REMOVAL & INSTALLATION

REMOVAL & INSTALLATION ENGINE 1. Mark hinges for reinstallation and remove hood. Drain crankcase and cooling system. Disconnect battery and alternator ground cables from engine. Remove air cleaner and intake duct assembly. 2. Disconnect upper and lower radiator hoses. Disconnect transmission oil cooler lines from radiator. Remove bolts attaching fan shroud to radiator. Remove radiator. 3. Remove fan, spacer, belt, pulley and shroud. Remove alternator bolts and position alternator aside. Disconnect oil pressure sending unit wire from sending unit. 4. Disconnect flexible fuel line at fuel tank line. On CFI equipped vehicles, relieve pressure in fuel lines before disconnecting. Plug fuel tank line. Disconnect accelerator cable from carburetor. Disconnect speed control cable (if equipped). 5. Disconnect throttle valve vacuum line from intake manifold (if equipped). Disconnect transmission filler tube bracket from engine block. On vehicles equipped with A/C, remove A/C compressor and set aside. 6. If power steering equipped, disconnect power steering pump bracket from cylinder head. Remove drive belt. Position pump aside. If power brake equipped, disconnect brake vacuum line from intake manifold. 7. Disconnect heater hoses from water pump and intake manifold. Disconnect coolant temperature sending unit wire from sending unit. Remove flywheel/converter housing-to-engine upper bolts. 8. Disconnect primary wiring connector from ignition coil (coil is located on right-hand strut tower on Continental). Remove wire harness and position aside. Disconnect ground strap from block. 9. Raise front of vehicle. Disconnect starter cable from starter. Remove starter. Disconnect muffler inlet pipes from exhaust manifolds. Disconnect engine support insulators. 10. Disconnect transmission cooler lines from retainer and remove converter housing inspection cover. Disconnect converter from drive plate. Secure converter assembly in housing. Remove remaining converter housing-to-engine bolts. 11. Lower vehicle and support transmission. Attach engine hoist and carefully separate engine from transmission. Remove engine. 12. To install, reverse removal procedure. INTAKE MANIFOLD Removal 1. Disconnect negative battery cable and drain cooling system. Remove crankcase ventilation and evaporative purge hoses. Disconnect automatic choke heat tube. 2. Disconnect accelerator cable and speed control linkage from throttle body. Disconnect vacuum lines at the intake manifold fitting. Remove distributor cap and wires as an assembly. Disconnect distributor vacuum hoses and wiring connector from distributor. Remove distributor. 3. Disconnect upper radiator hose at engine. Disconnect heater hose and water pump by-pass hose at intake manifold. Disconnect water pump by-pass hose at coolant outlet housing. 4. Disconnect wires at ECT, ACT, TP, ISC solenoid and EGR sensors. Disconnect injector wire connections, and fuel charging assembly wiring (SFI). Thursday, October 30, 2008 11:21:25 11:21:31 AM Page 1 2005 Mitchell Repair Information Company, LLC.

5. Disconnect fuel evaporative purge tube (if equipped). Disconnect fuel supply and return lines. Remove upper intake manifold. Remove lower intake manifold. Installation 1. Clean gasket mating surfaces. Apply oil resistant sealer at four junction points of seals and gaskets. Position front and rear seals on cylinder block and new gaskets on heads. 2. Make sure that holes in gaskets are aligned with holes in cylinder head. Position gaskets to interlock with seal tabs. Using guide pins, lower manifold in place. 3. Check for correct positioning of gaskets and seals before installing bolts. Remove guide pins. Install bolts and tighten in specified sequence. See Fig. 2. Reverse removal procedure to complete installation. 4. Start engine. Check and adjust ignition timing. Operate engine until it reaches normal operating temperature, then retighten manifold bolts. Thursday, October 30, 2008 11:21:25 AM Page 2 2005 Mitchell Repair Information Company, LLC.

Fig. 2: Intake Manifold Tightening Sequence Tighten bolts in 3 steps. EXHAUST MANIFOLD Removal 1. On right side exhaust manifolds, remove the air cleaner-to-throttle body tube and thermactor hardware. On left side manifolds, remove the oil dipstick and tube assembly, air cleaner and inlet duct assembly. Thursday, October 30, 2008 11:21:25 AM Page 3 2005 Mitchell Repair Information Company, LLC.

2. Disconnect the exhaust manifold from the muffler inlet pipe. Remove spark plug wires and plugs. Disconnect the exhaust gas oxygen sensor (EGO), if equipped. Remove exhaust manifold. Installation 1. Clean mating surfaces of exhaust manifold and cylinder head. Clean mounting flange and muffler inlet pipe. Position exhaust manifold on cylinder heads and install washers and retaining bolts. Tighten the bolts to specifications. 2. Install spark plugs and wires. Connect exhaust gas oxygen sensor (if equipped). To complete installation, reverse removal procedure. CYLINDER HEAD Cylinder head should only be removed when engine is cold. Check cylinder head for warped gasket surface, nicks or damage. If cylinder head refinishing is needed, DO NOT machine more than.010" (.25 mm) from gasket surface. Replace head if cracked. Remove burrs or scratches with an oil stone. Removal 1. Disconnect negative battery cable. Remove upper intake manifold and carburetor as an assembly. Remove lower intake manifold. Remove valve covers. If equipped, discharge A/C compressor and disconnect refrigerant lines. Remove compressor. 2. If equipped, disconnect power steering pump and bracket. Remove drive belt from pump pulley and position to one side. Remove alternator mounting bracket bolt, air cleaner inlet duct, ignition coil and thermactor crossover tube (from rear of cylinder head). 3. If equipped, remove fuel line from clip at front of cylinder head. Disconnect exhaust inlet pipes at exhaust manifolds. Loosen rocker arm fulcrum bolts and rotate rocker arms to side. Remove push rods, keeping them in proper sequence for reinstallation in original positions. 4. On some engines it may be necessary to remove exhaust manifold to gain access to lower cylinder head bolts. Remove exhaust valve stem caps. Remove cylinder head bolts and cylinder head. If cylinder head is to be serviced, remove carbon deposits from combustion chamber with scraper and wire brush before removing valves. When disassembling, mark all valve components for proper reassembly. Installation 1. Clean old gasket material from cylinder head and block. Check cylinder head and block gasket surface for warpage. Gasket surface maximum warpage is.003" (.08 mm) in any 6" (152 mm), and.006" (.152 mm) overall. 2. Position head gasket over dowels and onto block. Install cylinder head. Install bolts and tighten in three steps. See Fig. 3. 3. Clean push rods in solvent and blow out each oil passage with compressed air. Check ends of push rod for nicks, grooves or excessive wear. Ensure push rods are straight by checking with dial indicator and Thursday, October 30, 2008 11:21:25 AM Page 4 2005 Mitchell Repair Information Company, LLC.

"V" block. 4. If runout exceeds.015" (.38 mm), replace push rod. DO NOT attempt to straighten push rod. Apply Ford Polyethylene Grease (DOAZ-19584-A) to rocker arm contact points and push rod ends. Reverse removal procedure to complete installation. Fig. 3: Cylinder Head Tightening Sequence Tighten bolts in 3 steps. VALVE SPRINGS Removal 1. Remove valve cover and spark plug on cylinder to be serviced. Be sure piston is at top of stroke with both valves closed. Install air line with adapter in spark plug hole. Apply minimum of 140 psi line pressure. If air pressure fails to hold valve closed, remove cylinder head for inspection. 2. Remove required rocker arm and push rod. Use spring compressor to compress valve spring and remove retainer locks, sleeve, spring retainer and valve spring. Remove and discard valve stem seal. Do not remove air pressure, as this will allow valve to fall into cylinder if piston has been moved to bottom of cylinder. 3. Check valve spring for out of square with 90 degree straight edge. Valve spring out-of-square service limit is.078" (1.98 mm) for intake and exhaust springs on all models. Check valve spring compression pressure and replace any spring not within specification. Installation 1. Lubricate valve stem with engine oil and install new valve stem seal. Place spring in position over valve and install spring retainer. Compress valve spring and install locks. Check valve spring for proper installed height. 2. Remove air pressure and adapter and install spark plugs. Apply Ford Polyethylene Grease (DOAZ-19584- A) to ends of push rods and tip of valve stems. Install rocker arms and tighten. Thursday, October 30, 2008 11:21:25 AM Page 5 2005 Mitchell Repair Information Company, LLC.

VALVE STEM OIL SEALS 1. If valve or valve seat has not been damaged, valve springs, seals and retainers may be replaced by holding affected valve against seat using air pressure. Cup or umbrella type seals are used on all valves. An adapter can be constructed by welding an air hose connection to body of spark plug with porcelain removed. 2. Install Compressed Air Line Adapter (6513-ABA) in spark plug hole. A minimum of 140 psi (9.8 kg/cm 2 ) line pressure is required. If air pressure does not hold valve shut, valve is damaged or burnt and cylinder head must be removed for service. 3. With valve in head, install plastic seal protector cap over end of valve stem. Oil protector cap and start stem seal carefully over cap. Push seal down until seal jacket touches top of valve guide. Remove plastic seal protector cap. Using seal installer, bottom seal on valve guide. HYDRAULIC ROLLER LIFTER ASSEMBLY 1. Remove intake manifold and related components. Remove valve covers and loosen rocker arm bolts. Rotate rocker arms out of way and remove push rods keeping them in order for reinstallation in original positions. 2. On 5.0L engines with roller lifters, push rods have a collar at upper end and can only be installed one way. Balls at each end of push rod are not identical. 3. Remove lifter guide retainer bolts. Remove retainer and lifter guide plates. Label guide plates for reinstallation in original position. Remove lifters. Roller lifters must be installed in original position and orientation in bore so that roller rotates in same direction. 4. To install, reverse removal procedure. Lubricate lifter, lifter bore, rocker arms and fulcrum seats with engine oil. Apply Ford Polyethylene Grease (DOAZ-19584-A) to valve stem tips and push rod ends. HYDRAULIC VALVE LIFTER ASSEMBLY Before replacing hydraulic lifter for noisy operation, be sure noise is not caused by improper collapsed lifter gap, worn rocker arms, push rods or valve tips. If lifter assembly is stuck in bore, use Hydraulic Lifter Puller (T70L-6500-A) or magnet. 1. Hydraulic lifter assemblies must be installed in original locations. Remove cylinder head and related parts. Using lifter remover or magnet, remove lifters. Clean and inspect but do not mix components or positions. Parts are select-fitted and are not interchangeable. 2. If lifter is sticking, disassemble and clean dirt, metal chips or varnish from components. If lifter check valve is not functional, obstructions may be preventing it from closing when cam lobe is moving lifter, or check valve spring may be broken. Clean or replace components as necessary. Thursday, October 30, 2008 11:21:25 AM Page 6 2005 Mitchell Repair Information Company, LLC.

3. If plunger is not free in body of lifter, replace entire assembly. Plunger should drop to bottom of body by its own weight when assembled dry. Assemble lifter and check free operation by pressing down on cap. If lifter has been disassembled and cleaned, be sure to fill with test fluid before installing in engine. New lifters already contain test fluid. When performing leak-down test, note that lifters cannot be checked with engine oil in them, only test fluid can be used. 4. Place lifter upright in Hydraulic Lifter Leak-Down Tester (6500-E), and check leak-down rate. Leakdown rate is 10-15 seconds measure at.0625" (1.59 mm) plunger travel, under 50 lb. (22 kg) load. 5. Inspect lifter base-to-cam lobe contact area. Surface must have smooth and convex contact face. Replace any lifter with flat or concave surface. Inspect related cam lobe for proper lobe lift. Replace camshaft (and lifters if necessary) if any lobe is worn beyond specification. 6. Check lifter-to-bore clearance. Standard clearance is.0007-.0027" (.018-.069 mm). Service limit is.0050" (.130 mm) maximum. Standard diameter of lifter is.8740-.8745" (22.200-22.212 mm). Fig. 4: Exploded View of Valve Lifter Assembly OIL PAN Continental, Crown Victoria, Grand Marquis, Mark VII & Town Car 1. Remove air cleaner, disconnect accelerator and kickdown rods at carburetor and remove accelerator Thursday, October 30, 2008 11:21:25 AM Page 7 2005 Mitchell Repair Information Company, LLC.

mounting bracket. (With EEC, remove EGR valve and cooler.) Remove fan shroud bolts and position shroud over fan. Disconnect wiring from harness and remove wiper motor. 2. Disconnect windshield washer hose and remove wiper motor mounting cover. Remove dipstick and dipstick tube retaining bolt at exhaust manifold. With EEC, remove thermactor air dump tube retaining clamp and thermactor crossover tube at rear of engine. 3. On all models, raise vehicle and drain crankcase. With EEC, remove filler tube and drain transmission. Disconnect starter wiring, remove starter. On all models, disconnect fuel line from fuel pump and inlet pipes from exhaust manifold. CAUTION: Before disconnecting fuel lines on vehicles equipped with a high pressure electric fuel pump, relieve pressure at Schrader valve on fuel charging assembly. 4. With EEC, remove exhaust gas oxygen sensor from exhaust manifold and thermactor secondary air tubeto-converter housing clamps. Disconnect exhaust pipes to catalytic converter outlet. Remove catalytic converter secondary air tube and inlet pipes to exhaust manifold. 5. On all models, remove rear engine mount through bolts and shift crossover bolts at transmission. Disconnect transmission kickdown rod. Remove flywheel access cover. Remove brake line retainer from front crossmember. Using a jack, raise engine as far as possible. 6. Place support blocks between engine mounts and chassis brackets. Remove jack. Disconnect low oil sensor from oil pan, if equipped. Remove oil pan bolts and lower pan. Remove oil pump pickup tube assembly and place in oil pan. Remove oil pan. Vehicles equipped with dual sump oil pans require removal of both drain plugs to drain crankcase. Mustang 1. Disconnect negative battery cable. Remove fan shroud bolts and position shroud over fan. Remove engine oil dipstick tube assembly. Raise and support vehicle. Drain crankcase and disconnect steering flex coupling. 2. Remove steering gear to main crossmember bolts and let steering gear rest on frame. Remove nuts and washers from engine mounts to No. 2 crossmember and disconnect transmission cooler lines. Raise engine and place support blocks between engine mounts and No. 2 crossmember. 3. Remove flywheel access cover and rear "K" braces. Remove oil pan bolts and lower oil pan to frame. Remove oil pump bolts and inlet tube attaching nut. Lower oil pump into pan. Remove oil pan, rotating crankshaft if necessary to clear oil Pan. Cougar & Thunderbird 1. Disconnect negative battery cable and remove air cleaner assembly. Remove fan shroud bolts and position shroud over fan. Raise and support vehicle. Disconnect oil level indicator from oil pan. Drain crankcase and transmission. Remove driveshaft. 2. Disconnect gearshift bellcrank lever and speedometer cable from transmission. Remove flywheel access cover, and flywheel-to-converter bolts. Remove transmission kickdown control shaft and gear selector Thursday, October 30, 2008 11:21:25 AM Page 8 2005 Mitchell Repair Information Company, LLC.

valve-rod. Disconnect starter wiring and remove starter. 3. Remove exhaust catalyst converter and muffler inlet pipes. Using a jack, support transmission and remove converter housing-to-cylinder block bolts. Remove engine mount bolts. Remove No. 3 crossmember and transmission mount assemblies. 4. Unplug neutral start switch electrical connector and disconnect transmission oil cooler lines. Remove transmission and converter as an assembly. Remove flywheel and rear cover plate. Remove steering gear bolts and lay gear aside. 5. Raise and support engine in a position allowing adequate clearance for oil pan removal. Remove oil pan bolts and lower oil pan to crossmember. Remove oil pump and pickup tube assembly and place in pan. Remove oil pan from vehicle. REAR MAIN BEARING OIL SEAL Removal 1. With transmission and related components removed, punch hole into seal metal surface between seal lip and engine block with sharp awl. 2. Screw in threaded end of Slide Hammer (T77L-9533-B1). Use slide hammer to remove seal. Use caution to avoid scratching or damaging oil seal surface. Installation 1. Lubricate seal and seal mating surface with engine oil. Install oil seal on Seal Installer (T82L-6701-A) with spring side toward engine. Position tool and seal on rear of engine. 2. Alternate bolt tightening to properly seat seal. Install seal with rear face to seal within.005" (.13 mm) of rear face of block. If bolts are not available with installer, engine flywheel bolts may be used. See Fig. 5. Reverse removal procedure to complete installation. Thursday, October 30, 2008 11:21:25 AM Page 9 2005 Mitchell Repair Information Company, LLC.

Fig. 5: Installing Rear Main Oil Seal FRONT COVER Removal 1. Drain cooling system and crankcase. Remove fan, spacer, radiator shroud and all hoses or brackets attached to water pump. Remove crankshaft pulley and remove vibration damper using universal puller. Disconnect fuel pump outlet line from fuel pump. 2. Remove fuel pump bolts and lay pump to one side (with fuel line attached). Remove front cover bolts and cut oil pan gasket flush with cylinder block. Remove front cover and water pump as an assembly. If front cover is replaced, remove water pump from old cover. Install pump on new cover with new gasket. Cover front oil pan opening while cover assembly is off, to prevent dirt or gasket material from entering oil pan. Thursday, October 30, 2008 11:21:25 AM Page 10 2005 Mitchell Repair Information Company, LLC.

Installation 1. Clean all gasket surfaces. Cut and position required sections of new gasket on oil pan using contact cement. Apply RTV silicone sealer to corners and gasket junctions. 2. Install new front cover seal. Use Pilot/Front Cover Aligner (T61P-6019-B or 6059-F) to center front cover on crankshaft. Use care when installing cover to avoid seal damage or possible gasket mislocation. 3. With front cover in place, it may be necessary to force cover downward to slightly compress pan gasket. Install retaining bolts and tighten. Apply polyethylene grease to oil-seal-rubbing-surface of vibration damper inner hub to prevent seal damage. 4. Apply polyethylene grease to front of crankshaft for damper installation. Line up damper keyway with key on crankshaft and install damper. Install fuel pump with new gasket. Reverse removal procedure to complete installation. FRONT COVER OIL SEAL Removal Remove front cover. Using pin punch, drive out front cover oil seal. Use care to avoid damaging oil seal surfaces. Installation Coat seal with grease and drive into cover using Seal Driver (T53L-200-A and T58P-6700-B). Check seal to ensure it is fully seated and spring is positioned properly. Install front cover. TIMING CHAIN Removal 1. With crankshaft pulley, front cover and related components removed, align timing marks. See Fig. 6. Remove camshaft sprocket cap screw, washer, fuel pump eccentric and spacer (if equipped). Inspect chain as outlined below. 2. Slide both sprockets with timing chain forward and remove them as an assembly. Inspect timing chain and sprockets for worn gear teeth, stretched chain or damaged components. Inspection 1. With front cover removed, and timing chain installed, rotate crankshaft in counterclockwise direction to take up slack on left side of chain. Establish reference point on engine block and measure from this point to chain. 2. Rotate crankshaft in opposite direction to take up slack on right side of chain. Force left side of chain out and measure difference between reference point and chain. If deflection exceeds.500" (12.70 mm), replace timing chain. Installation Thursday, October 30, 2008 11:21:25 AM Page 11 2005 Mitchell Repair Information Company, LLC.

1. Position timing chain on sprockets with timing marks aligned. See Fig. 6. Slide both sprockets and timing chain onto engine as an assembly. Install spacer (if equipped), fuel pump eccentric, washer and sprocket cap screw. 2. Tighten sprocket bolt. Oil timing chain and sprockets. Clean gasket area and install new oil seal as necessary. Install front cover, new gaskets and related components. Fig. 6: Timing Chain Sprocket Alignment Thursday, October 30, 2008 11:21:25 AM Page 12 2005 Mitchell Repair Information Company, LLC.

CAMSHAFT Removal 1. Drain cooling system and remove radiator, A/C condenser and grille components, as necessary. Remove engine front cover, fuel pump and gaskets. Remove sprockets and timing chain as an assembly. 2. Remove intake manifold and related parts. Remove crankcase ventilation tube and tubes from valve covers. Remove EGR cooler (if equipped). Remove valve covers and loosen rocker arm fulcrum bolts. Rotate rocker arms to the side and remove push rods (identify for proper installation). 3. Remove and identify valve lifters for proper installation. Remove camshaft thrust plate. Carefully pull camshaft toward front of engine and remove. Use caution to avoid damage to camshaft bearings. Inspection 1. Check camshaft journals for out-of-round condition. If journals exceed.0005" (.013 mm) out-of-round, replace camshaft. Check camshaft end play. Standard end play is.001-.007" (.025-.178 mm). End play service limit is.009" (.228 mm). Replace thrust plate if clearance is excessive. 2. Check camshaft journal runout. Runout limit is.005" (.013 mm). Check camshaft for alignment. Use "V" block and dial indicator. If dial gauge reads more than.0015" (.040 mm), replace camshaft. Check camshaft journal-to-bearing clearance. Service limit is.006" (.15 mm). 3. Check camshaft lobe lift. Attach dial indicator with a ball/socket attachment to camshaft carrier or "V" block. Measure lobe lift. Allowable lobe lift loss is.005" (.013 mm). If not to specification, replace camshaft. Installation 1. Oil camshaft journals with engine oil and apply Lubriplate to camshaft lobes. Carefully slide camshaft through bearings and install camshaft thrust plate with groove toward cylinder block. 2. Lubricate lifters and lifter bores with oil and install in same order as removal. Apply polyethylene grease or Lubriplate to push rod ends and install in proper positions. Lubricate rocker arms and install. 3. If any valve train components have been replaced, perform valve clearance adjustment. Install other components previously removed to complete installation. OIL PUMP When draining engine oil, ensure both drain plugs are removed from dual sump oil pan. Failure to remove both plugs will result in incorrect oil level reading after crankcase refill. Removal 1. Disconnect negative battery cable. Remove fan shroud attaching bolts and reposition shroud back over fan. Remove dipstick and tube assembly. Raise vehicle and drain crankcase. 2. Disconnect steering flex coupling. Remove 2 bolts attaching steering gear to main crossmember. Set steering gear aside away from oil pan. Remove nuts and washers attaching engine mounts to No. 2 Thursday, October 30, 2008 11:21:25 AM Page 13 2005 Mitchell Repair Information Company, LLC.

crossmember. Disconnect transmission oil cooler lines and related components. 3. Raise engine and support with blocks between engine mounts and crossmember. Remove converter inspection plate. Remove 4 attaching bolts and rear "K" braces. Remove the oil pan and related parts. Remove oil inlet tube and screen assembly. Remove the oil pump attaching bolts and remove the oil pump and intermediate drive shaft. Disassembly 1. Remove cover bolts and cover from pump. Remove inner rotor and shaft assembly, then remove outer race. See Fig. 7. 2. Drill small hole and insert self-threading sheet metal screw into oil pressure relief cap and pull from chamber. Remove spring and plunger. Identification mark (dimple) on outer race must face outward and on same side as identification mark on rotor. Rotor and shaft assembly and outer race are serviced as an assembly and parts must be replaced together. Reassembly 1. Clean, inspect and oil all parts thoroughly. Install relief valve plunger, spring and new cap. Install outer race and inner rotor and shaft assembly. 2. Install oil pump end cover and tighten bolts. Install oil inlet tube on pump. Installation CAUTION: Do not attempt to force oil pump into position if it will not seat readily. The drive shaft hex may be misaligned with distributor shaft. To align, rotate intermediate drive shaft into new position. 1. Prime oil pump by filling either inlet or outlet port with oil. Rotate pump shaft to distribute oil within pump body. 2. Position intermediate drive shaft into distributor socket. With shaft firmly seated in socket, stop on shaft should touch roof of crankcase. If necessary, remove shaft and reposition stop. 3. With stop properly positioned, insert intermediate drive shaft into oil pump. Install pump and shaft as an assembly. Tighten oil pump attaching bolts. Reverse removal procedure to complete installation. Thursday, October 30, 2008 11:21:25 AM Page 14 2005 Mitchell Repair Information Company, LLC.

Fig. 7: Exploded View of Oil Pump Assembly Ensure drive shaft hex is aligned with distributor shaft. WATER PUMP Removal 1. Disconnect negative battery cable and drain cooling system. Remove carburetor air inlet tube. Remove fan shroud and position shroud over fan. Remove fan and spacer from water pump shaft. Remove shroud and all accessory drive belts. 2. Remove all accessory brackets attached to water pump. Remove water pump pulley. Disconnect radiator lower hose, heater hose and water by-pass hose at water pump. Remove bolts that attach water pump to front cover. Remove pump and discard gasket. Thursday, October 30, 2008 11:21:25 AM Page 15 2005 Mitchell Repair Information Company, LLC.

If installing new water pump, transfer pulley from old pump. Installation 1. Clean all surfaces of gasket material to ensure good seal. Apply sealant to water pump sealing surface. Apply sealer to new gasket and install. 2. While sealer is wet, install water pump and tighten attaching bolts. Install pulley, brackets and drive belts. Adjust drive belts to specified tension. Reverse removal procedure to complete installation. For further information on cooling systems, Refer to ENGINE COOLING system article in this section. OVERHAUL CYLINDER HEAD: VALVE ARRANGEMENT I-E-I-E-I-E-I-E (Right bank, front-to-rear). E-I-E-I-E-I-E-I (Left bank, front-to-rear). CYLINDER HEAD: VALVE GUIDE SERVICING When reconditioning valves, ensure interference angles of valve and seat are not lapped out. Remove all grooves and/or score marks from end of valve stem with an oil stone. DO NOT remove more than.010" (.254 mm) from end of valve stem. 1. Valve guides are integral with cylinder head. Check valve stem-to-guide clearance. If clearance exceeds service limits, recondition valve guide. To check valve guide wear, insert Valve Stem Clearance Tool (6505-E) onto valve stem until fully seated and tighten set screw. Permit valve to drop away from seat until tool contacts valve guide. 2. Attach dial gauge to cylinder head. Position gauge indicator against center portion of tool's spherical section at right angle. Move valve in guide and note guide wear shown on dial gauge. Divide reading by 2 (division factor for tool). Resulting measurement is valve stem clearance. See VALVE SPECIFICATIONS TABLE. 3. Use valve guide cleaning tool for cleaning guides. To ream guides for installation of valves with oversize stems, use reamers in sequence and reface valve seat after valve guide is reamed. 4. Valve guide reamers are furnished in:.003" (.076 mm) oversize with standard diameter pilot,.015" (.380 mm) oversize reamer with.003" (.076 mm) oversize pilot, and.030" (.760 mm) oversize reamer with.015" (.380 mm) oversize pilot. 5. If valve face is reground, check margin width dimension. Check valve seats for proper angle and seat width. Measure valve seat runout. Valve seat runout should be within.002" (.05 mm) for intake and exhaust. Valve seat must be refaced after guide has been reamed. 6. Intake and exhaust valve seat width is.060-.080" (1.52-2.03 mm). Use scraper to break (lightly chamfer Thursday, October 30, 2008 11:21:25 AM Page 16 2005 Mitchell Repair Information Company, LLC.

or bevel) sharp top inside edge of guide. After valve guide repair, inspect valve stem end for wear before installation. Valve stem end may be reconditioned by grinding. CYLINDER HEAD: VALVE SPRING INSTALLED HEIGHT Installed height of valve spring must not exceed specification. Measure height from surface of cylinder head pad to underside of spring retainer. See Fig. 8. If height is greater than specified, install.030" (.76 mm) shim spacer on head under spring to bring height within limits. CAUTION: Install shim spacers only if necessary. Do not use more than 2 spacers, as this will over-stress springs and overload camshaft lobes. Fig. 8: Measuring Valve Spring Installed Height CYLINDER BLOCK: PISTON & ROD ASSEMBLY When removing ridge at top of cylinder bore, never cut into ring travel area more than.03125" (.794 mm). DO NOT damage crankshaft journals or cylinder wall during removal. Thursday, October 30, 2008 11:21:25 AM Page 17 2005 Mitchell Repair Information Company, LLC.

Removal 1. Before removing piston and connecting rod, ensure rods and rod caps are labeled for proper reassembly. During removal, rotate crankshaft until piston assembly being removed is at bottom of stroke. With cylinder head and oil pan removed, inspect cylinder bores for ridges and/or deposits. Move piston to be removed to bottom of bore and cover with cloth to catch metal cuttings. 2. Remove ridge at top of cylinder bores (using ridge reamer) before removing pistons from block. Rotate crankshaft and inspect connecting rods and rod caps for cylinder identification. Label them if necessary. 3. Remove rod nuts and cap. Install rubber sleeves on rod bolts and push each piston and rod assembly out through top of cylinder bore. Take care not to nick crankshaft journal or cylinder wall. Remove bearing inserts from rod and cap. Inspect for size, wear and damage. Install rod caps on mating rods. Installation 1. Check fit of new piston and/or rings in cylinder bore before assembling piston and pin to connecting rod. Check piston pin for clearance, etching or wear. Install pistons on connecting rods. See Fig. 9. 2. Oil piston rings and cylinder walls with light coat of engine oil. Ensure ring gaps are properly spaced on piston and install ring compressor on piston. See Fig. 10. 3. After bearings have been inserted, apply oil to journals and bearings. Install rod bolt protectors before installing piston and rod assembly in bore. Turn crankshaft throw to bottom of its stroke. Tap gently with wooden handle to insert piston/rod assembly into cylinder bore. Guide piston/rod assembly over crankshaft journal until rod bearing seats. 4. Match rod cap to rod and install cap. Tighten cap nuts in two steps. Repeat procedure for each piston assembly. After piston/rod assembly is installed, check side clearance between connecting rods on each crankshaft journal. Thursday, October 30, 2008 11:21:25 AM Page 18 2005 Mitchell Repair Information Company, LLC.

Fig. 9: Piston and Connecting Rod Index Mark Locations W/ arrow forward, numbers on right are for right bank, and left for left bank. Thursday, October 30, 2008 11:21:25 AM Page 19 2005 Mitchell Repair Information Company, LLC.

Fig. 10: Piston Ring Gap Spacing Check that gaps are properly spaced and that marks face up. CYLINDER BLOCK: FITTING PISTONS 1. Inspect pistons and replace any showing signs of excessive wear, wavy ring lands, or fractures. Replace piston if sponge-like or eroded surface is on edge of piston top (caused by detonation or pre-ignition). 2. Note if shiny surface on thrust side of piston is found, check for bent connecting rod. Replace piston and/or rod as necessary. Inspect connecting rods for signs of fracture and bearing bores for out-of-round and taper. 3. If bore exceeds recommended limits and/or rod is fractured, replace rod. Check pistons for fractures at ring lands, skirts and pin bosses. Check for scuffed, rough or scored skirts. Thursday, October 30, 2008 11:21:25 AM Page 20 2005 Mitchell Repair Information Company, LLC.

4. Check piston-to-cylinder bore clearance by measuring piston and bore diameters. Inspect cylinder walls for scoring, roughness or other signs of wear. Check bore for out-of-round and taper. Cylinder bore outof-round limit is.0015" (.038 mm), and service limit is.005" (.127 mm). 5. Cylinder bore taper should not be more than.010" (.254 mm). Measure diameter of cylinder bore at top, middle and bottom with gauge at right angle and parallel to centerline of engine. Measure outer diameter of piston at centerline of pin bore and 90 degrees to pin bore axis. 6. If cylinder wall is severely marred and/or worn beyond specifications, refinishing will be necessary. Before any cylinder refinishing, ensure that main bearing caps are in place and tightened to specification to avoid distortion during refinishing operation. 7. After refinishing and before measurement, clean bore with soap/water solution and oil cylinder walls. Ensure piston and cylinder bore are clean, dry, and at room temperature: 70 F (21 C) during measurement. After any refinishing operation, allow bore to cool. CYLINDER BLOCK: FITTING PISTON RINGS 1. Clean ring grooves with ring groove cleaner or piece of broken ring. Ensure oil holes (or slots) in piston are clean. Measure piston ring side and end gap clearance for all pistons. Maximum piston ring side gap clearance is.006" (.152 mm). 2. Ring side clearance should be checked with feeler gauge between ring and piston lower ring land. Gauge should slide freely around entire circumference without blinding. If step has formed around inner portion of lower ring land, piston must be replaced. 3. Using piston to position ring in cylinder bore, check ring end gap at least.63" (16 mm) from bottom of bore. Ring end gap service limit is.019" (.50 mm). Install rings on pistons with end gaps staggered at proper intervals. Ensure ring gap is not in line with thrust face of pin bore. See Fig. 10. Be sure manufacturer's marks face up when rings are installed. 4. Install oil ring expander first, followed by lower oil ring side rail and upper side rail. Do not use ring expander on side rails. When installing lower side rail, place one end between piston ring groove and expander. Hold end firmly and press down portion to be installed until side rail is in position. Install upper side rail following same procedure. 5. Using ring expander, install intermediate and upper rings. Check that all components are within specifications. If new piston rings are to be installed and no visible cross-hatch marks remain on cylinder walls, remove cylinder wall glaze using spring-type hone. After honing, clean bore and block with soap and water solution. Oil cylinder walls. CYLINDER BLOCK: FITTING PISTON PINS When removing or installing piston pin, connecting rod should be in firm contact with body of pin setting tool. Removal 1. Remove bearing inserts from connecting rod and cap. Mark pistons, pins and inserts (if reusable) to assure assembly with same rod. Press piston pin from piston and connecting rod using arbor press and Piston Pin Remover/Replacer (T68P-6135-A). Thursday, October 30, 2008 11:21:25 AM Page 21 2005 Mitchell Repair Information Company, LLC.

2. Inspect and replace any piston pin showing signs of fracture, etching or wear. Check piston pin-to-rod bore fit. Lubricate pin and small end of rod bore with engine oil. Installation 1. Check piston to bore clearance before assembling piston and pin to connecting rod. Ensure connecting rod and cap numbers are on right side, and arrow on top of piston faces front for right bank of cylinders. Rod and cap numbers are on left side, and arrow faces front for left bank. See Fig. 9. 2. Place piston pin through piston and connecting rod. Using guide bar and push rod, press pin through both piston and rod until pin is centered in piston. See Fig. 11. After pilot hub bottoms, DO NOT exceed 5000 lbs. (2275 kg) pressure with press. Make certain piston floats during pin installation operation. Fig. 11: Replacing Piston Pins CYLINDER BLOCK: CONNECTING ROD BEARINGS Following procedures are with oil pan and cylinder head removed. Selective fit bearings are used in this engine. DO NOT scrape gum or varnish deposits from bearing shells. Clean inserts and caps thoroughly in solvent. DO NOT file or lap bearing caps or use bearing shims to obtain proper bearing clearance. 1. Remove connecting rod bearing caps. Mark rods and caps for proper installation. Inspect each bearing for Thursday, October 30, 2008 11:21:25 AM Page 22 2005 Mitchell Repair Information Company, LLC.

peeling, melting, seizure or improper contact. Replace defective bearings. Use Plastigage method for bearing clearance check. 2. Measure outside diameter of crankshaft connecting rod bearing journals to determine if out-of-round or tapered. Journal out-of-round must not exceed.0006" (.015 mm) per inch. Journal taper must not exceed.0006" (.015 mm). CAUTION: If bearing is fitted to out-of-round crankpin, be sure to fit to maximum diameter of crankpin. If bearing is fitted to minimum diameter, interference between bearing and crankpin will result causing rapid bearing failure. 3. When checking connecting rod clearances, crankshaft does not have to be supported. Instead, turn crankshaft until connecting rod to be checked starts moving toward top of engine, thus unloading lower bearing. 4. Cut Plastigage (D81L-6002-B) to width of rod bearing. Place Plastigage about.25" (6.35 mm) off-center (not over oil hole or groove). Place in bearing cap, parallel with crankshaft. Install rod bearing and cap. Tightening in two steps to specifications. Always install cap with markings in original position. 5. Do not turn crankshaft with Plastigage installed. Remove rod bearing cap from crankshaft and measure Plastigage at its widest part (using scale on Plastigage package). If clearance is found to be excessive, new bearing will be required. See Fig. 12. 6. Service bearings are available in standard size and.0005" and.0010" undersize for use with new and used standard size crankshafts. After inspection and/or replacement, coat bearing surfaces with heavy engine oil. Connecting rod bearing cap and rod identification numbers must remain on same side. Always replace bearings in pairs. Never combine new and used bearings. 7. Check for shiny surface on either side of piston pin boss, indicating bent connecting rod. Twisted rods will not create identifiable wear patterns, but will disturb the action of entire crankshaft assembly and may cause excessive oil consumption. 8. Check connecting rod side clearance with dial indicator contact point resting against rod cap. Pull cap toward front of engine and zero dial indicator. Push cap toward rear of engine and compare reading to specification. If excessive, replace connecting rod and cap. 9. If side clearance is less than specification, remove rod and cap. Check for scratches, burrs, nicks or dirt between crankshaft and rod. Dress minor imperfections with oil stone. 10. During assembly, ensure oil hole in bearing aligns with oil hole in connecting rod. Ensure bearing tangs are seated in appropriate slots in rod and cap. Ensure connecting rod bolt heads are properly seated in connecting rod. Tighten connecting rod bolts in two steps. Thursday, October 30, 2008 11:21:25 AM Page 23 2005 Mitchell Repair Information Company, LLC.

Fig. 12: Using Plastigage to Check Bearing Clearance DO NOT turn crankshaft or Plastigage will smear. CYLINDER BLOCK: MAIN BEARINGS Upper and lower main bearing halves are not interchangeable. Upper half is drilled and grooved for entry of oil. 1. Inspect each bearing for peeling, melting, seizure or improper contact. Replace defective bearings. If copper-lead bearing base is visible but is not showing in more than 20% of total area, bearing is not excessively worn. 2. Measure outside diameter of crankshaft main bearing journals in at least four places to determine out-ofround or taper. Journal out-of-round must not exceed.0006" (.015 mm). Journal taper must not Thursday, October 30, 2008 11:21:25 AM Page 24 2005 Mitchell Repair Information Company, LLC.

exceed.0004" (.010 mm) per inch. Standard main bearing journal runout is.002" (.05 mm) and service limit is.005" (.13 mm). Always replace bearings in pairs. Never combine new and used bearings. Observe location of high spots on main bearings. If high spots are not in line, crankshaft may be bent and should be checked. 3. To check main bearings, shim adjacent main bearings to bearing being checked. Alternate method is to position jack under counterweight adjoining bearing being checked so weight of crankshaft will not compress Plastigage and provide incorrect reading. 4. When checking No. 1 bearing, loosen accessory drive belts to prevent tapered reading on Plastigage. DO NOT position jack under crankshaft pulley. Crankshaft post damage will result. With all bearing caps tight (other than one being checked), check clearances using Plastigage method. If undersize bearings are used on more than one journal, position them in cylinder block rather than on bearing cap. Do not turn crankshaft with Plastigage installed. 5. If standard and undersize bearing combinations do not bring bearing clearance within specified limits, crankshaft will have to be refinished and undersized bearings installed. If journal will not clean up to maximum undersize bearing, replace crankshaft. 6. If journals are remachined, ensure same journal shoulder radius is reproduced. Too small a radius will result in fatigue failure of crankshaft. Too large a radius will result in bearing failure due to radial ride of bearing. 7. When journals are refinished, chamfer oil holes and polish journals with No. 320 grit polishing cloth and engine oil. After chamfer and polish operations, clean crankshaft thoroughly in solvent and blow out oil passages with compressed air. 8. Oil new upper bearing and insert plain (unnotched) end between crankshaft and notched side of block. Insert Main Bearing Remover/Installer (6331) into hole in crankshaft and rotate bearing (opposite of engine rotation) into place. 9. Oil new lower bearing and install in bearing cap. Install main bearing cap so that arrow faces front of engine. Tighten all main bearing caps to specifications in two steps. When changing rear main bearing, rear main seal must also be replaced. Refer to, in this article, REAR MAIN BEARING OIL SEAL CYLINDER BLOCK: THRUST BEARING ALIGNMENT Install all main bearing caps except thrust bearing cap and tighten. Install thrust bearing cap with bolts, tighten finger tight. Pry crankshaft to front of engine. Then pry thrust bearing cap to rear of engine. While holding crankshaft forward, tighten main bearing cap bolts. Check crankshaft end play. Crankshaft end play service limit is.012" (.31 mm). CYLINDER BLOCK: CAM LOBE LIFT 1. Check lift of each camshaft lobe in consecutive order as follows: Remove rocker arms and make sure each push rod is in valve lifter socket. Install dial indicator so ball socket adapter of indicator rests on end Thursday, October 30, 2008 11:21:25 AM Page 25 2005 Mitchell Repair Information Company, LLC.

of push rod, and in same plane as push rod movement. 2. Connect auxiliary starter switch to starter solenoid. Turn ignition switch off. "Bump" crankshaft until tappet is on base circle of camshaft lobe. This is push rod's lowest point. 3. Zero dial indicator and continue to rotate crankshaft until push rod is in fully raised position: highest indicator reading. Compare total lift from indicator readings with specifications. 4. To check accuracy of dial indicator readings, continue to rotate crankshaft until indicator reads zero. If lift on any lobe is.005" (.13 mm) less than specifications, valve lifters are operating on worn lobes. Replace camshaft and lifters as necessary. CYLINDER BLOCK: CAMSHAFT BEARINGS Removal 1. With camshaft, flywheel and crankshaft removed from engine, push pistons to top of cylinders. Remove camshaft rear bearing bore plug. Using Camshaft Bearing Driver/Puller (T65L-6250-A), remove camshaft bearings. 2. During inner bearing removal, wrap cloth around threads of puller to protect front bearing or journal. To remove front bearing, install puller from rear of cylinder block. Installation CAUTION: Failure to use correct size expanding collet during camshaft bearing installation can cause severe bearing damage. Ensure front bearing is installed at specified distance from front face of cylinder block. 1. Bearings are available prefinished to size for standard and.015" (.38 mm) undersize journal diameters. Bearings are not interchangeable from one bore to another. When installing new bearings, oil holes must be aligned. 2. Ensure pulling plate and puller screw are centered to avoid damage to bearing. Front bearing must be installed.005-.020" (.13-.51 mm) below front face of cylinder block. Apply sealer to outside diameter and install camshaft bearing bore plug. To complete installation, reverse removal procedure. CAUTION: When checking camshaft end play, DO NOT attempt to pry camshaft back and forth with valve train load on camshaft. CYLINDER BLOCK: CAMSHAFT END PLAY 1. When checking end play, back off rocker arm adjusting bolts to relieve tension on camshaft. With engine front cover removed, push camshaft toward rear of engine and install dial indicator so that indicator stylus is on camshaft sprocket cap screw. Zero dial indicator. 2. Position large screwdriver between camshaft sprocket and block. Pull camshaft forward and release it. If dial indicator reading is not within specifications, replace thrust plate. Readjust valve clearance. Ensure lifters have enough time to bleed down before starting engine. Thursday, October 30, 2008 11:21:25 AM Page 26 2005 Mitchell Repair Information Company, LLC.

LUBRICATION OVERVIEW System has force feed with rotor type oil pump. Pressure regulator valve is located in oil pump body and is not adjustable. All oil from pump flows through full flow oil filter before entering the engine. See Fig. 13. From oil filter, oil flows to main oil gallery located on right side of camshaft to lubricate engine components. Normal oil pressure is 40-60 psi (2.8-4.2 kg/cm 2 ) at 2000 RPM. CRANKCASE OIL CAPACITY CRANKCASE OIL CAPACITY Application Quarts (Liters) All w/o Filter 4 (3.8) All w/filter 5 (4.7) Thursday, October 30, 2008 11:21:25 AM Page 27 2005 Mitchell Repair Information Company, LLC.

Fig. 13: Engine Oiling Circuit COMPONENT LUBRICATION Main Bearings Oil from main gallery enters main bearings through drilled passages in block. Camshaft Bearings Passages are drilled from each main bearing to each camshaft Bearing. Connecting Rod Bearings Thursday, October 30, 2008 11:21:26 AM Page 28 2005 Mitchell Repair Information Company, LLC.

Passages are drilled in crankshaft from main bearings to connecting rod bearings. Timing Chain Oil is forced through drilled passage from oil pump intermediate shaft to groove in thrust plate and passes around camshaft. Flow continues through two grooves in timing chain sprocket and is deflected onto timing chain. Valve Lifters, Push Rods There are oil passages drilled from main oil gallery to each lifter gallery. Oil hole in valve lifter is indexed to lifter oil gallery and oil flows into lifter. Oil from lifter is metered through disc metering valve and flows up hollow push rod. Drilled hole in push rod is indexed to hole in rocker arm and oil lubricates the upper valve train and bearings. Excess oil is returned to oil pan through drain back holes at each end of cylinder head and block. TORQUE SPECIFICATIONS TORQUE SPECIFICATIONS Application (1) Ft. Lbs. (N.m) Camshaft Sprocket Bolt 40-45 (54-61) Camshaft Thrust Plate Bolt 9-12 (12-16) Connecting Rod Nut 19-24 (26-32) Crossmember-to-Frame Bolts 35-50 (47-68) Cylinder Front Cover Bolt 12-18 (16-24) Cylinder Head Bolt (2) 65-72 (88-97) Damper-to-Crankshaft Bolt 70-90 (95-122) Exhaust Manifold Retainer Bolt 18-24 (24-32) Fan-to-Water Pump Hub Bolt 12-18 (16-24) Flywheel Bolt 75-85 (102-115) Flywheel-to-Crankshaft Bolts 75-85 (102-115) Fuel Pump-to-Front Cover Bolt 19-27 (26-37) Intake Manifold Retainer Bolt (3) 23-25 (31-34) Main Bearing Cap Bolt 60-70 (81-95) Motor Mount Through Bolts 35-50 (47-68) Motor Mount-to-Crossmember Bolts 57-65 (77-88) Motor Mount-to-Engine Bolts 35-60 (47-81) Oil Pump Mount Bolt 22-32 (30-43) Inlet Tube-to-Pump Bolt 10-15 (14-20) Inlet Tube-to-Bearing Cap Bolt 22-32 (30-43) Pulley-to-Damper Bolt 35-50 (47-68) Thursday, October 30, 2008 11:21:26 AM Page 29 2005 Mitchell Repair Information Company, LLC.

Rear Mount-to-Trans. Bolts 50-70 (68-95) Rocker Arm Fulcrum Bolt 18-25 (24-34) Valve Cover Bolts 3-5 (4-7) Water Pump Mount Bolt 12-18 (16-24) INCH Lbs. (N.m) Oil Pan 106-133 (12-15) (1) Always replace self-locking fasteners. (2) Tighten in 2 steps: Step 1-55-65 ft. lbs. (75-88 N.m); Step 2-65-72 ft. lbs. (88-97 N.m). (3) After assembly, retighten with engine at operating temperature. ENGINE SPECIFICATIONS GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS (5.0L) Application Specification Displacement Cu. In. 302 Liters 5.0 Fuel System E.F.I. HP @ RPM 165 @ 3200 Torque Ft. Lbs. @ RPM 250 @ 1600 Compr. Ratio 8.4:1 Bore 4.00" (101.60mm) Stroke 3.00" (76.20mm) GENERAL SPECIFICATIONS (5.0L HO) Application Specification Displacement Cu. In. 302 Liters 5.0 Fuel System E.F.I. & 4-Bbl. HP @ RPM 210 @ 4400 Torque Ft. Lbs. @ RPM 265 @ 3200 Compr. Ratio 8.3:1 Bore 4.00" (101.60mm) Stroke 3.00" (76.20mm) CRANKSHAFT, MAIN & CONNECTING ROD BEARING Thursday, October 30, 2008 11:21:26 AM Page 30 2005 Mitchell Repair Information Company, LLC.