Ford Coyote Engines: How to Rebuild

In the early 1990s, Ford moved away from its decades-old small-block pushrod V-8 engine designs and introduced a new “modular” overhead-cam (OHC) V-8 engine, which was the 4.6L V-8. This design was used in all of Ford’s V-8 applications—from F-150 trucks to Mustangs and Crown Victorias. After 20 years of the 4.6L engine, it was once again time for a major update, and the Coyote V-8 engine was introduced for the 2011 model year. While more evolutionary than revolutionary, displacement was increased from 4.6L to 5.0L, and every part of the engine was improved with modern technology. The Coyote engine is simply better and more powerful than its predecessors.

Now, the Coyote engine is nearly 15 years old. While they are very durable engines, the older units have accumulated a significant number of miles and are starting to wear out. In Ford Coyote Engines: How to Rebuild, industry veteran Jim Smart takes you through all of the steps to return your Coyote engine to like-new condition. Heads, cams, the valvetrain, rotating assemblies, engine blocks, machining, break-in, and tuning are all covered.

In addition, Smart provides an in-depth history of the four different Coyote engine generations and provides expert knowledge about planning your build, parts selection, and the engine math that is required to make the best rebuild decisions. Whether you want to do your own rebuild or farm it out to a professional (as an informed customer), this book provides all of the knowledge you need to return your Coyote engine to its former glory.

Acknowledgments  

Chapter 1: Introduction to the Coyote Engine

The Block

Rotating Assembly

Advanced Cylinder Heads 

Camshaft and Valvetrain 

Induction

Exhaust 

Oiling System 

Cooling System 

The GT350 5.2L Voodoo 

Gen 3 Coyote: 2018–2023 

Gen 3 Cylinder Heads and Valvetrain 

Dual Fuel-Injection Technology 

Gen 4 Changes 

Coyote Economics 

Chapter 2: Before You Begin

Horsepower and Torque 

Engine Removal 

Organization and a Clean Shop 

Tools to Rent 

Torque Wrench/Torque-Angle 

Other Tools

Building a Coyote Stroker 

Stroker Power Facts 

Proper Assembly Technique 

Chapter 3: Teardown and Inspection

Inspection

Engine Electronics 

Broken Fasteners  

Casting Inspection 

Chapter 4: Selecting Parts

The Block 

Sleeves Equal Endurance 61 Rotating Assembly

Piston-Ring Selection 

Lubrication 

Cylinder-Head Selection 

Camshaft and Valvetrain 

Cooling System  

Induction 

Throttle Body 

Injectors 

Ignition 

Engine Electronics 84 More Details 

Chapter 5: Machine Shop 

Finding a Reputable Machine Shop 

Be Prepared 

Machine Work

Dynamic Balancing 

The Details 

Head Bolt/Stud Conversion 

Chapter 6: Final Assembly 

Getting Started  

Reciprocating Parts  

Lubrication  

Top End  

Cam Timing 

Finishing Touches 

Chapter 7: Final Preparation, Break-In, and Tuning 

Lubrication 

Cooling System 

Ready to Fire 

Ignition 

Exhaust System 

Calculating Fuel-Line Size 

Selecting Injector Size 

Fuel Pump 

E85 

Mass Airflow Sensor 

Dyno Tuning Provides Power and Reliability 

Chapter 8: Engine Math

Displacement 

Calculating Compression Ratio 

Combustion-Chamber Volume 

Converting Cubic Inches to Cubic Centimeters and Liters 

Compressed Head-Gasket Volume 

Piston/Deck-Height Volume 

Piston Dish/Dome Volume 

How Does This Affect Compression Ratio? 

Calculating Horsepower and Torque 

Power-to-Weight Facts 

Estimating Horsepower at the Drag Strip 

Appendix 

Source Guide