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Ford 2009 Mustang Workshop Manual

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SECTION 303-01C: Engine — 5.4L (4V)
DISASSEMBLY
Engine
Special Tool(s)
3-Jaw Puller
303-D121 or equivalent
Compressor, Valve Spring
303-452 (T93P-6565-AR)
Installer, Connecting Rod
303-442 (T93P-6136-A)
Remover, Crankshaft Front Oil Seal
303-107 (T74P-6700-A)
Remover, Crankshaft Rear Oil
Slinger
303-514 (T95P-6701-AH)
Remover, Crankshaft Rear Oil Seal
303-519 (T95P-6701-EH)
Slide Hammer
100-001 (T50T-100-A)
Strap Wrench
303-D055 (D85L-6000-A) or
equivalent
2009 Mustang Workshop Manual
Procedure revision date: 12/12/2008

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  Summary of Contents for Ford 2009 Mustang

  • Page 1 SECTION 303-01C: Engine — 5.4L (4V) 2009 Mustang Workshop Manual DISASSEMBLY Procedure revision date: 12/12/2008 Engine Special Tool(s) 3-Jaw Puller 303-D121 or equivalent Compressor, Valve Spring 303-452 (T93P-6565-AR) Installer, Connecting Rod 303-442 (T93P-6136-A) Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
  • Page 2 Material Item Specification Motorcraft® Metal Surface Prep — ZC-31-A Silicone Gasket Remover — ZC-30 NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage. NOTICE: 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.
  • Page 3 5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove the crankshaft rear seal. 6. Remove the 8 bolts and the rear seal retainer plate. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces.
  • Page 4 8. Disconnect the coolant hose from the thermostat housing. 9. Remove the coolant tube bracket nut. 10. Disconnect the 2 coolant vent hoses from the intake manifold.
  • Page 5 11. Disconnect the 2 upper radiator hoses from the intake manifold. 12. Disconnect the Engine Coolant Temperature (ECT) sensor electrical connector. 13. Remove the 2 nuts and the thermostat housing assembly. 14. Disconnect the coolant hose from the Charge Air Cooler (CAC).
  • Page 6 15. Loosen the 4 coolant pump pulley bolts. 16. Rotate the accessory drive belt tensioner clockwise and remove the accessory drive belt.
  • Page 7 17. Remove the bolt, Supercharger (SC) drive belt tensioner and the drive belt. 18. Remove the power steering tube bracket nut. 19. Remove the power steering tube bracket bolt. 20. Remove the 2 power steering reservoir bracket bolts.
  • Page 8 21. Remove the 3 bolts and the power steering pump and reservoir assembly. 22. Disconnect the generator electrical connector. 23. Remove the stud bolt, 2 bolts and the generator.
  • Page 9 24. Remove the bolt and the accessory drive belt tensioner. 25. Remove the stud bolt and the accessory drive belt idler pulley (smooth).
  • Page 10 26. Remove the bolt and the accessory drive belt idler pulley (grooved). 27. Remove the 4 bolts and the coolant pump pulley. 28. Remove the 3 bolts and the 3 drive belt idler pulleys. 29. Disconnect the 2 EGR tube fittings. Remove the EGR tube.
  • Page 11 30. Disconnect and remove the crankcase ventilation tube. 31. Disconnect the Throttle Position (TP) sensor electrical connector. 32. Disconnect the electronic throttle control electrical connector.
  • Page 12 33. Remove the 4 bolts and the and spacer assembly. 34. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector. 35. Detach the 2 wiring harness pin-type retainers (1 shown) from the coolant tube assembly bracket. 36. Disconnect the LH Heated Oxygen Sensor (HO2S) electrical connector and pin-type retainer.
  • Page 13 37. Disconnect the bubbler tube from the 38. Remove the 2 bolts and the wiring harness retaining bracket. 39. Detach the 2 wiring harness pin-type retainers.
  • Page 14 40. Disconnect the PCV valve electrical connector. 41. Disconnect the 4 RH fuel injector electrical connectors. 42. Disconnect the fuel rail pressure and temperature sensor electrical connector. 43. Remove the nut and the RH radio interference capacitor.
  • Page 15 44. Disconnect the EGR valve electrical connector. 45. Detach the wiring harness from the RH coil-on-plug cover stud bolt. 46. Detach the wiring harness retainers from the RH valve cover stud bolts.
  • Page 16 47. Remove the bolt, stud bolt and the RH coil-on-plug cover. 48. Disconnect the 4 RH coil-on-plug electrical connectors. Remove the 4 RH coil-on-plugs. 49. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and the 2 wiring harness pin-type retainers.
  • Page 17 51. Disconnect the Intake Air Temperature 2 (IAT2) sensor electrical connector. 52. Disconnect the 4 LH fuel injector electrical connectors. 53. Remove the nut and the LH radio interference capacitor.
  • Page 18 54. Detach the wiring harness retainers from the LH valve cover stud bolts. 55. Remove the 2 bolts and the LH coil-on-plug cover. 56. Disconnect the 4 LH coil-on-plug electrical connectors. Remove the 4 LH coil-on-plugs. 57. Remove the wiring harness assembly from the engine. 58.
  • Page 19 59. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Remove the 14 bolts and the intake manifold assembly.
  • Page 20 62. Clean and inspect the RH exhaust manifold. For additional information, refer to Section 303-00 63. Remove and discard the 8 RH exhaust manifold studs. 64. Remove the 4 bolts and the LH engine support insulator bracket. 65. Remove 8 nuts and the LH exhaust manifold. Discard the nuts and gaskets.
  • Page 21 69. Remove the oil level indicator, the bolt and the oil level indicator tube. Remove and discard the oil level indicator tube O-ring seal. 70. Remove the 3 bolts and the coolant tube assembly.
  • Page 22 71. NOTICE: A new oil cooler must be installed or severe damage to the engine can occur. Remove the 6 bolts and the oil cooler. Discard the oil cooler and the gaskets. 72. Remove the 8 bolts and the oil filter adapter. Discard the oil filter adapter gasket.
  • Page 23 Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces. 75. Remove the 3 bolts and the oil pump screen and pickup tube assembly. Discard the O-ring seal. 76.
  • Page 24 78. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Remove the bolts, stud bolts and LH valve cover.
  • Page 25 81. Remove the 4 bolts and the coolant pump. 82. Using the Strap Wrench, remove the crankshaft pulley bolt and the washer. Discard the bolt. 83. Using the 3-Jaw Puller, remove the crankshaft pulley.
  • Page 26 84. Using the Crankshaft Front Oil Seal Remover, remove the crankshaft front seal. 85. NOTICE: 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.
  • Page 27 NOTE: Use compressed air to remove any foreign material in the spark plug well before removing the spark plugs. NOTE: RH shown, LH similar. Remove the 8 spark plugs. 87. NOTICE: If the components are to be reinstalled, they must be installed in their original positions. Mark the components for installation into their original locations.
  • Page 28 90. Remove the crankshaft sensor ring. 91. Remove the crankshaft washer. 92. Remove the 2 bolts and the RH primary timing chain tensioner.
  • Page 29 93. Remove the RH primary timing chain tensioner arm. 94. Remove the RH primary timing chain. 95. Remove the 2 bolts and the RH primary timing chain guide. 96. Remove the 2 bolts and the LH primary timing chain tensioner.
  • Page 30 97. Remove the LH primary timing chain tensioner arm. 98. Remove the LH primary timing chain. 99. Remove the 2 bolts and the LH primary timing chain guide.
  • Page 31 100. Remove the crankshaft sprocket. 101. Remove the 3 bolts and the oil pump. 102. NOTICE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed. NOTICE: Place clean shop towels over exposed engine cavities.
  • Page 32 103. NOTICE: 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 cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
  • Page 33 105. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent, following manufacturer's instructions. 106. NOTE: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation Remove the bolts and the connecting rod caps for pistons No.
  • Page 34 108. To remove pistons 2, 3, 4, 5, 7 and 8, turn the crankshaft 90 degrees and repeat the previous steps. 109. NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage. Remove the crankshaft main bearing cap fasteners.
  • Page 35 110. Remove the main bearing caps, the lower crankshaft main bearings and the lower thrust washer. 111. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.