign objects can enter the
ABS sensor hole in the end cap of the hub unit.
34. Remove the bolt securing the ABS sensor to the
hub unit, and place the sensor out of the way. For
additional information, refer to section 206-03 of
the FG Falcon Workshop Manual.
AUS08755
35. Disconnect the LH and RH front upper control
arm balljoint stud from the spindles. For additional
27. Remove the LH and RH lower radiator support
information, refer to Section 204-01 of the FG
brackets.
Falcon Workshop Manual.
�
Remove the lower LH and RH radiator
36. Remove the LH and RH lower shock absorber
support bracket retaining bolts.
mounting bolts.
�
Remove the lower LH and RH radiator
37. Remove the bolt from the clamp at the lower end
support bracket through bolts and nuts.
of the intermediate shaft.
Note: Right hand shown, left hand similar.
AUS06705
AUS08817
38. Position a suitable subframe, engine and
28. Remove the LH and RH catalytic converters. For
transmission support tool below the subframe
additional information, refer to Section 309-00B
and carefully lower the vehicle on to the support
of the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
tool.
For Vehicles with Automatic Transmission
39. Secure the subframe, engine and transmission
assembly to the support tool.
29. Loosen the gearshift linkage shield retaining nuts
and remove the shield.
30. Remove the nut from the selector shaft and
disconnect the gearshift selector cable from the
selector shaft.
For All Vehicles
31. Remove the driveshaft. For additional information,
refer to section 205-01 of the FG Falcon
Workshop Manual.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-124
REMOVAL AND INSTALLATION (Continued)
40. Remove the transmission cross member bolts,
4.
With the transmission support insulator
and remove the cross member.
neutralized, tighten the transmission
crossmember to floor pan bolts to 63 Nm.
5.
Remove the restraints holding the engine,
subframe and transmission assembly to the
subframe support tool.
6.
Raise the vehicle. For additional information, refer
to Section 100-02 of the FG Falcon Workshop
Manual.
7.
Align the steering intermediate shaft with the
steering gear and insert the clamp bolt.
�
Tighten the clamp bolt to 22Nm.
8.
Insert the LH and RH lower shock absorber
mounting bolts.
AUS08819
�
Tighten to 80 Nm
41. Undo the subframe mounting nuts.
9.
Connect the LH and RH front upper control arm
balljoint stud with the spindles. For additional
information, refer to Section 204-01 of the FG
Falcon Workshop Manual.
10. Install the ABS sensor.
�
Tighten the ABS sensor retaining bolt to 9 Nm.
11. Install the LH and RH brake discs. For additional
information, refer to section 206-03 of the FG
Falcon Workshop Manual.
12. Install the brake calliper and the brake calliper
retaining bolts. For additional information, refer
to section 206-03 of the FG Falcon Workshop
AUS08818
Manual.
13. Install the driveshaft. For additional information,
42. Move the engine and subframe assembly
refer to section 205-01 of the FG Falcon
forwards to ensure that the steering intermediate
Workshop Manual.
shaft is free from the steering rack.
For Vehicles with Automatic Transmission
43. Slowly raise the vehicle until the subframe,
transmission and engine assembly are clear of
14. Install the gearshift selector cable and gearshift
the body.
selector cable retaining nut.
Installation
15. Install the gearshift linkage shield and gear linkage
Note: Ensure that the steering intermediate shaft
shield retaining nuts.
is properly engaged with the steering gear during
For All Vehicles
installation of the engine, transmission and subframe
assembly.
16. Install the LH and RH catalytic converters. For
additional information, refer to Section 309-00B
1.
Position the engine. subframe and transmission
of the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
assembly on the support tool beneath the
vehicle.
17. Install the LH and RH lower radiator support
brackets and bolts.
CAUTION
�
Tighten the lower LH and RH radiator support
bracket through bolts and nuts to 30 Nm.
Whilst lowering the vehicle, use extreme care
to ensure that excess load is not applied to any
�
Tighten the lower LH and RH radiator support
component due to misalignment.
bracket retaining bolts to 18Nm.
2.
Slowly lower the vehicle onto the subframe,
ensuring that the steering intermediate shaft
aligns correctly with the steering rack.
3.
Tighten the subframe mounting nuts to 300 Nm.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-125
REMOVAL AND INSTALLATION (Continued)
Note: Ensure that new O-Rings and slimline washers
�
Install the alternator and battery cable wiring
and retaining nuts to the fusebox.
meeting Ford specifications are installed prior to re-
assembly of A/C components.
�
Connect the electrical connector to the
Note: Lubricate the A/C O-ring seals and slimline
fusebox
washers with PAG Compressor Oil Valeo ZXL 100PG
�
Install the wiring and nut to the battery
prior to assembly.
positive cable.
18. Install the liquid line pad fitting to the bottom of
�
Install the wiring harness to the 2x wiring
the condenser. Tighten the nut to 15 Nm.
harness retaining clips on the fusebox.
19. Install the earth strap retaining bolt from the RH
32. Install the coolant expansion tank and the 2
body rail.
retaining bolts. For additional information, refer to
Section 303-03A of 2010 FPV 5.0L 4V Ti-VCT V8
20. Install the front wheels. For additional information,
Supplement.
refer to Section 204-04 of the FG Falcon
Workshop Manual.
33. Connect the supercharger boost vacuum hoses
to the intake manifold and supercharger actuator.
21. Lower the vehicle. For additional information,
refer to Section 100-02 of the FG Falcon
34. Connect the heater inlet/outlet hoses to the
Workshop Manual.
heater inlet/outlet pipes at the rear of the engine.
22. Position the fuel lines in the fuel line retaining
35. Connect the brake booster vacuum hose to the
clamp on the LH valve cover, and Install the fuel
brake booster.
line retaining clamp nut.
36. Install the air cleaner assembly and intake duct.
23. Connect the fuel evaporator hose running across
For additional information, refer to Section 303-12
rear of LH valve cover.
of the 2010 FPV 5.0L 4V Ti-VCT V8 Supplement.
24. Install the active exhaust valve vacuum hose to
For Vehicles with Manual Transmission
the supercharger intake snorkel.
37. Install the hydraulic clutch line. For additional
25. Install the throttle body bracket and retaining
information, refer to Section 501-12 of the FG
bolts.
Falcon Workshop Manual.
26. Install the throttle body. For additional information,
38. Install the 2 nuts retaining the gear shift lever
refer to Section 303-04D of the 2010 FPV 5.0L
assembly to the transmission stub lever
4V Ti-VCT V8 Supplement.
assembly.
27. Install the PCM and connect the main wiring loom
39. Install the centre console. For additional
wiring connector. For additional information, refer
information, refer to Section 501-12 of the FG
to Section 303-14B of the 2010 FPV 5.0L 4V Ti-
Falcon Workshop Manual.
VCT V8 Supplement.
40. Bleed the clutch system. For additional
Note: Ensure that new O-Rings and slimline washers
information, refer to Section 308-02 of the FG
meeting Ford specifications are installed prior to re-
Falcon Workshop Manual.
assembly of A/C components.
For All Vehicles
Note: Lubricate the A/C O-ring seals and slimline
washers with PAG Compressor Oil Valeo ZXL 100PG
41. Install the battery and battery tray. For additional
prior to assembly.
information, refer to Section 414-01B of the 2010
FPV 5.0L 4V Ti-VCT V8 supplement.
28. Install the A/C suction hose assembly to the pad
fittings on the side of the dual tube assembly.
42. Recharge the Air Conditioning (A/C) System
Tighten the nut to 15 Nm.
refrigerant. For additional information, refer to
section 412-00 of the FG Falcon workshop
29. Install the wiring harness retaining clip to the
manual.
body, below the battery tray.
43. Fill and bleed the cooling system. For additional
30. Install the wiring harness retaining clip to the
information, refer to Section 303-03A of the 2010
battery tray.
FPV 5.0L 4V Ti-VCT V8 Supplement.
31. Install the electrical power supply cables at
engine compartment fuse box.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-126
REMOVAL AND INSTALLATION (Continued)
Engine
3.
Release the alternator wiring retaining clips from
the front of the subframe.
Removal
Special Tool(s)
303-050
Lifting Bracket, Engine
General Workshop Tool(s)
AU-687
AU-687
Front and Rear Sub
AUS08822
Frame/Engine and
4.
Remove the bolt retaining the transmission
Transmission support
cooler line bracket to the subframe.
cradle.
AUS07065
Heavy Duty Floor Crane
014-00071 or equivalent
1.
Remove the engine, subframe and transmission
AUS08823
assembly. For additional information, refer to
Engine, Subframe and Transmission in this
5.
Remove the bolts retaining the power steering
section.
pressure line bracket to the subframe.
1.
Remove the transmission. For additional
information, refer to section 307-01C or 308-03
of the FG Falcon Workshop Manual.
2.
Release the alternator wiring retaining clips from
the LH side of the subframe.
x2
AUS06737
AUS08821
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-127
REMOVAL AND INSTALLATION (Continued)
6.
Remove the bolt retaining the steering gear to
11. Install an Engine Lifting Bracket on the side of the
power steering cooler line to RH of the subframe.
LH cylinder head.
AUS08824
7.
Place a drain pan under the steering gear.
12. Remove the lower retaining nut from the LH
engine mount.
8.
Remove the bolt retaining the pressure and
return lines to the steering gear and allow the
fluid to drain.
AUS08884
13. Remove the lower retaining nut from the RH
AUS06704
engine mount.
9.
Ensure that the duck bill seals are removed and
discarded.
Note: The duck bill seals will be located either in the
steering gear hose bores or attached to the hose
end forms.
10. Install an Engine Lifting Bracket on the rear of the
RH cylinder head.
AUS08885
14. Remove the engine from the subframe.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-128
REMOVAL AND INSTALLATION (Continued)
Installation
1.
Lower the engine assembly onto the subframe,
ensuring that the engine mountings are aligned
with the subframe.
2.
Install the LH and RH lower engine mount nuts.
�
Tighten to 55Nm.
3.
Remove the engine lifting brackets.
4.
Insert new duck bill seals into the steering gear
hose bores ensuring they are flush with the
clamping face.
5.
Install the bolt retaining the power steering
pressure/return line assembly to the steering
gear and torque to specification.
AUS06704
6.
Install the bolt retaining the steering gear to
power steering cooler line to RH of the subframe.
7.
Install the bolts retaining the power steering
pressure line bracket to the subframe.
�
Tighten to 25Nm.
8.
Install the bolt retaining the transmission cooler
line bracket to the subframe.
9.
Install the alternator wiring retaining clips to the
front of the subframe.
10. Install the alternator wiring retaining clips to the
LH side of the subframe.
11. Install the transmission. For additional information,
refer to section 307-01C or 308-03 of the FG
Falcon Workshop Manual.
12. Install the engine, subframe and transmission
assembly. For additional information, refer to
Engine, Subframe and Transmission in this
section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-129
REMOVAL AND INSTALLATION (Continued)
Engine Accessories
Removal
1.
Remove the engine. For additional information,
refer to Engine in this section.
2.
Remove the wiring harness retainer from the
engine front cover stud.
x2
AUS08827
5.
Release the power steering pressure/return line
and suction hose from the engine assembly.
�
Remove the power steering suction hose
bracket retaining bolt.
�
Disconnect the power steering suction hose
from the power steering pump.
AUS08825
�
Release the wiring clips from the power
3.
Remove the oil cooler coolant hose retaining
steering pressure/return line.
bracket nut, and remove the bracket from the
engine front cover stud.
�
Remove the high pressure line tube nut from
the power steering pump. Remove and
discard the power steering pressure line tube
nut seal.
AUS08826
x2
4.
Release the coolant pipe assembly from the front
of the engine.
AUS08828
�
Disconnect the coolant bleed hose from the
coolant outlet elbow.
�
Disconnect the coolant supply hose from the
heater outlet pipe.
�
Remove the 2 bolts retaining the thermostat
housing to the water pump housing and
remove the thermostat housing seal.
�
Disconnect the coolant outlet pipe from the
coolant outlet elbow.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-130
REMOVAL AND INSTALLATION (Continued)
6.
Release the A/C lines from the engine assembly.
7.
Remove the following components from the
engine as an assembly:
�
Remove the AC suction pipe bracket
retaining nut and position the bracket aside.
�
Power steering cooler
�
Remove the A/C discharge hose assembly
�
A/C evaporator
bolt from the pad fittings on the side of the
�
Radiator
A/C compressor and disconnect the A/C
hose assembly.
�
Cooling fans and shroud
�
Remove the A/C suction hose assembly
�
Power steering reservoir
bolts from the pad fittings on the side of the
�
Coolant expansion tank
A/C compressor and disconnect the A/C
suction hose assembly.
�
A/C lines
�
Disconnect the electrical connector.
�
Power steering lines
�
Coolant hoses
�
Thermostat and housing
�
Transmission cooler lines
AUS08840
AUS08841
8.
Disconnect the alternator electrical connectors.
AUS08842
9.
Release the alternator wiring from the retaining
clip on the RH side of the engine assembly, and
remove the alternator wiring from the engine
assembly.
10. Loosen (but do not remove) the coolant pump
pulley bolts.
11. Remove the accessory drive belt - alternator/
water pump. For additional information, refer to
Section 303-05B of the 2010 FPV 5.0L 4V Ti-VCT
V8 Supplement.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-131
REMOVAL AND INSTALLATION (Continued)
12. Remove the accessory drive belt - A/C
15. Release the power supply wiring retaining clip
compressor/ power steering pump /
below the supercharger intake snorkel.
Supercharger. For additional information, refer to
Section 303-05B of the 2010 FPV 5.0L 4V Ti-VCT
V8 Supplement.
13. Remove the alternator, follow the steps in
sequence.
�
Rotate the accessory drive belt tensioner
arm anti clockwise using a suitable socket
and wrench to allow withdrawal of the lower
alternator retaining bolt.
�
Whilst holding the accessory drive belt
tensioner out of the way, remove the lower
alternator retaining bolt.
AUS08844
�
Remove the upper alternator retaining nut.
16. Using the special tool, remove the power
steering pump pulley.
3
1
A7185
2
AUS08752
14. Release the power supply wiring from the
AUS08839
retaining clips around the valve cover.
17. Remove the power steering pump bracket
retaining bolts and nut. Remove the power
steering pump bracket and pump.
x6
x7
AUS08843
AUS08851
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-132
REMOVAL AND INSTALLATION (Continued)
18. Remove the retaining screws securing the
21. Release the wiring harness from around the LH
engine appearance plate and remove the
valve cover.
appearance plate from the engine assembly.
�
Disconnect the LH VCT solenoid electrical
connector.
�
Disconnect the LH coil on plug electrical
connectors.
0
x1
�
Disconnect the LH fuel injector electrical
connectors.
�
Disconnect the MAP sensor electrical
connector.
�
Remove the wiring harness retaining clips
around the LH valve cover.
AUS08694
x4
x6
19. Remove the rubber insulator beneath the engine
appearance plate.
x4
AUS08846
AUS08696
20. Disconnect the oil temperature and oil pressure
sensors.
AUS08845
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-133
REMOVAL AND INSTALLATION (Continued)
22. Release the wiring harness from around the rear
23. Release the wiring harness from around the RH
of the engine assembly.
valve cover.
�
Disconnect the LH and RH camshaft position
�
Disconnect the boost pressure sensor (BPS)
sensor electrical connectors.
electrical connector.
�
Disconnect the LH and RH radio ignition
�
Release the boost pressure sensor (BPS)
interference capacitor electrical connectors.
wiring retaining clip from the top of the intake
manifold.
�
Disconnect the LH and RH upstream HEGO
sensor electrical connectors, and release the
�
Disconnect the intake air temperature (IAT)
RH electrical connector from the RH valve
electrical connector from the RH side of the
cover.
intake manifold.
�
Disconnect the LH and RH knock sensor
�
Disconnect the RH coil on plug electrical
electrical connectors.
connectors.
�
Disconnect the crankshaft position sensor
�
Disconnect the RH fuel injector electrical
electrical connector.
connectors.
�
Disconnect the cylinder head temperature
�
Remove the wiring connector retaining
sensor electrical connector.
nut from the engine front cover stud, and
remove the wiring connector from the stud.
�
Release the wiring harness retaining clip from
the upper LH side of the supercharger intake
�
Disconnect the RH VCT solenoid electrical
snorkel.
connector.
�
Release the wiring harness retaining clips
�
Release the wiring harness retaining clips
from the underside of the supercharger
from the RH valve cover.
intake snorkel.
x6
AUS08848
AUS08847
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-134
REMOVAL AND INSTALLATION (Continued)
24. Remove the wiring harness and engine earth
27. Remove the oil cooler mounting bracket retaining
strap.
bolts and remove oil cooler and mounting
bracket assembly.
�
Disconnect the electrical connector from the
A/C compressor.
�
Remove the wiring harness from the engine
assembly.
�
Remove the engine earth strap retaining bolt
and remove the engine earth strap.
AUS08853
28. Disconnect and remove the PCV hose.
AUS08849
25. Remove the compressor and mounting bracket.
AUS08855
29. Disconnect the fuel line quick release couplings
between the LH and RH fuel rails.
30. Remove RH Fuel rail.
x3
�
Remove the Intake Air Temperature (IAT)
AUS08852
Sensor.
26. Remove the oil filter.
�
Remove fuel rail retaining bolts.
AUS08854
AUS08874
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-135
REMOVAL AND INSTALLATION (Continued)
31. Remove LH Fuel rail.
34. Carefully remove the intake manifold and super
charger assembly from the vehicle, and place on
�
Disconnect the fuel rail vent hose from the
a suitable clean work bench.
intake manifold.
�
Remove the fuel rail retaining bolts.
x2
AUS08706
35. Remove and discard the intake manifold to
AUS08875
cylinder head gaskets.
32. Remove the LH intake manifold retaining bolts.
x8
AUS08705
AUS08876
Installation
33. Remove the RH intake manifold retaining bolts.
1.
To install, reverse the removal procedure. Refer
to the relevant procedure in each section for
torque values.
AUS08877
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-136
DISASSEMBLY
Engine
Remover, Oil Seal
303-409 (T92C-6700-
Special Tool(s)
CH)
3 Jaw Puller
303-D121 or equivalent
Remover, Spark Plug
Tube Seal
303-1247/1
Handle
205-153 (T80T-4000-W)
Slide Hammer
100-001 (T50T-100-A)
Holding Tool, Crankshaft
303-448 (T93P-6303-A)
Item
Specification
Installer, Connecting Rod
Metal Surface Cleaner
WSE-M5B392-A
303-442 (T93P-6136-A)
F4A2-19A536-RA or
equivalen
Motorcraft� Silicone
_
Gasket Remover
ZC-30
Installer, Differential
Bearing Cone
205-142 (T80T-4000-J)
Remover, Crankshaft
Rear Oil Seal
303-519 (T95P-6701-
EH)
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-137
DISASSEMBLY (Continued)
Note: During engine repair procedures, cleanliness
4.
Remove the crankshaft sensor ring.
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
section.
1.
Remove engine. For additional information refer
5.
Using the Slide Hammer and the Crankshaft
to Engine removal procedure in this section.
Rear Oil Seal Remover, remove and discard the
2.
Remove the engine accessories. For additional
crankshaft rear seal.
information, refer to Engine Accessories
procedure in this section.
Note: Flexplate shown, flywheel similar.
Note: The flexplate/flywheel bolts are torque-to-yield
design and are not reusable.
3.
Remove the 8 bolts and the flywheel or flexplate.
�
Discard the bolts.
�
Remove the engine separator plate.
6.
Mount the engine on Engine work stand.
Note: When removing the ignition coils, a slight
twisting motion will break the seal and ease removal.
RH shown, LH similar.
7.
Remove the 8 bolts and the 8 ignition coils.
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.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-138
DISASSEMBLY (Continued)
8.
Remove 2 bolts and remove the coolant outlet
11. Remove the water pump pulley.
flange.
x4
AUS08879
AUS08873
12. Remove the water pump.
9.
Remove the front heater pipe retaining bolts.
�
Remove the idler pulley retaining bolt and
remove the idler pulley.
�
Remove the water pump retaining bolts.
1
AUS08878
x4
2
10. Remove heater pipe retaining bolts from the rear
AUS08720
of the RH cylinder head, and remove the heater
pipes.
AUS08856
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-139
DISASSEMBLY (Continued)
Note: Do not use metal scrapers, wire brushes,
Note: Do not use metal scrapers, wire brushes,
power abrasive discs or other abrasive means
power abrasive discs or other abrasive means
to clean the sealing surfaces. These tools cause
to clean the sealing surfaces. These tools cause
scratches and gouges which make leak paths. Use
scratches and gouges which make leak paths. Use
a plastic scraping tool to remove all traces of old
a plastic scraping tool to remove all traces of old
sealant
sealant.
13. Loosen the 11 bolts and 3 studs from LH valve
15. Loosen the 12 bolts and 2 studs, and remove the
cover.
RH valve cover and gasket.
AUS08788
AUS08768
�
Remove valve cover and gasket.
�
Clean the valve cover mating surface of the
cylinder head with silicone gasket remover
�
Clean the valve cover mating surface of the
and metal surface prep. Follow the directions
cylinder head with silicone gasket remover
on the packaging.
and metal surface prep. Follow the directions
on the packaging.
�
Discard the valve cover gasket. Clean the
valve cover gasket groove with soap and
�
Discard the valve cover gasket. Clean the
water or a suitable solvent.
valve cover gasket groove with soap and
16. Inspect the 2 VCT variable force solenoid seals.
water or a suitable solvent.
Remove any damaged seals.
14. Inspect the 2 VCT variable force solenoid seals.
Remove any damaged seals. For additional
17. Inspect the spark plug tube seals. Remove any
damaged seals. For additional information refer
information refer to Spark Plug Tube Seals and
to Spark Plug Tube Seals and Variable Camshaft
Variable Camshaft Timing (VCT) Solenoid
Timing (VCT) Solenoid Seals procedure in this
Seals procedure in this section.
section.
18. Remove lower RH Tensioner and pulley
assembly.
AUS08880
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-140
DISASSEMBLY (Continued)
22. Remove the 18x front cover retaining bolts.
19. Remove the crankshaft pulley bolt and washer.
x18
AUS08881
23. Carefully remove the front cover.
20. Using the 3 Jaw Puller and the crankshaft pulley
bolt, remove the crankshaft pulley.
Note: Do not use metal scrapers, wire brushes,
power abrasive discs or other abrasive means
�
Discard the crankshaft pulley bolt.
to clean the sealing surfaces. These tools cause
scratches and gouges which make leak paths. Use
a plastic scraping tool to remove all races of old
sealant.
�
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.
Note: Use care not to damage the engine front
cover or the crankshaft when removing the seal.
21. Using the Oil Seal Remover tool, remove the
crankshaft front oil seal.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-141
DISASSEMBLY (Continued)
24. Remove (RH & LH) Exhaust manifolds. For
31. Remove the oil pan from the engine.
additional information refer to Exhaust manifold
�
Remove the 16 bolts and the oil pan.
procedure in this section.
25. Remove the timing drive components. For
additional information refer to Timing Drive
components procedure in this section.
26. Remove (RH & LH) camshafts. For additional
information refer to Camshaft procedure in this
section.
27. Remove (RH & LH) cylinder heads. For additional
information refer to Cylinder Head procedure in
this section.
28. Remove the valve train components. For
additional information refer to Camshaft
Roller Follower, Valve Springs and valve Seals
AUS08831
procedure in this section.
32. Remove the 3 bolts and the oil pump screen and
29. Remove the knock sensor retaining bolts and
pickup tube.
remove the knock sensors.
�
Remove and discard the O-ring seal.
x2
AUS07368
30. Remove the bolt and the Crankshaft Position
(CKP) sensor.
x1
AUS08832
33. Remove and inspect the oil pan baffle and
Note: Do not use metal scrapers, wire brushes,
gasket.
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.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-142
DISASSEMBLY (Continued)
Note: Verify that the connecting rod and rod cap
34. Remove the 6 bolts and the crankshaft rear seal
retainer plate.
have orientation numbers cast into them. If not,
number the connecting rod and rod cap for correct
Note: Do not use metal scrapers, wire brushes,
orientation. Failure to do so can result in engine
power abrasive discs or other abrasive means
damage.
to clean the sealing surfaces. These tools cause
scratches and gouges which make leak paths. Use
38. Remove the bolts and the connecting rod cap.
a plastic scraping tool to remove all traces of old
Discard the bolts.
sealant.
35. Clean and inspect the sealing surfaces.
Note: Do not scratch the cylinder walls or crankshaft
journals with the connecting rod or engine damage
may occur.
36. Remove the 2 bolts, the 2 stud bolts and the oil
pump.
39. Use the connecting rod Installer to push the
piston through the top of the cylinder block.
37. Before removing the pistons, inspect the top
of the cylinder bores. If necessary, remove the
40. Repeat the previous 2 steps for each of the
ridge or carbon deposits from each cylinder
remaining pistons.
using an abrasive pad or equivalent, following the
41. Disassemble the 8 pistons. For additional
manufacturer's instructions.
information, refer to Piston procedure in this
section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-143
DISASSEMBLY (Continued)
44. Remove the crankshaft (1), the upper crankshaft
42. Remove the fasteners.
main bearings (2) and the upper thrust washer
�
Remove (1) and discard the cross-mounted
(3) from the cylinder block.
main cap bolts.
�
Remove (2) and discard the main bearing
cap bolts and stud bolt.
45. Remove the 4 bolts and 4 piston cooling jets
from the cylinder block.
43. Remove the main bearing caps (1), the lower
crankshaft main bearings (2) and the lower thrust
bearing (3).
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-144
DISASSEMBLY (Continued)
WARNING
Since the retainer ring has a tendency to
spring out, cover the end of the pin bore with a
hand or shop rag when removing the ring. Wear eye
protection. Failure to follow these instructions may
result in serious personal injury.
46. Remove the piston rings from the piston.
�
Discard the piston rings.
47. Mark the piston and the connecting rod on the
same side for assembly reference.
48. Remove the piston pin retainers and the piston
pin.
49. Separate the piston from the connecting rod.
50. Clean and inspect the piston and connecting rod.
For additional information, refer to Section 303-
00.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-145
ASSEMBLY
Engine -- Bottom End
11
10
7
9
4
8
12
3
6
13
2
5
14
1
15
16
17
19
18
35
34
29
20
33
21
32
23
31
28
30
22
27
26
44
43
42
45
41
25
46
40
39
24
47
37
48
36
49
50
38
51
52
59
57
53
60
58
56
55
61
54
62
63
64
66
65
67
68
AUS07379
Item
Description
1
Idler pulley bolt
2
Idler pulley
3
Power steering pump/engine front cover bolt
4
Engine front cover
5
RH timing chain tensioner arm pin
6
RH timing chain tensioner arm
7
RH primary timing chain
8
LH timing chain tensioner arm
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-146
ASSEMBLY (Continued)
Item
Description
9
LH timing chain tensioner arm pin
10
RH timing chain guide bolt
11
RH timing chain guide slotted insert
12
RH timing chain guide
13
Crankshaft sprocket
14
LH timing chain guide pin
15
LH timing chain guide
16
LH timing chain guide pin
17
LH primary timing chain
18
Engine front cover bolt (8 required)
19
Crankshaft front oil seal
20
Crankshaft pulley
21
Crankshaft pulley bolt
22
Thermostat housing assembly
23
Heater outlet tube
24
Coolant pump pulley bolt (4 required)
25
Coolant pump pulley
26
Coolant pump
27
Engine block
28
Crankshaft rear seal retainer plate
29
Crankshaft position sensor assembly
30
Crankshaft rear seal retainer plate
31
Crankshaft rear seal (spring)
32
Crankshaft rear seal
33
Crankshaft sensor ring
34
Flywheel
35
Flywheel bolt
36
Oil pump bolt
37
Oil pump
38
Piston cooling jet
39
Connecting rod cap bolt (16 required)
40
Connecting rod cap (8 required)
41
Connecting rod bearing (16 required)
42
Connecting rod (8 required)
43
Piston (8 required)
44
Upper compression ring (8 required)
45
Lower compression ring (8 required)
46
Oil control ring lower
47
Oil control ring spacer
48
Oil control ring upper
49
Piston pin retainer
50
Piston pin
51
Thrust washer
52
Crankshaft upper main bearing (5 required)
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-147
ASSEMBLY (Continued)
Item
Description
53
Woodruff key
54
Oil pump screen and pickup tube
55
Oil pump screen and pickup tube spacer
56
Crankshaft lower main bearing
57
Crankshaft
58
Crankshaft lower main bearing
59
Oil cooler housing
60
Oil cooler mounting insert bolt
61
Oil cooler
62
Oil filter
63
Crankshaft main bearing cap (5 required)
64
Crankshaft main bearing cap bolt (10 required)
65
Crankshaft main bearing cap bolt (9 required)
66
Crankshaft main bearing cap stud bolt
67
Oil pan baffle and gasket
68
Oil pan
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-148
ASSEMBLY (Continued)
Engine
Special Tool(s)
Holding Tool, Crankshaft
303-448 (T93P-6303-A)
Alignment Pins, Cylinder Head
303-1040 (SR-015486)
Installer, Connecting Rod
303-442 (T93P-6136-A)
Compressor, Piston Ring
303-D032 (D81L-6002-C) or equivalent
Installer, Differential Bearing Cone
205-142 (T80T-4000-J)
Handle
205-153 (T80T-4000-W)
Installer, Front Cover Oil Seal
303-335 (T88T-6701-A2 plate only)
Heavy Duty Floor Crane
014-00071 or equivalent
Installer, Front Crank Seal and Damper
303-1531
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-149
ASSEMBLY (Continued)
Item
Specification
Silicone Gasket and Sealant
WSE-
F7AZ-19554-EA or Loctite 5900
M4G323-A4
or equivalent
Metal Surface Cleaner F4A2-
WSE-M5B392-A
19A536-RA or equivalent
Engine Oil IISAC GF-4 SAE 5W-
WSS-M2C930-A
20
Motorcraft� Silicone Gasket
Installer, Rear Main Seal
--
Remover ZC-30
303-1250
Motorcraft� Specialty Orange
Engine Coolant VC-3-B
WSS-M97B44-D
(US); CVC-3-B (Canada); or
equivalent
Silicone Brake Calliper Grease
and Dielectric Compound XG-
ESE-M1C171-A
3-A
Installer, Spark Plug Tube Seal
303-1247/2
Lifting Bracket, Engine
303-F047 (014-00073) or equivalent
Strap Wrench
303-D055 (D85L-6000-A) or equivalent
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-150
ASSEMBLY (Continued)
Note: The connecting rod must be installed into the
Note: During engine repair procedures, cleanliness
piston with the marks made during disassembly on
is extremely important. Any foreign material, including
the same side. If a new piston or connecting rod is
any material created while cleaning gasket surfaces,
being installed, it can be installed in either direction.
that enters the oil passages, coolant passages or the
oil pan, can cause engine failure.
1.
Position the connecting rod in the piston.
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 Section 303-00.
7.
Record the main bearing code found on the front
of the engine block.
8.
Record the main bearing code found on the rear
of the crankshaft.
2.
Lubricate the piston pin and pin bore with clean
engine oil.
3.
Install the piston pin in the piston and connecting
rod assembly.
4.
Install the piston pin retaining clips in the piston.
5.
Lubricate the piston and the new piston rings
with clean engine oil.
6.
Install the piston rings onto the piston.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-151
ASSEMBLY (Continued)
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.
9.
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.
Note: This chart is for selecting main bearings 2, 3
and 4 only.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-152
ASSEMBLY (Continued)
10. Using the data recorded earlier and the Bearing
Select Fit Chart, Standard Bearings, determine
therequired 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.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-153
ASSEMBLY (Continued)
14. Install the main bearing caps and fasteners on the
Note: Before assembling the cylinder block, all
cylinder block and, keeping the caps as square
sealing surfaces must be free of chips, dirt, paint and
as possible, alternately draw the caps down
foreign material. Also, make sure the coolant and oil
evenly using the cap fasteners.
passages are clear.
11. Install the 4 piston cooling jets and 4 bolts.
Tighten in 2 stages.
�
Stage 1: Tighten to 10 Nm.
�
Stage 2: Tighten an additional 45 degrees.
15. Push the crankshaft forward to seat the
crankshaft thrust washer. Hold the crankshaft in
the forward position.
12. 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.
13. 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.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-154
ASSEMBLY (Continued)
16. Tighten the vertical main bearing cap fasteners in
the sequence shown, in 4 stages.
�
Stage 1: Tighten fasteners 1 through 20 to 20
Nm.
�
Stage 2: Tighten fasteners 1 through 10 to 40
Nm.
�
Stage 3: Tighten fasteners 11 through 20 to
65 Nm.
�
Stage 4: Tighten fasteners 1 through 20 an
additional 90 degrees.
18. Check the crankshaft end play. For additional
information, refer to Section 303-00.
19. Check that crankshaft torque-to-turn does not
exceed 6 Nm.
20. Check the piston-to-cylinder block and piston
ring clearances. For additional information, refer
to Section 303-00.
21. Assemble the pistons. For additional information,
refer to Piston in this section.
22. Make sure the ring gaps (oil spacer-A, oil ring-B,
compression ring-C) are correctly spaced around
the circumference of the piston.
17. Install the cross-mounted main bearing cap
fasteners and tighten in the sequence shown, in
3 stages.
�
Stage 1: Tighten to 10 Nm.
�
Stage 2: Tighten to 30 Nm.
�
Stage 3: Tighten an additional 60 degrees.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-155
ASSEMBLY (Continued)
Note: Do not scratch the cylinder walls or crankshaft
23. Make sure the dimple in the piston faces the front
journals with the connecting rod or engine damage
of the engine.
may occur.
25. Once the connecting rod is seated on the
crankshaft journal, remove the Connecting Rod
Installers.
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.
24. Use the Piston Ring Compressor and the
Connecting Rod Installers to install the
connecting rod and check spacing.
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.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-156
ASSEMBLY (Continued)
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.
26. 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 3
stages.
�
Stage 1: Tighten to 20 Nm.
�
Stage 2: Tighten to 38 Nm.
�
Stage 3: Tighten an additional 105 degrees.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-157
ASSEMBLY (Continued)
27. Install the oil pump screen and pickup tube
30. Apply a 3.75 mm bead of silicone Gasket and
spacer and Torque it to 25 Nm.
sealant to the rear crankshaft seal retainer mating
surface on the engine block.
28. 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.
29. Tighten the fasteners in the sequence shown in 3
stages:
�
Stage 1: Hand tighten.
�
Stage 2: Tighten the bolt (1) to 10 Nm, the
stud bolt (2) to 25 Nm, the bolt (3) to 10 Nm
and the stud bolt (4) to 20 Nm.
31. Install the crankshaft rear seal retainer plate and
�
Stage 3: Tighten the bolt (1) an additional
the 6 bolts, tighten in the sequence shown in 2
45 degrees, the stud bolt (2) an additional
stages.
75 degrees, the bolt (3) an additional 45
�
Stage 1: Tighten to 10 Nm.
degrees and the stud bolt (4) an additional
60 degrees.
�
Stage 2: Tighten an additional 45 degrees.
Note: Failure to use silicone Gasket and sealant
Note: Do not use metal scrapers, wire brushes,
may cause the engine oil to foam excessively and
power abrasive discs or other abrasive means
result in serious engine damage.
to clean the sealing surfaces. These tools cause
scratches and gouges, which make leak paths. Use
Note: If the rear crankshaft seal retaining plate is
a plastic scraping tool to remove all traces of old
not secured within 4 minutes, the sealant must be
sealant.
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.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-158
ASSEMBLY (Continued)
34. Position the oil pan baffle and gasket.
32. Inspect the oil pan and engine sealing surfaces.
Clean the mating surfaces of the engine and
Note: The 2 oil pump screen and pickup tube-to-oil
oil pan with silicone gasket remover and metal
pump bolts must be tightened prior to tightening the
surface prep. Follow the directions on the
oil pump screen and pickup tube-to-spacer bolt.
packaging.
35. Using a new O-ring seal, install the oil pump
Note: Failure to use silicone Gasket and sealant
screen and pickup tube and the 3 bolts.
may cause the engine oil to foam excessively and
result in serious engine damage.
�
Tighten the 2 oil pump screen and pickup
tube-to-oil pump bolts to 12 Nm.
Note: If the oil pan is not installed and the fasteners
tightened within 5 minutes, the sealant must be
�
Tighten the oil pump screen and pickup tube-
removed and the sealing area cleaned. To clean
to-spacer bolt to 30 Nm.
the sealing area, use silicone gasket remover and
�
the bracket holding bolt to 30 Nm.
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 within 5
minutes of applying the sealer and final torque all of
3
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
2
surfaces.
33. Apply an 8 mm bead of silicone Gasket and
sealant to the crankshaft rear seal retainer plate-
to-cylinder block sealing surfaces and the engine
1
front cover-to- cylinder block sealing surfaces.
AUS08834
AUS08833
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-159
ASSEMBLY (Continued)
36. Install the oil pan hand tight the bolts and torque
37. The Crankshaft Position (CKP) sensor must be
the bolts in sequence.
positioned into the fitting on the crankshaft rear
seal retainer plate and be flush against the boss
�
Stage 1: (1- 16) Torque to 12 Nm.
on the engine block before the bolt is installed. If
�
Stage 2: (17-26) Tighten to 12 Nm.
the CKP sensor is installed incorrectly, the CKP
sensor can be damaged.
28
27
Position the CKP sensor and install the bolt.
11
12
�
Tighten to 10 Nm.
14
16
13
15
2
18
1
17
20
19
4
3
22
6
21
5
24
8
23
7
9
10
26
25
AUS07348
Note: Make sure that the engine oil drain plug is
installed.
38. Install the 2 Knock Sensor (KS) and 2 bolts.
� Tighten to 20 Nm.
AUS07368
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-160
ASSEMBLY (Continued)
Note: TheVariable Camshaft Timing (VCT) variable
39. Verify the crankshaft keyway is in the 9 o'clock
position and install the crankshaft sprocket with
force solenoid pins must be fully depressed to avoid
the flange facing forward.
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, RH similar.
45. Fully depress the VCT variable force solenoid
pins.
40. Install the valve train components to the cylinder
heads. For additional information refer to
Camshaft Roller Follower, Valve Springs and valve
Seals procedure in this section.
41. Install (RH & LH) Cylinder heads. For additional
information refer to Cylinder head procedure in
Note: The engine front cover must be installed
this section.
and all fasteners final tightened within 5 minutes of
42. Install (RH & LH) Camshafts. For additional
applying the sealer. If this cannot be accomplished,
information refer to Camshaft procedure in this
install the engine front cover and tighten fasteners 6,
section.
7, 8, 9, 10 and 11 to 8 Nm within 5 minutes of applying
the sealer. All of the fasteners must then be final
43. Install Timing drive components. For additional
tightened within 1 hour of applying the sealer. If this
information refer to Timing drive components
time limit is exceeded, all sealant must be removed
procedure in this section.
and the sealing area cleaned. To clean the sealing
44. Install (RH & LH) Exhaust manifolds. For additional
area, use silicone gasket remover and metal surface
information refer to Exhaust manifold procedure
prep. Follow the directions on the packaging. Failure
in this section.
to follow this procedure can cause future oil leakage.
46. Apply a bead of silicone sealer 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
gaskets are in place on the engine front cover before
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-161
ASSEMBLY (Continued)
installation.
to follow this procedure can cause future oil leakage.
47. Using new gaskets, position the engine front
48. Tighten the bolts in the sequence shown in 2
cover onto the dowels.
stages.
�
Install the 13 engine front cover bolts, 2 stud
�
Stage 1: Tighten bolts 1-15 to 25 Nm and bolts
bolts and the 4 oil pan-to-engine front cover
16-19 to 10 Nm.
bolts finger-tight.
�
Stage 2: Tighten bolts 1-15 an additional 60
degrees and bolts 16-19 an additional 45
degrees.
14
13
10
9
12
5
4
3
15
8
11
11
2
1
6
7
17
18
19
16
Note: The engine front cover must be installed
AUS08796
and all fasteners final tightened within 5 minutes of
applying the sealer. If this cannot be accomplished,
49. Position the wiring harness and install the 2 wiring
install the engine front cover and tighten fasteners 6,
harness retainer nuts to the front oil pan stud
7, 8, 9, 10 and 11 to 8 Nm within 5 minutes of applying
bolts.
the sealer. All of the fasteners must then be final
tightened within 1 hour of applying the sealer. If this
Note: Lubricate the engine front cover bore and the
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
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-162
ASSEMBLY (Continued)
crankshaft front oil seal inner lip with clean engine oil.
50. Using the Front Crank Seal and Damper Installer
and the Front Cover Oil Seal Installer (plate only),
install the crankshaft front oil seal.
53. Using the Front Crank Seal and Damper Installer
and the Front Cover Oil Seal Installer (plate only),
install the crankshaft pulley.
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.
51. Apply silicone sealer to the Woodruff key slot in
the crankshaft pulley.
54. 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.
�
Stage 2: Loosen 360 degrees.
�
Stage 3: Tighten to 100 Nm.
�
Stage 4: Tighten an additional 90 degrees.
52. Lubricate the crankshaft pulley sealing surface
with clean engine oil prior to installation.
55. Install the lower RH Tensioner and pulley
assembly.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-163
ASSEMBLY (Continued)
AUS08880
56. Install new spark plug seals. For additional
information refer to Spark Plug Tube Seals and
Variable Camshaft Timing (VCT) Solenoid Seals
procedure in this section.
Note: Installation of new seals is only required if
damaged seals were removed.
Note: RH is similar to LH
57. Installation of the LH valve cover is reversal of
removal procedure.
58. Position the LH valve cover and new gasket on
the cylinder head.
�
Tighten the bolts in the sequence shown to
10 Nm.
59. Installation of the RH valve cover is reversal
removal procedure.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-164
ASSEMBLY (Continued)
60. Position the RH valve cover and new gasket on
66. Install the idler pulley and torque the retaining
the cylinder head.
bolts to the correct torque. Refer to the
specifications table in this section.
�
Tighten the stud and bolts in the sequence
67. Install the water pump pulley.
shown to 10 Nm.
68. Tighten to 25 Nm. For additional information refer
to section 303-03A 2010 FPV 5.0L 4V Ti-VCT V8
Supplement.
x4
AUS08879
69. Install the Heater pipes and the pipe retaining
bolts to the rear of the Rh cylinder head and
torque to the specifications. For additional
information refer to section 303-03A 2010 FPV
5.0L 4V Ti-VCT V8 Supplement.
61. Install the coolant pump. For additional
information, refer to Section 303-03A of 2010
FPV 5.0L 4V Ti-VCT V8 Supplement.
CAUTION
Do not rotate the coolant pump housing once
installed in the engine. Damage to the O-Ring
AUS08856
seal can occur, causing the coolant pump seal to
leak.
70. Install the front heater pipe retaining bolts
Note: Install a new coolant pump O-Ring seal and
and torque to specifications. For additional
lubricate with the same clean engine coolant that is
information refer to section 303-03A 2010 FPV
present in the system. Do not mix coolant types.
5.0L 4V Ti-VCT V8 Supplement.
62. To install, reverse the removal procedure.
63. Clean and inspect the sealing surfaces.
64. Ensure that the coolant outlet elbow and
thermostat housing seals are installed correctly.
If the seal is damaged, worn or shows signs of
compression set, then it should be replaced with
a new seals.
65. Tighten to 20 Nm plus an additional 60 degrees.
Refer to the specifications table in this section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-165
ASSEMBLY (Continued)
AUS08878
71. Install the Coolant outlet Flange and torque the
Note: RH shown, LH similar.
bolts to the correct specifications.
Note: Lubricate the seal lips and bore with clean
engine oil prior to installation.
74. Position the Rear Main Seal Installer onto the end
of the crankshaft and slide a new crankshaft rear
seal onto the tool.
AUS08873
72. 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.
75. Using the Rear Main Seal Installer and Handle,
install the new crankshaft rear seal.
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, LH similar.
73. Install the 8 ignition coils and 8 bolts.
�
Tighten to 6 Nm.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
303-01B
Engine - FPV 5.0L 4V Ti-VCT V8
303-01B-166
76. Install the crankshaft sensor ring.
77. Install the engine separator plate, the flywheel or
flexplate and the 8 bolts.
�
Tighten in the sequence shown in 2 stages.
Stage 1: Tighten to 20 Nm.
n
Stage 2: Tighten an additional 60
n
degrees.
78. Install all Engine accessories. For additional
information refer to Engine Accessories in this
section.
79. Install engine. For additional information refer to
Engine removal procedure in this section.
Version: 2010.0 FPV 5.0L 4V Ti-VCT V8 Supplement
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