Complete replacement of the 5.0L Coyote V8 long block assembly, including removal of transmission, front accessories, exhaust, and all engine-mounted components, then installation and timing of the new long block.

Warnings

Tools required

Parts

• 5.0L Coyote long block assembly × 1 — Use OEM specification
• Engine oil filter × 1 — FL-820S or equivalent
• Oil drain plug crush washer × 1 — Use OEM specification
• Valve cover gaskets (left and right) × 2 — Use OEM specification
• Timing cover gasket × 1 — Use OEM specification
• Oil pan gasket × 1 — Use OEM specification
• Intake manifold gaskets × 2 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• Thermostat housing gasket × 1 — Use OEM specification
• Water pump gasket × 1 — Use OEM specification
• Spark plugs (set of 8) × 8 — Motorcraft SP-520 or equivalent
• Serpentine belt × 1 — Use OEM specification
• Engine coolant (extended life) × 1 — Motorcraft Orange Premium
• RTV silicone sealant (Motorcraft TA-357) × 1 — TA-357
• Anti-seize compound × 1 — Use high-temperature rated
• Thread locker (blue) × 1 — Loctite 242 or equivalent

Fluids

• Motorcraft 5W-20 Synthetic Blend — 7.5 qt
• Motorcraft Orange Coolant — 16 qt
• Motorcraft MERCON LV ATF — 2 qt

Preparation

1. Park vehicle on level surface, engage parking brake, and place wheel chocks behind rear wheels
2. Disconnect negative battery cable, then positive cable. Remove battery and battery tray for access
3. Drain engine coolant completely from radiator petcock and block drains into appropriate container
4. Drain engine oil and remove oil filter
5. Relieve fuel system pressure by removing fuel pump fuse and cranking engine until it dies, then crank 2-3 more times
6. Raise vehicle on lift or jack stands at all four corners to allow transmission and transfer case access
7. Remove engine cover (plastic decorative cover on top of engine)
8. Remove front skid plate if equipped
9. Label and photograph all electrical connections, vacuum lines, and hose routing with phone or camera

Procedure

1. 1

   Remove Hood and Front Accessories
   With helper, mark hood hinge positions with paint marker, then remove four hood bolts and lift hood away. Remove air intake system from air box to throttle body including mass airflow sensor. Remove radiator hoses (upper and lower), heater hoses at firewall, and all coolant bypass hoses. Remove power steering reservoir and lines from pump. Cap all open lines. Disconnect transmission cooler lines at radiator. Remove radiator support brackets and lift radiator and fan assembly out as complete unit.
2. 2

   Disconnect Engine Electrical and Fuel Systems
   Disconnect both fuel lines at fuel rail using fuel line disconnect tools. Disconnect throttle body electrical connector, eight fuel injector connectors, both ignition coil harness connectors (4 coils per side), both camshaft position sensor connectors, crankshaft position sensor, oil pressure sensor, coolant temperature sensors, and knock sensors. Disconnect main engine harness connector at firewall (large multi-pin connector). Remove alternator electrical connections. Disconnect oxygen sensor connectors (4 total - 2 upstream, 2 downstream). Tie engine harness up and away from block.
3. 3

   Remove Exhaust System and Accessories
   From underneath vehicle, disconnect exhaust Y-pipe from both exhaust manifolds at flange connections. Support Y-pipe and remove four nuts per side (8 total). Lower exhaust forward section and set aside. Remove serpentine belt using tensioner tool. Remove alternator (three bolts) and power steering pump with lines attached, securing them to frame with mechanics wire. Remove A/C compressor mounting bolts but leave hoses connected - secure compressor to frame rail with wire to avoid hose damage.
4. 4

   Remove Transmission and Transfer Case Connections
   From underneath, remove front driveshaft from transfer case (mark orientation). Remove rear driveshaft from transfer case (mark orientation). Disconnect transfer case shift motor electrical connector and vent hose. Disconnect transmission electrical connectors (main harness, speed sensors). Remove transmission crossmember bolts and carefully lower crossmember. Support transmission with transmission jack. Remove starter motor (three bolts). Remove flywheel/flexplate inspection cover. Mark flexplate-to-torque converter relationship, then remove four torque converter nuts through inspection hole while rotating engine by crankshaft bolt.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
5. 5

   Disconnect Motor Mounts and Prepare for Engine Removal
   Remove passenger side motor mount through-bolt (vertical bolt through mount). Remove driver side motor mount through-bolt. Ensure transmission jack is securely supporting transmission weight. Verify all electrical connectors, hoses, lines, and mechanical connections are disconnected from engine. Double-check throttle cable/electronic throttle, brake booster vacuum line, and any remaining PCV or evaporative emission hoses are clear.
   Torque spec

   Mounting Bolts59 Nm (44 lb-ft)
6. 6

   Remove Transmission-to-Engine Bolts
   With transmission securely supported on transmission jack, remove all transmission-to-engine bellhousing bolts. There are typically 8-10 bolts in various locations around bellhousing perimeter including upper bolts accessed from above and lower bolts accessed from beneath. Ensure torque converter remains fully seated in transmission as engine is separated. Install at least two guide pins (long bolts with heads cut off) in upper bolt holes to prevent engine from binding during extraction.
   Torque spec

   Transmission-to-Engine Bolts55 Nm (41 lb-ft)
7. 7

   Extract Engine from Vehicle
   Position engine hoist with load leveler attached. Install lifting chains to factory lifting eyes on engine (one front, one rear of cylinder heads). Take up slack in hoist and support full engine weight. Carefully raise engine slightly while observing for any remaining attached components. Tilt engine slightly nose-up using load leveler to clear transmission input shaft and bellhousing. Slowly lift and pull engine forward, keeping it level side-to-side. Once clear of transmission, raise engine high enough to clear radiator support and front of vehicle. Roll hoist with engine away from vehicle and lower onto engine stand or suitable work surface.
8. 8

   Transfer External Components to New Long Block
   If new long block does not include external components, transfer the following from old engine to new long block: alternator bracket, power steering pump bracket, A/C compressor bracket, motor mount brackets, oil filter adapter, engine lifting eyes, coolant temperature sensors, oil pressure sender, knock sensors, crankshaft position sensor, camshaft position sensors, flywheel/flexplate (if reusing), engine-to-transmission dowel pins. Clean all mounting surfaces thoroughly. Apply anti-seize to sensor threads. Install flywheel/flexplate to crankshaft flange in original orientation using new bolts, tightening in star pattern.
   Torque spec

   Flywheel Bolts95 Nm (70 lb-ft)

   Sensor Bolts14 Nm (10 lb-ft)
9. 9

   Verify New Long Block Timing and Preparation
   Confirm new long block timing marks are properly aligned at TDC cylinder #1. Both camshaft timing marks should align with cylinder head marks and crankshaft keyway should be at 12 o'clock. Verify all freeze plugs are installed and not leaking. Check that oil galley plugs are tight. Install new oil drain plug with new crush washer. Verify valve covers are properly torqued in sequence or install with new gaskets if not pre-installed. Apply thin coat of assembly lube to crankshaft seal surface. Install new oil filter and pre-fill with clean oil. Rotate engine by hand two complete revolutions and verify smooth rotation with no binding.
   Torque spec

   Oil Drain Plug35 Nm (26 lb-ft)

   Cover Bolts20 Nm (15 lb-ft)
10. 10

    Install New Long Block into Vehicle
    Position hoist with new long block over engine bay. Install guide pins in upper transmission bolt holes. Carefully lower engine into bay while aligning with transmission bellhousing and motor mount brackets. Tilt engine using load leveler to align transmission input shaft with pilot bearing/bushing in crankshaft. Ensure torque converter remains fully seated in transmission. Guide engine rearward onto transmission, ensuring input shaft enters clutch disc hub or torque converter pilot smoothly without forcing. Continue lowering until motor mount through-bolt holes align with frame brackets.
11. 11

    Install Motor Mounts and Transmission Bolts
    Install motor mount through-bolts on both sides and torque to specification. Remove guide pins and install all transmission-to-engine bellhousing bolts, starting with upper bolts and working around perimeter. Tighten all bolts evenly in star pattern to specification. Verify torque converter pilot hub is fully engaged in crankshaft. Align torque converter to flexplate using marks made during disassembly and install four torque converter nuts through inspection cover, rotating crankshaft as needed. Torque converter nuts to 27 Nm (20 lb-ft). Install flexplate inspection cover. Remove transmission jack once all bolts are secured.
    Torque spec

    Mounting Bolts59 Nm (44 lb-ft)

    Transmission-to-Engine Bolts55 Nm (41 lb-ft)
12. 12

    Install Front Accessories and Exhaust
    Install starter motor and torque bolts to 25 Nm (18 lb-ft). Reinstall transmission crossmember and torque mounting bolts to specification. Install A/C compressor to mounting bracket and torque bolts. Install power steering pump to bracket and torque bolts. Install alternator and torque mounting bolts. Apply anti-seize to exhaust manifold studs. Position new exhaust manifold gaskets (if replacing) and install exhaust Y-pipe to manifolds, starting nuts by hand. Torque exhaust manifold nuts to specification working from hot center of manifold to cold outer edges.
    Torque spec

    Exhaust Manifold Nuts30 Nm (22 lb-ft)
13. 13

    Reconnect All Electrical and Fuel Connections
    Reconnect main engine harness connector at firewall. Working systematically, reconnect all electrical connections: throttle body, eight fuel injectors, eight ignition coils (verify proper coil-to-cylinder assignment), both camshaft position sensors, crankshaft position sensor, oil pressure sender, coolant temperature sensors, knock sensors, oxygen sensors (all four), transmission connectors, and transfer case shift motor. Reconnect both fuel lines to fuel rail, ensuring they click securely into quick-connect fittings. Verify no connectors remain disconnected.
14. 14

    Install Cooling System and Drive Components
    Install radiator and fan assembly into radiator support and secure with mounting brackets. Connect upper and lower radiator hoses with new clamps. Connect heater hoses at firewall. Connect transmission cooler lines to radiator. Reconnect power steering lines to pump. Install serpentine belt following correct routing diagram (typically found on fan shroud decal) and ensure proper seating on all pulleys. Install front and rear driveshafts to transfer case matching orientation marks made during removal. Torque driveshaft bolts to specification (24 Nm / 18 lb-ft for U-joint straps).
15. 15

    Fill Fluids and Final Preparations
    Fill engine with 7.5 quarts of Motorcraft 5W-20 synthetic blend oil. Fill cooling system with 16 quarts of Motorcraft Orange extended-life coolant mixed 50/50 with distilled water. Start filling at radiator, then engine block. Run engine briefly and add coolant as system purges air. Check transmission fluid level and add MERCON LV as needed (approximately 2 quarts lost during cooler line disconnection). Check power steering fluid and top off with MERCON LV. Reinstall battery tray, battery, and connect positive then negative terminals. Remove all tools from engine bay. Reinstall engine cover. With helper, install hood aligning with marks made during removal. Adjust hood as necessary for proper fit and gaps.

Reassembly

1. Verify all torque specifications were followed, particularly TTY bolts which must not be reused
2. Ensure all electrical connectors are fully seated with locking tabs engaged
3. Check that no tools, rags, or parts remain in engine bay or underneath vehicle
4. Verify serpentine belt is properly routed and tensioned
5. Confirm all fluid levels are correct: engine oil, coolant, power steering, transmission
6. Double-check that all hose clamps are tight and properly positioned

Verification

• Turn ignition to ON position (not start) and verify no warning lights remain illuminated except normal oil pressure light. Listen for fuel pump priming (2-3 second hum from rear of vehicle)
• Start engine and verify immediate oil pressure indication. If no pressure within 5 seconds, shut down immediately and investigate
• Allow engine to idle and warm to operating temperature while monitoring for leaks (oil, coolant, fuel, exhaust). Address any leaks immediately
• Verify cooling fans cycle on at appropriate temperature (approximately 200-205°F)
• Check that transmission shifts smoothly through all gears with vehicle in park (selector movement only)
• After reaching operating temperature, shut down engine and allow to cool for 30 minutes. Recheck all fluid levels and top off as necessary
• Perform test drive starting with low-speed neighborhood operation. Verify smooth acceleration, no abnormal noises, proper engine temperature, and no warning lights. Monitor oil pressure gauge
• After test drive, recheck all fluid levels and inspect entire engine bay and underneath vehicle for any new leaks
• Check and record any diagnostic trouble codes using OBD-II scanner. Clear any codes related to battery disconnection
• After 500 miles, change engine oil and filter, then recheck all fluid levels and retorque valve cover bolts to specification

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