Connecting Rod Bearings

This procedure covers the removal, inspection, and replacement of the connecting rod bearings on the 5.0L Coyote V8 engine, requiring complete engine disassembly from the vehicle.

Warnings

Tools required

Parts

• Connecting rod bearing set (standard or appropriate oversize) × 1 — Measure crankshaft journals before ordering
• Oil pan gasket × 1 — Use OEM specification
• Front cover gasket × 1 — Use OEM specification
• Timing chain cover seal × 1 — Use OEM specification
• Valve cover gaskets × 2 — Use OEM specification
• Oil filter × 1 — Motorcraft FL-820-S or equivalent
• Connecting rod bolts × 16 — Use OEM specification - replace mandatory
• Head gaskets (if heads removed) × 2 — Use OEM specification
• Intake manifold gaskets × 1 — Use OEM specification
• Exhaust manifold gaskets × 2 — Use OEM specification
• RTV silicone sealant (Motorcraft TA-357) × 2 — Use OEM specification

Fluids

• Motorcraft 5W-20 Synthetic Blend — 7.5 qt
• Motorcraft Orange Coolant — 16 qt

Preparation

1. Position vehicle on level ground with parking brake engaged and wheel chocks installed
2. Disconnect negative battery cable and remove engine cover
3. Drain engine oil completely and remove oil filter
4. Drain cooling system into appropriate container
5. Remove radiator, cooling fans, and upper/lower radiator hoses
6. Label and disconnect all electrical connectors, vacuum lines, and fuel lines from engine
7. Relieve fuel system pressure before disconnecting fuel lines
8. Remove air intake system, throttle body, and intake manifold
9. Remove serpentine belt and all accessory brackets (alternator, A/C compressor, power steering)
10. Disconnect exhaust system at manifolds
11. Support transmission with jack and remove bellhousing-to-engine bolts
12. Attach engine hoist with chains to factory lifting points on cylinder heads
13. Remove engine mount bolts and carefully lift engine from vehicle
14. Mount engine securely on engine stand and position for access to oil pan

Procedure

1. 1

   Remove oil pan and windage tray
   Remove all oil pan bolts in reverse of tightening sequence. Carefully separate oil pan from engine block using plastic gasket scraper - do not pry on sealing surfaces. Remove windage tray mounting bolts and remove tray. Inspect oil pan for metal debris indicating bearing failure.
2. 2

   Remove oil pump and pickup tube
   Remove oil pump mounting bolts and carefully withdraw oil pump assembly. Remove oil pump pickup tube mounting bolts. Inspect pump pickup screen for debris. Set aside pump components for reinstallation.
3. 3

   Identify and mark connecting rods
   Rotate crankshaft to position cylinder 1 at bottom dead center. Each connecting rod and cap should have factory markings (1-8). If markings are unclear, use permanent marker to clearly mark each rod and cap with cylinder number and orientation (forward direction). Mark caps to ensure they are reinstalled on the same rod in the same orientation.
4. 4

   Remove connecting rod caps and pistons
   Starting with cylinder 1, remove both connecting rod bolts and carefully lift off rod cap with bearing shell. Push piston and rod assembly upward out of cylinder bore - guide carefully to avoid scratching cylinder wall. Remove upper bearing shell from rod. Place rod cap with lower bearing back onto rod and loosely install old bolts to keep matched. Repeat for all 8 cylinders, keeping all components organized by cylinder number.
   ⚠Do not allow connecting rods to strike crankshaft journals during removal. Cover rod bolts with rubber hose if necessary to prevent damage.
5. 5

   Inspect crankshaft journals
   Clean all 8 connecting rod journals with lint-free cloth and solvent. Inspect each journal for scoring, discoloration, or damage. Use micrometer to measure diameter of each rod journal in at least 3 places (top, middle, bottom) and check for out-of-round condition. Journal diameter should be 2.0870-2.0878 inches. Record all measurements to determine if crankshaft requires grinding and what bearing size is needed (standard, 0.010", 0.020", etc.).
   ℹ️If any journal is more than 0.001" out-of-round or under minimum specification, crankshaft must be reground or replaced.
6. 6

   Clean and inspect connecting rods
   Thoroughly clean all connecting rods and caps with solvent. Inspect rod big end bores for scoring or damage. Use dial bore gauge to measure big end bore diameter with cap torqued to specification using NEW bolts. Inspect rod small end bushings for wear. Check connecting rods for twist or bend using specialized alignment fixture if available. Replace any damaged connecting rods.
   ⚠Small end bushings in Coyote rods are not serviceable. If worn, entire rod must be replaced.
7. 7

   Select and prepare new bearings
   Based on crankshaft measurements, select correct bearing size. Bearings must be specific to 5.0L Coyote engine. Clean bearing installation surfaces on connecting rods and caps with clean lint-free cloth - they must be completely free of oil. Inspect new bearing shells for damage and ensure oil holes align properly with rod oil passages.
8. 8

   Check bearing clearance with Plastigage
   Install upper bearing shell (with oil hole) into connecting rod, ensuring tang engages slot. Install lower bearing shell into rod cap. Place strip of Plastigage lengthwise on crankshaft journal. Install rod cap with bearings onto crankshaft journal in correct orientation. Install NEW connecting rod bolts and torque using the three-step procedure: Step 1 to 18 lb-ft, Step 2 to 33 lb-ft, then Step 3 rotate additional 90 degrees. Do NOT rotate crankshaft with Plastigage installed. Remove cap and measure crushed Plastigage width using package scale. Clearance should be 0.0011-0.0024 inches. Repeat for all 8 rod journals.
   ⚠Bearings must be completely dry during Plastigage measurement. Any oil will cause false readings.
   ℹ️If clearance is too tight, verify correct bearing size. If too loose, undersize bearings may be needed.
   Torque spec

   Connecting Rod Bolts45 Nm (33 lb-ft) + 90°
9. 9

   Install connecting rod bearings
   Once bearing clearances are verified acceptable, remove all Plastigage residue completely. Lubricate crankshaft journals and new bearing shells thoroughly with clean engine assembly lube or fresh engine oil. Install upper bearing shell into connecting rod with tang engaged in slot. Position piston ring gaps per manufacturer specification (typically staggered 120 degrees apart). Compress piston rings using ring compressor.
   ℹ️Ring end gaps should be staggered so no two rings have gaps aligned.
10. 10

    Install piston and rod assemblies
    Rotate crankshaft to position journal for cylinder 1 at bottom dead center. Guide piston and rod assembly into cylinder 1 bore with piston facing forward (mark on piston crown faces front of engine). Tap piston gently into bore using wooden or plastic handle while guiding rod onto journal. Install lower bearing shell into rod cap with tang engaged. Lubricate lower bearing thoroughly. Install rod cap in correct orientation matching marks made earlier.
    ⚠Ensure connecting rod does not scratch cylinder wall during installation. Use rod bolt protectors if needed.
11. 11

    Torque connecting rod bolts
    Install NEW connecting rod bolts hand-tight. Using torque wrench and angle gauge, torque bolts in three-step sequence: First torque to 18 lb-ft, then torque to 33 lb-ft, then rotate each bolt an additional 90 degrees using angle gauge. Verify rod side clearance on journal is 0.0051-0.0119 inches using feeler gauge. Repeat installation process for remaining 7 cylinders. After all rods are installed, rotate crankshaft by hand through 2 complete rotations to verify no binding.
    ⚠️Connecting rod bolts are torque-to-yield design and must be replaced. Never reuse old bolts.
    Torque spec

    Connecting Rod Bolts45 Nm (33 lb-ft) + 90°
12. 12

    Reinstall oil pump and pickup
    Install new O-ring on oil pump pickup tube. Install pickup tube and torque mounting bolts to specification. Prime oil pump by packing with petroleum jelly. Install oil pump assembly and torque mounting bolts to specification. Verify pump rotates freely by turning crankshaft.
    Torque spec

    Mounting Bolts34 Nm (25 lb-ft)
13. 13

    Install oil pan
    Clean all gasket surfaces thoroughly on engine block and oil pan using plastic scraper. Apply thin bead of RTV sealant (Motorcraft TA-357) at front cover-to-block and rear seal retainer-to-block joints. Install new oil pan gasket. Position oil pan and install all bolts hand-tight. Torque oil pan bolts to specification in sequence starting at center and working outward. Allow RTV to cure for minimum 30 minutes before adding oil.
    Torque spec

    Gasket Bolts25 Nm (19 lb-ft)
14. 14

    Reinstall engine and accessories
    Remove engine from stand and attach to engine hoist. Carefully lower engine into vehicle, aligning with transmission bellhousing and engine mounts. Install and torque engine mount bolts and bellhousing bolts to specification. Reinstall all accessories, brackets, intake manifold, exhaust manifolds, and cooling system components in reverse order of removal. Reconnect all electrical connectors, vacuum lines, and fuel system. Install new oil filter and fill engine with 7.5 quarts of Motorcraft 5W-20 oil. Refill cooling system with 16 quarts of Motorcraft Orange coolant.
    ℹ️Double-check all electrical connections and ensure no components were left disconnected.
15. 15

    Initial startup and break-in
    Reconnect battery. Prime oil system by cranking engine with fuel pump fuse removed and spark plugs removed until oil pressure gauge shows pressure (typically 5-10 seconds). Reinstall spark plugs and fuel pump fuse. Start engine and immediately verify oil pressure. Allow engine to idle and monitor for leaks, unusual noises, or low oil pressure. Engine should be brought up to operating temperature slowly. Monitor oil pressure during initial 30-minute break-in period. Avoid high RPM or load for first 500 miles.
    ⚠️If oil pressure light remains on or pressure gauge shows low pressure, immediately shut down engine and investigate. Running engine without oil pressure will destroy new bearings instantly.
    ⚠Monitor engine closely for first several minutes of operation. Any knocking or unusual noise may indicate bearing installation problem.

Reassembly

1. All gaskets and seals must be replaced - never reuse old gaskets
2. Follow all torque specifications precisely using calibrated torque wrench
3. Connecting rod bolts must be torqued in three-step sequence with final angle rotation
4. Apply thread locker only where specified by manufacturer
5. Ensure all wiring harnesses are routed properly and secured with factory clips
6. Verify serpentine belt is routed correctly and properly tensioned

Verification

• Engine should start readily and maintain oil pressure above 20 PSI at idle when warm
• No oil leaks visible from oil pan, front cover, or valve covers after 30-minute run period
• Engine runs smoothly with no knocking, ticking, or abnormal noises
• Verify coolant level is stable and no leaks present after reaching operating temperature
• Check oil level after initial run and top off if necessary - level may appear high initially due to oil coating internal components
• Monitor oil pressure during test drive under various loads - should increase with RPM
• Perform oil and filter change after first 500 miles of break-in period

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