303-01b Engine — 5.

4L (3V) 303-01b

SECTION : 303-01b Engine — 5.4L (3V)

VEHICLE APPLICATION : 2006.0 BF Falcon
CONTENTS PAGE
SPECIFICATIONS
Specifications .......................................................................................................................303-01b-1
DESCRIPTION AND OPERATION
Engine ..................................................................................................................................303-01b-5
DIAGNOSIS AND TESTING
Engine ..................................................................................................................................303-01b-7
IN-VEHICLE REPAIRS
Intake Manifold Upper ..........................................................................................................303-01b-8
Valve Cover LH and RH (shown) .........................................................................................303-01b-9
Crankshaft Pulley ..............................................................................................................303-01b-12
Crankshaft Front Oil Seal .................................................................................................303-01b-13
Engine Front Cover ...........................................................................................................303-01b-14
Timing Gears, Chains, Tensioners, VCT Sprocket Assemblies and VCT Housings ........303-01b-17
Camshaft (LH shown, RH opposite hand) ........................................................................303-01b-28
Rocker Arm, Lash Adjuster, Valve Spring and Valve Stem Seal ......................................303-01b-37
Valve Spring and Valve Stem Seal ....................................................................................303-01b-37
Exhaust Manifold (LH shown, RH opposite hand) .............................................................303-01b-38
Oil Filter Adapter ................................................................................................................303-01b-39
Oil Pressure Sender ..........................................................................................................303-01b-40
Oil Level Indicator and Tube ..............................................................................................303-01b-40
Oil Pan ...............................................................................................................................303-01b-40
Oil Pump Screen and Pickup Tube ....................................................................................303-01b-43
Drive-Plate .........................................................................................................................303-01b-43
Crankshaft Rear Oil Seal ..................................................................................................303-01b-44
Engine Mounts - RH ...........................................................................................................303-01b-45
Engine Mounts - LH ...........................................................................................................303-01b-45
Engine Removal .................................................................................................................303-01b-46
DISASSEMBLY
Engine ................................................................................................................................303-01b-55
DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES
Cylinder Head ....................................................................................................................303-01b-66
ASSEMBLY
Engine ................................................................................................................................303-01b-70

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303-01b-1 Engine - 5.4L (3V) 303-01b-1

SPECIFICATIONS

General Specifications
Description Specification
Lubricants and Sealants
SAE 5W-20 Premium Synthetic Blend Motor Oil WSS-M2C153-H replaced by
XO-5W20-QSP or equivalent WSS-M2C930-A (at Copperhead) - Initial Fill
Only. This Oil is then replaced with 5W-30
ILSAC GF3 WSS-M2C915-A at First Vehicle
Service in FoA, in order to be common with
4.0L I6 Engine Oil.
Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon WSS-M97B51-A1 (yellow color)
VC-7-B) or equivalent¹
Metal Surface Prep ZC-31
Silicone Gasket and Sealant F7AZ-19554-EA or equivalent WSE-M4G323-A4
Instant Adhesive E8AZ-19554-A or equivalent WSK-M2G402-A4
Silicone Gasket Remover ZC-30
Engine
Displacement 5.4L (330 CID)
Number of cylinders 8
Bore 90.2 mm (3.55 in)
Stroke 105.8 mm (4.17 in)
Firing order 1-3-7-2-6-5-4-8
Oil pressure minimum at 2,000 rpm (engine at normal 517 kPa (75 psi)
operating temperature)
Oil capacity 6.0 Litres (with new Oil Filter)
Compression ratio 9. 8:1
Cylinder Head and Valve Train
Combustion chamber volume 48.1-51.1 cc (2.94-3,12 cu in)
Valve arrangement (front to rear) - LH I-E-I-I-E-I-I-E-I-I-E-I
Valve arrangement (front to rear) - RH I-E-I-I-E-I-I-E-I-I-E-I
Valve guide bore diameter 6.015-6.044
Valve stem diameter intake 5.975-5.995
Valve stem diameter exhaust 5.95-5.97
Valve stem-to-guide clearance - intake 0.020-0.045
Valve stem-to-guide clearance - exhaust 0.069-0.094
Valve head diameter intake 33.62-33.98
Valve head diameter exhaust 37.32-37.68
Valve face runout 0.05
Valve face angle 45.5 deg
Valve seat width intake 1.2-1.4mm
Valve seat width exhaust 1.4-1.6mm
Valve seat runout 0.05mm
Valve seat angle cyl head 44.5-45.0 deg
Valve spring free length 55.7 mm
Valve spring compression pressure at specified height (lbs) 350N +/- 17.5N at 42.04mm +13N for creep
when stored 760N +/- 39N at 31.04mm
Valve spring installed height 42.04 mm
Valve spring installed pressure 350N +/- 17.5N at 42.04mm +13N for creep
when stored
Roller follower ratio TBD

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303-01b-2 Engine - 5.4L (3V) 303-01b-2

SPECIFICATIONS (Continued)

Description Specification
Hydraulic Lash Adjuster
Diameter 15.988-16.000 mm
Clearance-to-bore 0.018-0.069 mm
Service limit -
Hydraulic leakdown rate 5-25 seconds
Collapsed lash adjuster gap 0.45-0.85 mm
Camshaft
Theoretical valve lift @ lash Intake 11.1 mm / Exhaust 11.0 mm
Lobe lift Intake 5.520 mm / Exhaust 5.506 mm
Allowable lobe lift loss 0.127 mm
Journal diameter 28.607-28.633 mm
Camshaft journal bore inside diameter 28.657-28.682 mm
Camshaft journal-to-bearing clearance 0.024-0.075 mm
Runout 0.03 mm
End play 0.075-0.185 mm
Cylinder Block
Cylinder bore diameter -grade 1 90.200-90.210 mm (3.5512-3.5516 in)
Cylinder bore diameter -grade 2 90.210-90.220 mm (3.5516-3.5520 in)
Cylinder bore diameter -grade 3 90.220-90.230 mm (3.5520-3.5524 in)
Cylinder bore maximum taper 0.006 mm (0.0002 in)
Cylinder bore maximum out-of-round 0.020 mm (0.0008 in)
Main bearing bore inside diameter 72.400-72.424 mm (2.850-2.851 in)
Crankshaft
Main bearing journal diameter 67.481-67.505 mm (2.6568-2.6576 in)
Main bearing journal maximum taper (straightness) 0.004 mm (0.0002 in)
Main bearing journal maximum out-of-round 0.0075 mm (0.0003 in) between cross
sections
Main bearing journal-to-cylinder block clearance 0.048-0.024 mm (0.0019-0.0009 in)
Connecting rod journal diameter 53.003-52.983 mm (2.0867-2.0859 in)
Connecting rod journal maximum taper 0.004 mm (0.0002 in)
Connecting rod journal maximum out-of-round 0.0075 mm (0.0003 in) between cross
sections
Crankshaft maximum end play 0.075-0.377 mm (0.0030-0.0148 in)
Piston and Connecting Rod
Piston diameter - grade 1 (at right angle to pin bore) 90.175-90.165 mm (3.5502-3.5498 in)
Piston diameter - grade 2 (at right angle to pin bore) 90.185-90.175 mm (3.5506-3.5502 in)
Piston diameter - grade 3 (at right angle to pin bore) 90.195-90.185 mm (3.5510-3.5506 in)
Piston-to-cylinder bore clearance (at grade size) 0.025-0.045 mm (0.0010-0.0018 in)
Piston ring end gap - top 0.15-0.30 mm (0.006-0.012 in)
Piston ring end gap -intermediate 0.25-0.50 mm (0.0098-0.0197 in)
Piston ring end gap - oil control 0.15-0.65 mm (0.0059-0.0256 in)
Piston ring groove width - top 1.52-1.55 mm (0.0602-0.0610 in)
Piston ring groove width - intermediate 1.52-1.54 mm (0.0598-0.0606 in)
Piston ring groove width - oil control 3.030-3.050 mm (0.1193-0.1201 in)
Piston ring width 1.50-1.47mm (0.0590-0.0578 in)
Piston ring-to-groove clearance - top 0.020-0.080 mm (0.0008-0.0031 in)
Piston ring-to-groove clearance - intermediate 0.030-0.070 mm (0.0012-0.0028 in)

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303-01b-3 Engine - 5.4L (3V) 303-01b-3

SPECIFICATIONS (Continued)

Description Specification
Piston pin bore diameter 22.008-22.014 mm (0.8665-0.8667 in)
Piston pin diameter 22.0010-22.0030 mm (0.8662-0.8663 in)
Piston pin length 61.8 mm (2.433 in)
Piston pin-to-piston fit (clearance) 0.005-0.0130 mm (0.0002-0.0005 in)
Connecting rod-to-pin clearance 0.009-0.0235 mm (0.0004-0.0093 in)
Connecting rod pin bore diameter 22.012-22.024 mm (0.8666-0.8671 in)
Connecting rod length (centerline bore-to-bore) 169.1 mm (6.6575 in)
Connecting rod maximum allowed bend ± 0.038 mm (0.0015 in)
Connecting rod maximum allowed twist ± 0.05 mm (0.0020 in)
Connecting rod bearing bore diameter (with assembled liners) 53.049-53.027 mm (2.0885-2.0877 in)
Connecting rod bearing-to-crankshaft clearance 0.064-0.026 mm (0.0025-0.0010 in)
Connecting rod side clearance 0.475-0.125 mm (0.0187-0.0049 in)
Accessory Drive Belt
Drive belt 6 ribs
¹ The addition of Motorcraft Cooling System Stop
Leak Pellets, VC-6, darkens Motorcraft Premium Gold
Engine Coolant from yellow to golden tan.

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303-01b-4 Engine - 5.4L (3V) 303-01b-4

SPECIFICATIONS (Continued)

Torque Specifications Description Nm

Description Nm Motor mount-to-cylinder block bolts 63
Valve cover bolts 10 Motor mount through bolt 200
Camshaft bearing cap bolts¹ - Motor mount nut 103
Variable camshaft timing (VCT) sprocket - Oil pressure switch 14
assembly bolts¹ Power steering reservoir bracket bolts 25
Cylinder head temperature sensor (CHT) 26 Power steering reservoir bracket nut 25
Camshaft position (CMP) sensor bolt 10 Ground strap nut 10
Crankshaft position (CKP) sensor bolt 10 Fuel injection supply manifold bolts 10
Connecting rod bolts¹ - Generator bracket bolts 10
Crankshaft damper pulley bolt¹ - Intake manifold bolts¹ -
Crankshaft main bearing bolts - Transmission cooler line bracket nut 10
(cross-mounted)¹
¹ Refer to the procedure in this section.
Crankshaft main bearing bolts (vertical)¹ -
Cylinder heads bolts¹ -
Exhaust manifold nuts 25
Exhaust manifold studs 12
Exhaust manifold-to-Y-pipe nuts 40
Drive belt idler pulley bolt 25
Flywheel bolts 80
Engine front cover bolts¹ -
Transmission-to-engine bolts 48
Torque converter-to-flexplate nuts 35
Fuel injection supply manifold bracket bolts 10
Generator upper mounting bracket bolts 10
Generator lower mounting bolts 25
Ignition coil 6
Intake manifold to cylinder head bolts¹ -
Knock sensor 20
Oil filter 16
Oil filter adapter bolts 25
Oil level indicator tube bolt 10
Oil pan bolts¹ -
Oil pan drain plug 14
Oil pressure switch 14
Oil pump bolts 10
Oil pump screen and pickup tube bolts 10
Oil pump screen and pickup tube spacer 25
Oil pump screen and pickup tube spacer bolt 25
Power steering pump bolts 25
Rear main oil seal retainer bolts Spark plugs 10
Spark plugs 18
Thermostat housing bolts 10
Throttle body spacer-to-intake manifold bolts 10
Timing chain guide bolts 10
Timing chain hydraulic tensioner bolts 25
Coolant pump bolts 25
Coolant pump pulley bolts 25

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303-01b-5 Engine - 5.4L (3V) 303-01b-5

DESCRIPTION AND OPERATION

Engine A constant fuel pressure drop is maintained across

the fuel injectors by the fuel pressure regulator. The
The 5.4L (3V) is a V-8 engine with the following fuel pressure regulator:
features: is positioned upstream from the fuel injectors on
single overhead camshafts on each bank the fuel injection supply manifold.
three valves per cylinder Valve Train
sequential multiport fuel injection (SFI)
The valve train operates as follows:
an aluminum intake manifold
Ball tip hydraulic lash adjusters provide automatic
aluminum cylinder heads lash adjustment.
a cast iron, 90-degree V-cylinder block Roller followers ride on the camshaft lobes,
individually chain-driven camshafts with a transferring the up-and-down motion of the
hydraulic timing chain tensioner on each timing camshafts to the valves in the cylinder heads.
chain
the electronic ignition system with eight ignition Positive Crankcase Ventilation System
coils All engines are equipped with a closed-type positive
crankcase ventilation system recycling the crankcase
Identification vapors to the upper intake manifold.
Always refer to these labels when new parts are
required or when checking engine calibrations. The Lubrication System
engine parts often differ within a CID family. The engine lubrication system operates as follows:
Verification of the identification codes will make sure Oil is drawn into the oil pump through the oil
that the correct parts are obtained. These codes pump screen cover and tube in the sump of the oil
contain all the pertinent information relating to the pan.
dates, optional equipment and revisions. The Ford
Master Parts Catalog contains a complete listing of Oil enters the main oil gallery where it is
the codes and their application. distributed to the crankshaft main journals and to
both cylinder heads.
Code Information From the main journals, the oil is routed through
The engine code information label, located on the side cross-drilled passages in the crankshaft to
of the LH valve cover towards the rear, contains the lubricate the connecting rod bearings. Controlled
following: leakage through the crankshaft main bearings and
connecting rod bearings is slung radially outward
engine build date to cool and lubricate the cylinder walls as well as
engine plant code the entire connecting rod, piston and piston rings
engine code assembly.
The left cylinder head is fed from a drilling into the
Induction System supply passage feeding the main gallery at the
The sequential multiport fuel injection (SFI) provides front of the cylinder block. The right cylinder head
the fuel/air mixture needed for combustion in the is fed from a drilling into the rear of the main
cylinders. The eight solenoid-operated fuel injectors: gallery. Main gallery pressure is reduced as it
are mounted in the fuel injection supply manifold enters the cylinder head galleries through fixed
and the intake manifold above the cylinder heads. serviceable orifices located at the upper part of
the feed passages. It is this reduced pressure in
meter fuel into the air intake stream in accordance the cylinder head galleries which feeds the
with engine demand. camshaft journals, the hydraulic lash adjusters
are positioned so that their tips direct fuel just and the primary and secondary timing chain
ahead of the engine intake valves. tensioners.
are connected in series with the fuel pressure The camshaft lobe and roller followers are
regulator. lubricated by splash created through valve train
supply fuel from the fuel tank by a fuel pump operation.
mounted in the fuel tank.

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303-01b-6 Engine - 5.4L (3V) 303-01b-6

DESCRIPTION AND OPERATION (Continued)

Oil Pump
The lubrication system of the 5.4L (3V) engine is
designed to provide optimum oil flow to critical
components of the engine through its entire operating
range. The heart of the system is a positive
displacement internal gear oil pump using top seal
rotors.
Generically this design is known as a gerotor pump,
which operates as follows:
The oil pump is mounted on the front face of the
cylinder block.
The inner rotor is piloted on the crankshaft post
and is driven through flats on the crankshaft.
System pressure is limited by an integral,
internally-vented relief valve which directs the
bypassed oil back to the inlet side of the oil pump.
Oil pump displacement has been selected to
provide adequate volume to ensure correct oil
pressure both at hot idle and maximum speed.
The relief valve calibration protects the system
from excessive pressure during high viscosity
conditions.
The relief valve is designed to provide adequate
connecting rod bearing lubrication under
high-temperature and high-speed conditions.

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303-01b-7 Engine - 5.4L (3V) 303-01b-7

DIAGNOSIS AND TESTING

Engine
For basic engine mechanical concerns, refer to
Section 303-00. For driveability concerns, refer to
Powertrain Control/Module in Section 303-14.

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303-01b-8 Engine - 5.4L (3V) 303-01b-8

IN-VEHICLE REPAIR

Intake Manifold Upper 10. Remove the ten (10) bolts that secure the intake
manifold.
Removal
1. Relieve the fuel pressure. Refer to chapter 310-00
Fuel System.
2. Disconnect the battery ground cable. For
additional information, refer to Section 414-01.
3. Remove PCV hose from LH valve cover.
4. Remove the air cleaner outlet from throttle body.
For additional information, refer to Section
303-12.
5. Disconnect the electrical connectors from throttle
body motor.
6. Disconnect the electrical connectors from the
MAP sensor.
7. Disconnect the electrical connectors from the
alternator.
8. Remove the four (4) screws securing the fuel rail
to the intake manifold.

11. Lift intake manifold and throttle body.

12. Disconnect the brake booster vacuum line from
the intake manifold.
13. Remove the intake manifold.
14. Remove the intake gasket.
9. Remove the fuel rail and fuel injectors as one
assembly gently. CAUTION: 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.

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303-01b-9 Engine - 5.4L (3V) 303-01b-9

IN-VEHICLE REPAIR (Continued)

15. Clean and inspect the sealing surfaces. Materials

Silicone Gasket and Sealant WSE-M4G323-A4
F7AZ-19554-EA or equivalent
Instant Adhesive WSK-M2G402-A4
Removal
1. Disconnect the battery and remove. Refer to
Chapter 414-01, Battery, Mounting and Cables
2. Remove the coolant supply tank and secure out of
the way. (RH side only) Refer to chapter 303-03
Engine Cooling.
3. Unclip the positive battery cable from the valve
cover. And secure out of the way. (RH side only)
4. Disconnect the variable cam timing connection at
the front of each valve cover
Installation 5. Disconnect the ignition coils
Install in reverse order applying intake sealant to the
mating surfaces of the intake manifold. Tighten the
intake manifold bolts in the order illustrated below.

6. Remove the ignition coils.

7. Disconnect the valve cover ventilation hose from

the RH valve cover. (RH side only)
Valve Cover LH and RH (shown)
8. Disconnect the PCV valve and hose. Secure out
Materials of the way. (LH side only)
SAE 5W-20 Premium WSS-M2C153-H 9. Remove the rear RH and front LH lifting eyes.
Synthetic Blend Motor Oil 10. Remove the valve cover bolts.
XO-5W20-QSP or equivalent 11. Remove the valve cover.
Silicone Gasket Remover ZC-30 12. Remove the valve cover gasket.
Metal Surface Prep ZC-31

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303-01b-10 Engine - 5.4L (3V) 303-01b-10

IN-VEHICLE REPAIR (Continued)

RH Valve Cover shown

Item Description
1 Bolt
2 Valve Cover
3 Valve Cover Gasket

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303-01b-11 Engine - 5.4L (3V) 303-01b-11

IN-VEHICLE REPAIR (Continued)

Installation
1. Clean and inspect the sealing surfaces with
silicone gasket remover and metal surface prep.
CAUTION: 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.
2. Apply instant adhesive completely around the
gasket groove in the valve cover. Install a new
valve cover gasket.

4. Position the valve cover and gasket on the

cylinder head and install the bolts loosely. Tighten
the bolts in the sequence shown. (RH side shown
LH side is a mirror image)

3. Apply silicone gasket and sealant in two places

where the engine front cover meets the cylinder
head.
NOTE: If not secured within four minutes, the
sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone
gasket remover and metal surface prep. Follow
the directions on the packaging. Failure to follow 5. Install the rear RH and front LH lifting eyes.
this procedure can cause future oil leakage.
6. Reconnect the PCV valve and hose. (LH side
only)
7. Reconnect the valve cover ventilation hose from
the RH valve cover. (RH side only)
8. Install the ignition coils.
9. Reconnect the variable cam timing connection at
the front of each valve cover
10. Install the coolant supply tank (RH side only)
11. Install the battery. (RH side only)

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303-01b-12 Engine - 5.4L (3V) 303-01b-12

IN-VEHICLE REPAIR (Continued)

12. Clip the positive battery cable to the valve cover. 4. Using the special tool, remove the crankshaft
(RH side only) pulley.

Crankshaft Pulley
Special Tool(s)

Remover, Crankshaft
Vibration Damper
303-009 (T58P-6316-D)

Special Tool(s)

Installer, Crankshaft Vibration

Damper Installation
303-102 (T74P-6316-B) 1. Apply silicone gasket or LOCTITE 5900 or
equivalent to the Woodruff key slot on the
crankshaft pulley.
NOTE: The crankshaft pulley must be installed
within four minutes after applying the silicone.

Materials
Silicone Gasket and Sealant WSE-
F7AZ-19554-EA or LOCTITE 5900 or M4G323-
equivalent A4
Removal
1. Remove the drive belt. For additional information,
refer to Section 303-05.
2. Raise and support the vehicle. For additional
information, refer to Section 100-02.
3. Remove the crankshaft pulley bolt.

2. Using the special tool, install the crankshaft

pulley.

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303-01b-13 Engine - 5.4L (3V) 303-01b-13

IN-VEHICLE REPAIR (Continued)

3. Install the bolt and washer. Tighten the bolt in four Materials
stages: SAE 5W-20 Premium Synthetic Blend WSS-
1. Stage 1: Tighten to 90 Nm Motor Oil M2C910-
2. Stage 2: Loosen one full turn. 10W-30GF2 Engine Oil or equivalent A2
3. Stage 3: Tighten to 50 Nm
Removal
4. Stage 4: Tighten an additional 85-95 degrees.
1. Remove the crankshaft pulley. For additional
information, refer to Crankshaft Pulley in this
section.
2. Using the special tool, remove the crankshaft front
oil seal.

4. Lower the vehicle.

5. Install the drive belt. For additional information,
refer to Section 303-05.

Crankshaft Front Oil Seal Installation

Special Tool(s)
1. Apply silicone gasket sealant to outer perimeter
Installer, Crankshaft Front Oil surface of crankshaft front seal.
Seal 2. Lubricate the engine front cover and the
303-635 crankshaft front oil seal inner lip with clean engine
oil.

Special Tool(s)

Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)

Special Tool(s)

Remover, Crankshaft Front

Oil Seal Item Description
303-107 (T74P-6700-A) 1 Lubricate with engine oil
2 Seal with silicone gasket sealant

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303-01b-14 Engine - 5.4L (3V) 303-01b-14

IN-VEHICLE REPAIR (Continued)

3. Using the special tools, install the crankshaft front

oil seal into the engine front cover.
Item Description
1 Bolts
2 Water pump pulley
3. Remove the crankshaft pulley. For additional
information, refer to Crankshaft Pulley in this
section.
4. Remove the Power Steering (P/S) bolts and
position the power steering pump aside.

4. Install the crankshaft pulley. For additional

information, refer to Crankshaft Pulley in this
section.

Engine Front Cover

Materials
Metal Surface Cleaner WSE-M5B392-A
F4AZ-19A536-RA or equivalent
Silicone Gasket and Sealant WSE-M4G323-A4 5. Remove A/C Compressor.
F7AZ-19554-EA or LOCTITE 6. Disconnect the crankshaft position (CKP) sensor.
5900 or equivalent
10W-30GF2 Engine Oil or WSS-M2C910-A2
equivalent
Removal
1. Remove the left and right valve cover (6582). For
additional information, refer to Valve Cover-LH
and Valve Cover-RH in this section.
2. Remove the water pump pulley.
Remove the four bolts
Remove the water pump pulley

7. Drain the engine oil.

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303-01b-15 Engine - 5.4L (3V) 303-01b-15

IN-VEHICLE REPAIR (Continued)

8. Remove the four front sump bolts (as shown). 12. Remove the engine front cover, bolts, studs, and
the gaskets.

9. Remove the crankshaft front oil seal. For

additional information, refer to Crankshaft Front 13. Clean and inspect the sealing surfaces with
Oil Seal in this section. silicone gasket remover and metal surface prep.
10. Disconnect the camshaft position (CMP) sensor. CAUTION: 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.
Installation
1. Apply silicone gasket and sealant in the locations
shown.
NOTE: If the front cover and gasket are not
secured within four minutes, the sealant must be
removed and the sealing surface cleaned with
metal surface cleaner.

11. Remove the bolt and the belt idler pulley (8678).

2. Position the engine front cover and install the

bolts and the studs in three stages:
Stage 1: Tighten numbers one through five to
25 Nm
Stage 2: Tighten numbers six and seven to 50
Nm
Stage 3: Tighten numbers 11 through 15 to
25 Nm

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303-01b-16 Engine - 5.4L (3V) 303-01b-16

IN-VEHICLE REPAIR (Continued)

3. Install the belt idler and the bolt.

4. Connect the CMP sensor.

Item Description 5. Raise the vehicle.

1 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 6. Tighten the sump bolts in three stages:
2 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 a. Stage 1: Tighten to 2 Nm
3 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 b. Stage 2: Tighten to 20 Nm
4 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 c. Stage 3: Tighten an additional 60 degrees.
5 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
6 Stud, Hex-Head Pilot, M10 x 1.5 x 30
7 Stud, Hex-Head Pilot, M10 x 1.5 x 30
8 Bolt, Hex-Head Flange, M8 x 1.25 x 50
9 Bolt, Hex-Head Flange, M8 x 1.25 x 50
10 Bolt, Hex-Head Flange, M8 x 1.25 x 50
11 M8 x 1.25 x 53
12 M8 x 1.25 x 53
13 Bolt Hex Shoulder Pilot, M8 x 1.25 x 65
14 Stud Hex Shoulder Pilot, M8 x 1.25 x 65 - M8
x 1.25 x 27
15 Bolt Hex Shoulder Pilot, M8 x 1.25 x 65
7. Install the crankshaft front oil seal. For additional
information, refer to Crankshaft Front Oil Seal in
this section.

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IN-VEHICLE REPAIR (Continued)

8. Install the drain plug. 13. Install the water pump pulley and install the bolts.

9. Connect the CKP sensor. 14. Install the left and right valve cover. For additional
information, refer to Valve Cover-LH and Valve
Cover-RH in this section.
15. Refill the engine crankcase with clean engine oil.

Timing Gears, Chains, Tensioners,

VCT Sprocket Assemblies and VCT
Housings
Special Tool(s)

3 Valve Camshaft Holding

Tool
SST303-775

10. Refit A/C compressor.

11. Position the power steering pump and install the
bolts.
Crankshaft Position Tool
SST303-448

Materials
Super Premium SAE 5W-20 WSS-M2C153-H
XO-5W20-QSP or equivalent
Hydraulic Chain Tensioner 1L3Z-6P250-AA
Retaining Clip

12. Install the crankshaft pulley. For additional

information, refer to Crankshaft Pulley in this
section.

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IN-VEHICLE REPAIR (Continued)

Item Description
1 RH timing chain tensioner
2 RH timing chain tensioner arm
3 LH timing chain tensioner arm
4 LH timing chain tensioner bolts
5 LH timing chain tensioner
6 LH timing chain tensioner bolts

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IN-VEHICLE REPAIR (Continued)

Item Description
1 RH timing chain
2 LH timing chain
3 Crankshaft sprocket
4 Ignition pulse wheel

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IN-VEHICLE REPAIR (Continued)

Item Description
1 RH timing chain guide bolt
2 RH timing chain guide
3 LH timing chain guide bolt
4 RH timing chain guide bolt
5 LH timing chain guide bolt
6 RH timing chain guide

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IN-VEHICLE REPAIR (Continued)

Item Description
1 RH camshaft phaser sprocket
assembly
2 RH camshaft phaser sprocket
assembly bolt
3 LH camshaft phaser sprocket
assembly bolt
4 LH camshaft phaser sprocket
assembly

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IN-VEHICLE REPAIR (Continued)

Item Description
1 RH variable camshaft timing (VCT)
housing assembly
2 RH VCT housing assembly bolts
3 LH VCT housing assembly bolts
4 LH variable camshaft timing (VCT)
housing assembly

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IN-VEHICLE REPAIR (Continued)

Removal
1. Remove the engine front cover. For additional
information, refer to Engine Front Cover in this
section.
2. Remove the LH and RH valve covers. For
additional information, refer to Valve Cover in this
section.
3. Remove the bolts, the LH timing chain tensioner
and tensioner arm.
4. Remove the bolts, the RH timing chain tensioner
and tensioner arm.

5. Remove the ignition pulse wheel from the

crankshaft.

6. Remove the RH and LH timing chains and the

crankshaft sprocket.
Remove the RH timing chain from the
camshaft sprocket.
Remove the RH timing chain from the
crankshaft sprocket.
Remove the LH timing chain from the
camshaft sprocket.
Remove the LH timing chain.

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IN-VEHICLE REPAIR (Continued)

7. Remove the crankshaft sprocket. 9. Fit the SST 303-775 to camshaft in the central
8. Remove both timing chain guides. position between caps and tighten to prevent
rotation.
CAUTION: Unless otherwise instructed, at
no time when the timing chains are removed WARNING: When tightening hex key bolts
and the cylinders heads are installed is the on SST 303-775 make sure both bolts are
crankshaft or camshaft to be rotated. Severe tightened evenly.
piston and valve damage will occur.
Remove the bolts.
Remove both timing chain guides.

10. Remove bolt and washer on RH camshaft.

CAUTION: Apply an even force on hand
tools to remove the camshaft phaser sprocket
assembly or damage may occur to the
camshaft or camshaft phaser unit.
11. Discard RH Phasor sprocket.

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IN-VEHICLE REPAIR (Continued)

12. Remove the bolts and the variable camshaft 3. With SST303-775 in place holding the camshafts,
timing housing. tighten the bolts in two stages
Discard the gasket. Stage 1: Tighten to 40 Nm.
Stage 2: Tighten an additional 90 degrees.

CAUTION: Only use hand tools to remove

the camshaft phaser sprocket assembly or
damage may occur to the camshaft or
camshaft phaser unit.
4. Repeat steps 1 to 3 for the LH camshaft phaser
sprocket.
5. Compress the tensioner plunger, using a vice.
CAUTION: Timing chain procedures must
be followed exactly or damage to valves and
pistons will result.

13. Repeat steps 9 to 11 for removal of LH

components.
Installation
1. Install a new gasket, the variable camshaft timing
housing and the bolts.

6. Install a retaining clip on the tensioner to hold the

plunger in during installation.
NOTE: If the retaining clip is not available insert a
paper clip into the tensioner spring hole.

2. Install the RH camshaft variable timing sprocket

assembly and loosely install a new bolt and
washer.

7. Remove the tensioner from the vice.

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IN-VEHICLE REPAIR (Continued)

8. Pre-position the camshafts. 12. Install the crankshaft sprocket, making sure the
Rotate the LH camshaft until the timing mark flange faces forward.
is approximately at 12 o’clock.
Rotate the RH camshaft until the timing mark
is approximately at 11 o’clock.

13. If copper links are not visible on timing chains,

hold chains straight mark two links on one end
and one link on the other end and use as timing
marks.
9. Position the crankshaft so the number on cylinder
is at TDC using special tool 303-448
NOTE: The number one cylinder is at top dead
centre (TDC) when the stud on the engine block
fits into the slot in the handle of the special tool.

14. Position the lower end of the LH (inner) timing

chain on the crankshaft sprocket, aligning the
timing mark on the outer flange of the crankshaft
sprocket with the single copper link (or single
marked link) on the chain.
10. Install the timing chain guides

11. Remove the crankshaft holding tool

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IN-VEHICLE REPAIR (Continued)

15. Position the timing chain on the camshaft 17. Remove the retaining clip or paperclip from the
sprocket with the camshaft sprocket timing mark LH timing chain tensioner.
positioned between the two copper (marked)
chain links.
NOTE: Make sure the upper half of the timing
chain is below the tensioner arm dowel.

18. Position the lower end of the RH (outer) timing

chain on the crankshaft sprocket, aligning the
timing mark on the sprocket with the single copper
(marked) chain link.

19. Position the RH timing chain on the camshaft

16. Position the LH timing chain tensioner arm on the sprocket. Make sure the camshaft sprocket timing
dowel pin and install the LH timing chain tensioner mark is positioned between the two copper
bolts. (marked) chain links.
NOTE: The LH timing chain tensioner arm has a NOTE: The lower half of the timing chain must be
bump near the dowel hole for identification. positioned above the tensioner arm dowel.
20. Position the RH timing chain tensioner arm on the
dowel pin and install the RH timing chain
tensioner bolts.

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IN-VEHICLE REPAIR (Continued)

21. Remove the retaining clip from the RH timing 23. Install the crankshaft sensor ring on the
chain tensioner. crankshaft.
WARNING: Check markings on sensor
ring to ensure correct installation.

22. As a post-check, verify correct alignment of all

timing marks.
24. Install the engine front cover. For additional
information, refer to Engine Front Cover in this
section.
25. Install the LH and RH Valve covers. For additional
information, refer to Valve Covers in this section.

Camshaft (LH shown, RH opposite

hand)
Special Tool(s)

Crankshaft Position Tool

303-448

Camshaft holding tool

303-775

Materials
Super Premium SAE 5W-20 WSS-M2C153-H
XO-5W20-QSP or equivalent
Metal Surface Prep ZC-31

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IN-VEHICLE REPAIR (Continued)

Item Description
1 RH camshaft phaser sprocket
assembly
2 RH camshaft phaser sprocket
assembly bolt
3 LH camshaft phaser sprocket
assembly bolt
4 LH camshaft phaser sprocket
assembly

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IN-VEHICLE REPAIR (Continued)

Item Description 3. Position the crankshaft so the number one

1 LH camshaft bearing cap bolt cylinder is at TDC with the special tool, 303-448.
2 Front LH camshaft bearing cap NOTE: The number one cylinder is at top dead
center (TDC) when the stud on the engine block
3 LH camshaft bearing cap fits into the slot in the handle of the special tool.
4 LH camshaft
5 Camshaft roller follower
6 Hydraulic lash adjuster
Removal
1. Remove the LH and RH valve covers. For
additional information, refer to Valve Cover in this
section.
2. Remove the engine front cover. For additional
information, refer to Engine Front Cover in this
section.

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IN-VEHICLE REPAIR (Continued)

4. Remove the bolts, the timing chain tensioner and 8. Fit the SST 303-775 to the camshaft in the central
tensioner arm. position between the caps and tighten to prevent
rotation.
WARNING: When tightening hex key bolts
on SST 303-775 make sure both bolts are
tightened evenly.
9. Remove the bolt and the camshaft phaser
sprocket assembly.
Discard the bolt and washer.

CAUTION: Apply an even force on hand

tools to remove the camshaft phaser sprocket
assembly or damage may occur to the
camshaft or camshaft phaser unit.
CAUTION: Do not use the timing chains
5. Compress the tensioner plunger, using a vice. to prevent rotation when loosening the central
bolt as this load will be transmitted through
CAUTION: Timing chain procedure must
the locked phaser mechanism and could
be followed exactly or damage to valves and
cause damage.
pistons will result.

6. Install a retaining clip on the tensioner to hold the 10. Do not allow the timing chains to slip off the
plunge in during installation. crankshaft sprocket.
11. Remove SST 303-775.

7. Remove the tensioner from the vice.

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IN-VEHICLE REPAIR (Continued)

12. Remove the camshaft bearing cap bolts in the Installation

sequence shown. 1. Lubricate the camshaft journals with clean engine
oil.
2. Install the camshaft and the camshaft bearing
caps in their original locations.
NOTE: The camshaft bearing caps must be
installed in their original locations. Record
camshaft bearing cap locations.
Lubricate the camshaft bearing caps with
clean engine oil.
Position the camshaft bearing caps.
Install the bolts loosely.
3. Tighten the bolts in the sequence shown to 10
Nm.

13. Remove the camshaft bearing caps and the

camshaft.
NOTE: The camshaft bearing caps must be
installed in their original locations. Record
camshaft bearing cap locations.
14. Clean and inspect the camshaft bearing caps.
15. Repeat steps 4 to 11 for RH camshaft.

4. Fit the SST 303-775 to the LH camshaft in the

central position between the caps and tighten to
prevent rotation.

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IN-VEHICLE REPAIR (Continued)

5. Install the camshaft variable timing sprocket 9. Rotate the LH camshaft with the Camshaft
assembly and loosely install a new bolt and positioning tool until the timing mark is
washer. (RH shown) approximately at 12 o’clock.

6. Tighten the bolt in two stages: 10. Rotate the RH camshaft with the Camshaft
positioning tool until the timing mark is
CAUTION: Only use hand tools to remove approximately at 11 o’clock.
the camshaft phaser sprocket assembly or
11. Tighten the camshaft holding tools.
damage may occur to the camshaft or
camshaft phaser unit. CAUTION: Do not turn the engine over
Stage 1: Tighten to 40 Nm. with the camshaft positioning tool or damage
Stage 2: Tighten an additional 90 degrees. to the camshaft sprocket or bolt may occur.
7. Loosen SST 303-775 camshaft holding tool but do CAUTION: Unless otherwise instructed, at
not remove. no time when the timing chains are removed
8. If copper links are not visible on timing chains, and the cylinder heads are installed is the
hold chains straight mark two links on one end crankshaft or camshaft to be rotated. Severe
and one link on the other end and use as timing piston and valve damage will occur.
marks.
CAUTION: Rotate the crankshaft
counterclockwise only. Do not rotate past
position and/or valve damage can occur.
12. Position the crankshaft so the number one
cylinder is at TDC with the special tool.
NOTE: The number one cylinder is at top dead
centre (TDC) when the stud on the engine block
fits into the slot in the handle of the special tool.

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IN-VEHICLE REPAIR (Continued)

13. Install the timing chain guide.

NOTE: Illustration shows both LH and RH timing
guides.

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IN-VEHICLE REPAIR (Continued)

14. Position the lower end of the LH (inner) timing

chain on the crankshaft sprocket, aligning the
timing mark on the outer flange of the crankshaft
sprocket with the single copper (marked) link on
the chain.

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IN-VEHICLE REPAIR (Continued)

15. Position the timing chain on the camshaft 18. Remove the retaining clip or paperclip from the
sprocket with the camshaft sprocket timing mark LH timing chain tensioner.
positioned between the two copper (marked)
chain links.
NOTE: Ensure the upper half of the timing chain
is below the tensioner arm dowel.

19. Repeat steps 4 to 18 for the RH camshaft.

20. As a post-check, verify correct alignment of all
timing marks.

21. Install the crankshaft sensor ring on the

crankshaft.
16. Remove the camshaft holding tool.
WARNING: Check markings on sensor
17. Position the LH timing chain tensioner arm on the ring to ensure correct installation.
dowel pin and install the LH timing chain
tensioner.
NOTE: The LH timing chain tensioner arm has a
bump near the dowel hole for identification.

22. Install the engine front cover. For additional

information, refer to Engine Front Cover in this
section.
23. Install the LH and RH Valve covers. For additional
information, refer to Valve Covers in this section.

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IN-VEHICLE REPAIR (Continued)

Rocker Arm, Lash Adjuster, Valve 2. Remove the keys, retainers and valve spring
using a suitable valve spring compressor.
Spring and Valve Stem Seal
Materials
Super Premium SAE 5W-20 WSS-
XO-5W20-QSP or equivalent M2C153-H
Removal
The rocker arm and lash adjuster are clipped together
to prevent rocker displacement under extraordinary
start up conditions. Care should be taken when
removing the assembly, so as not to strain the clip.
Do not remove the clip unless either the rocker arm of
lash adjuster are to be eplafed and fit a new clip. Do
not remove the clip unless either the rocker arm of
lash adjuster are to be replaced and fit a new clip. If
the clip is loose on the rocker arm it should be
replaced when the rocker and lash adjuster assembly 3. Remove the valve stem seal/spring seat assembly
is removed from the cylinder head. with pliers or multi-grips, being careful not to mark
the valve stem.
1. Remove the valve cover. For additional
information, refer to Valve Cover removal in this Installation
section. 1. Pressurise the cylinder via an air line and adaptor.
2. Remove the camshaft. For additional information, Do not exceed 800 KPa.
refer to camshaft removal in this section. 2. Use an appropriate inside diameter tube to gently
3. Remove the camshaft roller follower(s) seat the valve stem seal.
NOTE: Mark each camshaft roller followers to 3. Reassemble in the reverse order to the procedure
make sure it is returned to its original position. above.
NOTE: The valve spring must be fitted with the
4. Remove the hydraulic lash adjusters. smaller diameter end upwards.
NOTE: Mark each hydraulic lash adjuster to make
sure it is returned to its original position.

Installation
1. Install in the reverse order to the removal.

Valve spring and Valve Stem Seal

Removal
1. Remove the appropriate spark plug, and
pressurise the cylinder via an air line and adaptor.
DO NOT exceed 800 KPa.

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IN-VEHICLE REPAIR (Continued)

Exhaust Manifold (LH shown, RH

opposite hand)

Item Description Installation

1 Exhaust manifold gasket 1. Install a new gasket
2 Exhaust manifold 2. Install the exhaust manifold to the cylinder head.
3 Exhaust manifold nuts Tighten the exhaust manifold nuts in the
sequence shown.
Removal
1. Remove the exhaust manifold.
Discard the gasket.
Clean the sealing surfaces with metal surface
prep.
CAUTION: Do not use metal scrapers,
wire brushes, power abrasive discs, or
other abrasive means to clean the sealing
surfaces. These may cause scratches and
gouges resulting in leak paths. Use a
plastic scraper to clean the sealing
surfaces.

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IN-VEHICLE REPAIR (Continued)

Oil Filter Adapter 6. Disconnect the radiator lower hose.

Removal
1. Raise and support the vehicle. For additional
information, refer to Section 100-02.
2. Drain the cooling system. For additional
information, refer to Section 303-03.
3. Remove the oil filter.

7. Remove the four bolts and the filter adapter.

Discard the gasket

4. Disconnect the oil pressure sensor.

5. Remove the oil pressure sender.

Installation
1. Install in the reverse order to the removal.
NOTE: Install a new oil filter adapter gasket.

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IN-VEHICLE REPAIR (Continued)

Oil Pressure Sender 2. Remove the bolt.

Materials
Pipe Sealant with Teflon© WSK-
D8AZ-19554-A or equivalent M2G350-
A2 and
ESR-
M18P7-A
Removal
1. Raise and support the vehicle. For additional
information, refer to Section 100-02.
2. Disconnect the oil pressure sender electrical
connector.

3. Remove the oil level indicator tube.

a. Install a new O-ring seal.

3. Remove the oil pressure sender.

Installation
1. Install in the reverse order to the removal.

Oil Pan
Special Tool(s)

3-Bar Engine Support

303-F073

Installation
1. Install in the reverse order to the removal. Materials
Metal Surface Cleaner WSE-M5B392-A
Oil Level Indicator and Tube F4AZ-19A536-RA or
Removal equivalent
1. Remove the oil level indicator Silicone Gasket and Sealant WSE-M4G323-A4
F7AZ-19554-EA or LOCTITE
5900 or equivalent
10W-30GF2 Engine Oil or WSS-M2C910-A2
equivalent

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IN-VEHICLE REPAIR (Continued)

Removal 7. Raise the engine 63.5 mm.

1. Remove alternator, refer to Section 414-02.

8. Raise the vehicle

2. Install the special tool. 9. Remove the bolts, oil pan and gasket.
Inspect the oil pan gasket for damage.
NOTE: Be careful when removing oil pan
gasket. It is re-usable if not damaged.

3. Raise and support the vehicle. For additional

information, refer to Section 100-02.
4. Remove through bolts from the engine mount
bracket and chassis. Installation
5. Drain the engine oil. 1. Clean the mating surfaces.
CAUTION: 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
2. Apply silicone gasket and sealant at the rear oil
seal retainer-to-cylinder block sealing surface.
NOTE: If the oil pan and the oil pan gasket are
not secured within four minutes, the sealant must
be removed and the sealing area cleaned with
metal surface cleaner. Allow to dry until there is
no sign of wetness, or four minutes, whichever is
6. Lower the vehicle. longer. Failure to follow this procedure can cause
future oil leakage.

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IN-VEHICLE REPAIR (Continued)

5. Tighten the bolts in three stages, in the sequence

shown.
Stage 1: Tighten to 2 Nm.
Stage 2: Tighten to 20 Nm.
Stage 3: Tighten an additional 60 degrees

3. Apply silicone gasket and sealant at the front

cover-to-cylinder block sealing surface.
NOTE: If the oil pan and the oil pan gasket are
not secured within four minutes, the sealant must
be removed and the sealing area cleaned with
metal surface cleaner. Allow to dry until there is
no sign of wetness, or four minutes, whichever is
longer. Failure to follow this procedure can cause
future oil leakage.

6. Lower the vehicle.

7. Lower the engine.
Remove the special tool.

4. Install the oil pan gasket and the oil pan and
loosely install the 16 bolts.

8. Raise the vehicle.

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IN-VEHICLE REPAIR (Continued)

9. Install through bolt to the engine mount bracket can cause foam in the lubrication system, low oil
and chassis. pressure and severe engine damage.
NOTE: Clean and inspect the mating surfaces and
install a new O-ring. Lubricate with clean engine oil.
3. Install the oil pan. For additional information, refer
to Oil Pan Installation in this section.

Drive-plate
Removal
1. Remove the transmission. For additional
information, refer to Automatic Transmission
chapter 307-01. No Manual Transmission.
2. Remove six of the eight bolts. Loosen the two
remaining bolts but leave in place.
10. Lower the vehicle. CAUTION: Two bolts should be loosened
11. Install the alternator. For additional information, but left in to prevent the flywheel (6375) from
refer to Section 414-02. falling
12. Install the lower intake manifold. For additional
information, refer to Intake Manifold-Upper.
13. Refill the engine crankcase with clean engine oil.

Oil Pump Screen and Pickup Tube

Materials
10W-30 GF2 engine oil or equivalent WSS-
M2C910-
A2
Removal
1. Remove the oil pan. For additional information,
refer to Oil Pan in this section
2. Remove the three (A) bolts and the (B) oil pump 3. Separate the Drive-plate from the crankshaft
screen cover and tube. 4. Remove the bolts remaining in the crankshaft.
5. Remove the Drive-plate.
Installation
1. Position the Drive-plate onto the crankshaft and
install the Drive-plate-to-crankshaft bolts (6379).
Apply the threadlock and sealer to bolt
threads.

Installation
1. Clean and inspect the mating surfaces.
Inspect the O-ring seal
2. Install the oil pump screen cover and tube and
install the bolts.

CAUTION: Make sure the O-ring is in place

and not damaged. A missing or damaged O-ring

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IN-VEHICLE REPAIR (Continued)

2. Install the disc and pressure plate. Manual Special Tool(s)

transmission only. For additional information, refer
to Clutch chapter 308-01 Remover, Crankshaft Rear Oil
3. Install the transmission. Refer to Automatic Slinger
Transmission chapter 307-01. 303-514 (T95P-6701-AH)

Crankshaft Rear Oil Seal

Special Tool(s)

Installer, Crankshaft Rear Oil

Seal Installer, Crankshaft Rear Oil
303-518 (T95P-6701-DH) Slinger
303-517 (T95P-6701-CH)

Remover, Crankshaft Rear Oil

Seal Impact Slide Hammer
303-519 (T95P-6701-EH) 100-001 (T50T-100-A)

Installer, Crankshaft Rear Oil

Seal Removal
303-516 (T95P-6701-BH) 1. Remove the Flywheel. For additional information,
refer to Flywheel in this section.
2. Using the special tools, remove the crankshaft oil
slinger.

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IN-VEHICLE REPAIR (Continued)

3. Using the special tools, remove the crankshaft Engine Mounts - LH

rear oil
Special Tool(s)
Installation
1. Using the special tool, install the crankshaft rear 3-Bar Engine Support
oil seal. Using the special tools, install the 303-F073
crankshaft rear oil seal.
2. Using the special tools, install the crankshaft oil
slinger
3. Install the Flywheel. For additional information,
refer to Flywheel in this section.

Engine Mounts - RH Removal

Special Tool(s) 1. Remove the lower intake manifold. For additional
information, refer to Intake Manifold-Upper in this
3-Bar Engine Support section
303-F073 2. Install the special tool

Removal
1. Install the special tool.
2. Raise and support the vehicle. For additional
information, refer to Section 100-02.

3. Raise and support the vehicle. For additional

information, refer to Section 100-02.
4. Remove the through bolt.

3. Remove the engine mount bracket through bolt.

4. Remove crossmember
5. Remove engine mount & bracket assembly from
the engine.
6. Remove engine mount heat shield.
7. Remove the engine mount.
Installation 5. Lower the vehicle.
1. Install in the reverse order to the removal.

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IN-VEHICLE REPAIR (Continued)

6. Raise the engine 63.5 mm 4. Remove the fan shroud.

Remove the screws.
Lift and remove the fan pack, out of the
vehicle.

7. Remove the engine mount from the vehicle.

Installation
1. Install in the reverse order to the removal.
5. Disconnect the transmission fluid cooler fittings.
Engine Removal Disconnect the upper transmission fluid cooler
Special Tool(s) fitting.
Disconnect the lower transmission fluid cooler
Modular Engine Lifting Bar fitting
303-F047 (014-00073) NOTE: To avoid disturbing the transmission
oil cooler fittings, use a support spanner when
releasing cooling lines.

Holding Wrench, Fan Pulley

303-239 (T84T-6312-C)

Wrench, Fan Clutch Hub Nut

303-240 (T84T-6312-D)

6. Drain coolant from engine at tap left hand lower

corner.

Materials
10W-30 GF2 engine oil or WSS-M2C910-A2
equivalent
Removal
1. Disconnect lower pivot hood struts.
2. Tie hood back.
3. Remove the radiator upper hose from the engine.

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IN-VEHICLE REPAIR (Continued)

7. Disconnect the lower radiator hose from the 18. Remove the ground strap retaining bolt.
radiator and the engine.

19. Disconnect the lower radiator hose.

8. Disconnect the surge tank hose from the radiator. 20. Disconnect the heater hoses from rear of engine.
Release the clamp. 21. Disconnect brake booster vacuum hose.
Slide the hose off the radiator fitting. 22. Disconnect purge valve connection.
9. Remove the surge tank from vehicle 23. Disconnect air intake to throttle body and remove
Disconnect vent and supply hoses from surge entire air cleaner assembly.
tank 24. Disconnect fuel lines using special tool, as
Remove surge tank from vehicle. outlined in Section 310-00.
10. Remove surge tank from vehicle. 25. Disconnect the power steering pressure (PSP)
Remove the bolts sensor.
Remove the upper radiator support brackets 26. Remove the bolts and position the power steering
pump out of the way
Remove bolts attaching condensor to radiator
Lift the radiator off the radiator mounting
insulators.
Remove the radiator mounting insulators.
11. Remove the accessory drive belt. For additional
information, refer to Section 303-05.
12. Disconnect the alternator electrical connectors.
13. Disconnect battery and alternator cables from RH
Relay box..
14. Remove PCM, refer to Section 303-14.
15. Disconnect the wiring harness (PCM ’A’
connector & 24 pin connector) from vehicle.
16. Disconnect transmission wiring harness from
transmission.
17. Disconnect hego sensor wiring plugs. Refer to
chapter Section 303-14 for more information.

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IN-VEHICLE REPAIR (Continued)

27. Disconnect the starter motor electrical 30. Disconnect the crankshaft position (CKP) sensor.
connections.
Remove the two nuts
Remove the battery cable.
Remove the starter solenoid wire.

31. Disconnect the A/C compressor electrical

connector.

28. Remove the nut and the starter motor ground

cable

32. Remove the bolts and the A/C compressor.

NOTE: Do not degas, position A/C compressor
out of the way.
33. Remove nut holding exhaust heatshield and
29. Remove the 2 bolts and the starter motor. discard, then remove heatshield.
34. Disconnect the pipes at the exhaust manifolds.
NOTE: If studs are removed from exhaust
manifolds during disassembly, then discard studs
and nut and replace with new parts.
35. Remove the through bolt from the LH engine
mount.

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IN-VEHICLE REPAIR (Continued)

36. Remove the through bolt from the RH motor 39. Remove the 6 bolts from the transmission.
mount

40. Lower the vehicle.

37. Remove the plate bolts and the inspection cover
41. Install rear lifting hook and front lifting hook.
42. Support the transmission with a floor jack and a
block of wood.
43. Remove the engine from the vehicle.

38. Remove the four bolts from the torque converter

and discard (Auto tran only).
NOTE: Gain access to the nuts by turning the
crank dampener counterclockwise.
Installation
1. Support the transmission with a floor jack and a
block of wood.
2. Install the engine in the vehicle.
3. Remove the special tool.

4. Raise the vehicle. For additional information, refer

to Section 100-02.

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IN-VEHICLE REPAIR (Continued)

5. Position the transmission level indicator tube and 8. Install 4 new bolts to the torque converter (Auto
install the bolt. trans only).
NOTE: Gain access to the nuts by turning the
crank dampener counter-clockwise.

6. Install the five bolts to the bell housing.

9. Install the plug (Auto trans only).

7. Install the oil filter.

10. Install the inspection cover and the bolts.

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IN-VEHICLE REPAIR (Continued)

11. Install the bolt to the RH engine motor mount. 14. Connect the cable and install the motor nut.

12. Install the bolt to the LH engine motor mount. 15. Connect the starter motor electrical connectors.
Position the starter solenoid wire.
Position the battery cable.
Install the nuts.

13. Install the starter motor and 2 bolts.

16. Install the starter motor solenoid terminal cover.

17. Install the RH exhaust manifold studs.
18. Connect the exhaust pipes to the exhaust
manifolds and torque nuts to specification.

19. Install the heatshield and fasten with a new

heatshield nut.

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IN-VEHICLE REPAIR (Continued)

20. Install the A/C compressor and bolts. 23. Position the power steering pump and install the
bolts.

21. Connect the A/C compressor electrical connector.

24. Connect the power steering pressure sensor.
25. Lower the vehicle.
26. Connect the lower radiator hose.
27. Install the stud and reposition the A/C muffler.
28. Install battery into vehicle.
29. Connect the heater hoses to rear of engine.

22. Connect the crankshaft position sensor.

30. Install surge tank into vehicle.

31. Connect vent and supply hoses to surge tank.
32. Connect the surge tank return hose.
33. Install the two bolts retaining the transmission to
the engine.

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IN-VEHICLE REPAIR (Continued)

34. Connect the transmission wiring harness to 41. Install the radiator.
transmission. Install the radiator mounting insulators.
Position the radiator on the radiator mounting
insulators.
Position the brackets.
Install the bolts.

35. Connect wiring harness (PCM ’A’ connector and

24 pin connector) to vehicle.
36. Install the alternator and alternator bracket.

42. Install the surge tank hose to the radiator.

Release the clamp.
Slide the hose onto the radiator fitting.

37. Connect the alternator electrical connectors.

43. Connect the lower radiator hose and the upper

radiator hose.
44. Connect the transmission fluid cooler fittings.
Connect the lower transmission fluid cooler
fitting.
Connect the upper transmission fluid cooler
fitting.
NOTE: To avoid disturbing the transmission
oil cooler fittings, use a support hammer when
tightening fuel lines.
38. Connect battery and alternator cables to RH relay
box.
39. Install the accessory drive belt. For additional
information, refer to Section 303-05.
40. Install the intake manifold. For additional
information, refer to Intake Manifold-Upper in this
section.

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IN-VEHICLE REPAIR (Continued)

45. Install the fan shroud.

Install the fan blade and fan shroud, as a unit,
in the vehicle.
Install the screws.

46. Recharge the A/C system. For additional

information, refer to Section 412-00.
47. Fill the engine with oil.
48. Fill the engine cooling system. For additional
information, refer to Section 303-03.

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DISASSEMBLY

Engine Disassembly
NOTE: The crankshaft rear oil seal, the oil seal slinger
Special Tool(s) and the oil seal retainer plate must be removed before
mounting the engine on the engine stand.
Remover, Crankshaft Rear Oil
Slinger 1. Remove the bolts and the flexplate or the
303-514 (T95P-6701-AH) flywheel.

Remover, Crankshaft Rear Oil

Seal
303-519 (T95P-6701-EH)

Slide Hammer
100-001 (T50T-100-A)
2. Using the special tools, remove the crankshaft
rear oil slinger.

Installer, Connecting Rod

303-442 (T93P-6136-A)

Lift Bracket Set, Engine

303-DS086 (D93P-6001-A)

3. Using the special tools, remove the crankshaft

rear oil seal.

Remover, Crankshaft Vibration

Damper
303-009 (T58P-6316-D)

Remover, Crankshaft Front Oil

Seal
303-107 (T74P-6700-A)

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DISASSEMBLY (Continued)

4. Remove the bolts, oil pan and oil pan gasket. 9. Remove the intake manifold gaskets.
Clean and inspect the sealing surfaces. Clean and inspect the sealing surfaces.
CAUTION: 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.

5. Remove the bolts and the crankshaft rear oil seal

retainer plate.
Clean and inspect the sealing surfaces.

10. Remove the bolts and the generator support

bracket.

6. Install the engine onto a suitable engine stand.

7. With the engine on the engine stand, remove the
engine control sensor wiring harness.
8. Remove the bolts and the intake manifold
assembly.

11. Remove the bolts and the generator.

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DISASSEMBLY (Continued)

12. Remove the bolt. Clean the valve cover gasket groove with
soap and water or a suitable solvent.
CAUTION: 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.
NOTE: The bolts are part of the valve cover
and should not be removed.
NOTE: LH is shown, RH is similar.

13. Remove the bolts and the water bypass tube

assembly.

16. Remove the nuts and the two radio interference

capacitors.
NOTE: RH is shown, LH is similar.

14. Remove the eight bolts and the eight coil packs.
NOTE: RH is shown, LH is similar.

15. Remove the bolts and the valve covers.

Fully loosen the bolts and remove the valve
cover.
Clean the valve cover mating surface of the
cylinder head with silicone gasket remover
and metal surface prep. Follow the directions
on the packaging.
Inspect the valve cover gasket. If the gasket
is damaged, remove and discard the gasket.

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DISASSEMBLY (Continued)

17. Remove the eight nuts and the RH exhaust 20. Remove the bolt and the crankshaft position
manifold. (CKP) sensor.
Clean and inspect the sealing surfaces.

21. Remove the eight nuts and the LH exhaust

18. Remove the bolts and the A/C compressor. manifold.
Clean and inspect the sealing surfaces.

19. Remove the bolts and the A/C compressor

bracket. 22. Remove the bolts and the power steering pump.

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DISASSEMBLY (Continued)

23. Remove the bolts and the oil filter adapter. 26. Remove the bolts.

24. Remove the bolts, the coolant pump pulley, and 27. Remove the coolant pump from the cylinder block.
the accessory drive belt idler pulley.

28. Remove and discard the crankshaft pulley bolt.

25. Remove the bolts and the accessory drive belt Using the special tool, remove the crankshaft
tensioner. pulley.

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DISASSEMBLY (Continued)

29. Using the special tool, remove the crankshaft front 32. Remove the crankshaft sensor ring from the
seal. crankshaft.

30. Remove the fasteners. 33. Compress the valve springs, and remove the
NOTE: Correct fastener location is essential for camshaft roller followers.
assembly procedure. Record fastener location. NOTE: The use of a special tool may be required
for this step.
NOTE: The camshaft roller followers must be
reinstalled in their original locations. Record the
camshaft roller follower locations.
34. Position the crankshaft with the keyway at the 9
o’clock position.

31. Remove the engine front cover from the cylinder

block.

35. Remove the bolts, the RH timing chain tensioner

and tensioner arm.

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DISASSEMBLY (Continued)

36. Remove the bolts, the LH timing chain tensioner

and tensioner arm.

37. Remove the RH and LH timing chains and the

crankshaft sprocket.
Remove the RH timing chain from the
camshaft sprocket.
Remove the RH timing chain from the
crankshaft sprocket.
Remove the LH timing chain from the
camshaft sprocket.
Remove the LH timing chain and crankshaft
sprocket.

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DISASSEMBLY (Continued)

38. Remove both timing chain guides.

Remove the bolts.
Remove both timing chain guides.

39. Remove the bolt and the oil level indicator tube.
40. Remove the bolts and discard.
RH is shown; LH is similar.
2. Remove the cylinder heads.
CAUTION: The cylinder head bolts
must be discarded and new bolts must be
installed. They are tighten-to-yield
designed and cannot be reused.
CAUTION: Place cylinder head on a
cardboard or wood surface to prevent
damage to the joint face. 41. Discard the cylinder head gaskets. Clean the
engine block sealing surfaces with silicone gasket
CAUTION: Aluminum surfaces are remover and metal surface prep. Follow the
soft and can be scratched easily. Never directions on the packaging.
place the cylinder head gasket surface,
unprotected, on a bench surface. CAUTION: Do not use metal scrapers,
NOTE: The cylinder heads are cleaned as wire brushes, power abrasive discs or other
part of the cylinder head disassembly abrasive means to clean the sealing surfaces.
process. These tools cause scratches and gouges
which make leak paths. Use a plastic scraper
to remove all traces of the head gasket.
42. Remove the bolts and the oil pump screen and
pickup tube.
43. Remove the oil pump screen and pickup tube
spacer.

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DISASSEMBLY (Continued)

44. Remove the oil pump. 46. Remove the bolts and the connecting rod cap.
Discard the bolts.
1. Remove the bolts.
2. Remove the oil pump. CAUTION: 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.

45. Before removing the pistons, inspect the top of

the cylinder bores. If necessary, remove the ridge
or carbon deposits from each cylinder using a
cylinder ridge reamer, following the manufacturer
instructions.

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DISASSEMBLY (Continued)

47. Use the special tool to push the piston through 48. Remove the fasteners.
the top of the cylinder block.
1. Remove and discard the cross-mounted main
CAUTION: Do not scratch the cylinder cap bolts.
walls or crankshaft journals with the 2. Remove the dowels.
connecting rod. 3. Remove and discard the main bearing cap
bolts.

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DISASSEMBLY (Continued)

49. Remove the five main bearing caps, the lower

crankshaft main bearings and the lower thrust
washer.

50. Remove the crankshaft, the upper crankshaft

main bearings and the upper thrust washers from
the cylinder block.

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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

2. Remove the bolts and the variable camshaft

Cylinder Head timing housing.
Special Tool(s)
Installer, Valve Stem Oil Seal
303-383 (T91P-6571-A)

Materials
Motorcraft Silicone —
Gasket Remover
ZC-30
Motorcraft Metal Surface — 3. Remove the bolts and the bearing caps.
Prep NOTE: The camshaft bearing caps must be
ZC-31 reinstalled in their original locations. Record the
SAE 10W-30 Premium WSS-M2C153-H camshaft bearing cap locations.
Synthetic Blend Motor Oil
XO-10W30-QSP

Disassembly
CAUTION: Cylinder head machining or
milling is not authorized by the Ford Motor
Company. Cylinder head flatness must be within
0.0254 mm (0.001 in) across a 38.1 mm (1.5 in)
square area.

CAUTION: Place the cylinder head on a

cardboard or wood surface to prevent damage to
the joint face.
1. Install the special tool and remove the bolt and
the camshaft phaser sprocket assembly.
Discard the bolt and washer.
CAUTION: Only use hand tools to
remove the camshaft phaser sprocket
assembly or damage may occur to the
camshaft or camshaft phaser unit.

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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

4. Remove the camshaft.

7. Remove the valve stem seals.

5. Remove the hydraulic lash adjusters.
NOTE: The hydraulic lash adjusters must be
reinstalled in their original locations. Record the
hydraulic lash adjuster locations.

8. Clean the cylinder head sealing surfaces.

1. Remove any large deposits of silicone or
gasket material with a plastic scraper.
2. Apply silicone gasket remover, following
6. Compress the valve springs and remove the package directions, and allow to set for
valves. several minutes.
1. Remove the valve spring retainer keys. 3. Remove the silicone gasket remover with a
plastic scraper. A second application of
2. Remove the valve spring retainers. silicone gasket remover may be required if
3. Remove the valve springs. residual traces of silicone or gasket material
4. Remove the valves. remain.
4. Apply metal surface prep, following package
CAUTION: Keep the valves and valve directions, to remove any remaining traces of
spring retainer keys in order so they can oil or coolant, and to prepare the surfaces to
be reinstalled in their original locations. bond with the new gasket. Do not attempt to
NOTE: The use of a special tool may be make the metal shiny. Some staining of the
required for this step. metal surfaces is normal.
CAUTION: 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.

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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

5. Install the hydraulic lash adjusters in their original

CAUTION: Observe all warnings or cautions locations.
and follow all application directions contained on NOTE: Lubricate the hydraulic lash adjusters
the packaging of the silicone gasket remover and using clean engine oil.
the metal surface prep.
NOTE: If there is no residual gasket material present,
metal surface prep can be used to clean and prepare
the surfaces.

Assembly
1. Install the valves in the valve guides located in the
cylinder head.
NOTE: Lubricate the valve stems using clean
engine oil.

6. Lubricate the camshaft journals with clean engine

oil.

2. Install the valve stem seals.

NOTE: The use of a special tool may be required
for this step.
3. Install the valve springs and the valve spring
retainers onto the valves.
7. Install the camshaft.
NOTE: Lubricate the camshaft using clean engine
oil.

4. Compress the valve springs. Install the valve

spring retainer keys.
NOTE: The use of a special tool may be required
for this step.

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DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES (Continued)

8. Install the bearing caps and the bolts and tighten 10. Install the camshaft variable timing sprocket
in the sequence shown. assembly and loosely install the bolt.
NOTE: The camshaft bearing caps must be
reinstalled in their original locations. Record the
camshaft bearing cap locations.
NOTE: Lubricate the bearing caps using clean
engine oil.

11. Install the special tool.

12. Tighten the bolt in two stages:

Stage 1: Tighten to 40 Nm (30 lb-ft).
Stage 2: Tighten an additional 90 degrees.
CAUTION: Only use hand tools to
remove the camshaft phaser sprocket
9. Install a new gasket, the variable camshaft timing
assembly or damage may occur to the
housing and the bolts.
camshaft or camshaft phaser unit.

13. Remove the special tool.

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ASSEMBLY

Engine Special Tool(s)

Installer, Crankshaft Rear Oil
Special Tool(s) Seal
Installer, Connecting Rod 303-516 (T95P-6701-BH)
303-442 (T93P-6136-A)

Installer, Crankshaft Rear Oil

Slinger
Installer, Crankshaft Vibration 303-517 (T95P-6701-CH)
Damper
303-102 (T74P-6316-B)

Lifting Bracket Set, Engine

303-DS086 (D93P-6001-A)
Installer, Crankshaft Front Oil
Seal
303-635

Modular Engine Lift Bracket

303-F047 (014-00073) or
Installer, Front Cover Oil Seal equivalent
303-335 (T88T-6701-A)

Compressor, Piston Ring

303-D032 (D81L-6002-C) or
equivalent

Holding Tool, Crankshaft

303-448 (T93P-6303-A)

Installer, Crankshaft Rear Oil

Seal
303-518 (T95P-6701-DH)

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ASSEMBLY (Continued)

Materials 2. Record the main bearing code found on the back

of the crankshaft.
Motorcraft Silicone —
Gasket Remover
ZC-30
Motorcraft Metal Surface —
Prep
ZC-31
Silicone Gasket and WSE-M4G323-A4
Sealant
F7AZ-19554-EA or
equivalent
Instant Adhesive WSK-M2G402-A4
E8AZ-19554-A
SAE 10W-30 Premium WSS-M2C153-H
Synthetic Blend Engine
Oil 3. Using the data recorded earlier and the Bearing
XO-10W30-QSP or Select Fit Chart, Standard Bearings, determine
equivalent the required bearing grade for each main bearing.
Motorcraft Premium ESE-M97B44-A (green in Read the first letter of the engine block main
Engine Coolant color) bearing code and the first letter of the
VC-4-A (in Canada crankshaft main bearing code.
CXC-10; in Oregon VC-5)
Read down the column below the engine
or equivalent. Do not mix
coolant types. block main bearing code letter, and across the
row next to the crankshaft main bearing code
Motorcraft Premium Gold WSS-M97B51-A1 (yellow letter, until the two intersect. This is the
Engine Coolant in color) required bearing grade for the number one
VC-7-A (in Oregon crankshaft main bearing.
VC-7-B) or equivalent.
As an example, if the engine block code letter
Do not mix coolant types.
is ‘‘F’’ and the crankshaft code letter is ‘‘D’’,
Hydraulic Chain 1L3Z-6P250-AA the correct bearing grade for this main
Tensioner Retaining Clip bearing is a ‘‘2’’.
Repeat this process for the remaining four
Assembly main bearings.
All Engines
1. Record the main bearing code found on the front
of the engine block.

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ASSEMBLY (Continued)

Bearing Select Fit Chart, Standard Bearings

4. If oversize bearings are being used, use the

procedure in the previous step and the Bearing
Select Fit Chart, Oversize Bearings to determine
the required bearing grade for each main bearing.

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ASSEMBLY (Continued)

Bearing Select Fit Chart, Oversize Bearings

5. Install the crankshaft upper main bearings into the

cylinder block and lubricate them with clean
engine oil.
NOTE: Before assembling the cylinder block, all
sealing surfaces must be free of chips, dirt, paint
and foreign material. Also, make sure the coolant
and oil passages are clear.
6. Install the crankshaft onto the upper crankshaft
main bearings.
NOTE: The upper thrust washers are shown for
location purposes only. Do not install the upper
thrust washers until the crankshaft is installed.
Refer to the following two steps.

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ASSEMBLY (Continued)

7. Push the crankshaft rearward and install the rear

crankshaft upper thrust washer at the back of the
No. 5 main boss.
NOTE: The oil groove on the thrust washer must
face toward the front of the engine (against the
crankshaft thrust surface).

10. Install the crankshaft lower main bearings into the

main bearing caps and lubricate them with clean
engine oil. Locate the main bearing cap on the
cylinder block and tap into place using a plastic or
dead-blow hammer.

8. Push the crankshaft forward and install the front

crankshaft upper thrust washer at the front of the
No. 5 main boss.
NOTE: The oil groove on the thrust washer must
face toward the front of the engine (against the
crankshaft surface).

9. Install the lower crankshaft thrust washer to the

back side of the No. 5 main bearing cap, with oil
grooves facing the crankshaft surface.
NOTE: To aid in assembly, apply petroleum jelly
to the back of the crankshaft thrust washer.
NOTE: The oil groove on the thrust washer must
face toward the rear of the engine (crankshaft
surface).

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ASSEMBLY (Continued)

11. Install the dowel pins so the flat sides face the 12. Install the vertical main bearing cap fasteners and
crankshaft. tighten in the sequence shown.
Tighten to 40 Nm (30 lb-ft).
Tighten an additional 90 degrees.

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ASSEMBLY (Continued)

13. Install the side bolts and tighten them in the

sequence shown.
Tighten to 30 Nm (22 lb-ft).
Tighten an additional 90 degrees.

15. Once the connecting rod is seated on the

crankshaft journal, remove the Connecting Rod
Installer.
CAUTION: Do not scratch the cylinder
walls or crankshaft journals with the
connecting rod.

14. Use the special tools to install the piston and

connecting rod with the upper connecting rod 16. Position the lower bearing and connecting rod,
bearing in place. and install the new bolts loosely.

CAUTION: Do not scratch the cylinder CAUTION: The rod cap installation must
walls or crankshaft journals with the keep the same orientation as marked during
connecting rod. disassembly.
NOTE: The next three steps are for all eight NOTE: The connecting rod caps are of the
connecting rods, rod caps and pistons. Only one ‘‘cracked’’ design and must mate with the
connecting rod, rod cap and piston is shown. connecting rod ends. Excessive bearing clearance
NOTE: Make sure the identification marks on the will result if not mated correctly.
piston and connecting rod face toward the front of
the engine.

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303-01b-77 Engine - 5.4L (3V) 303-01b-77

ASSEMBLY (Continued)

17. Tighten the bolts in two stages, using the 19. Position the head gasket over the dowel pins.
sequence shown.
RH is shown; LH is similar.
Stage 1: Tighten to 43 Nm (32 lb-ft).
Stage 2: Tighten an additional 105 degrees. CAUTION: Make sure all coolant
NOTE: Main bearing caps are removed for residue and foreign material are cleaned
clarity. from the block surface and cylinder bore.
CAUTION: The use of sealing aids
(aviation cement, copper spray, and glue)
is not permitted. The gasket must be
installed dry.

20. Rotate the crankshaft until the crankshaft keyway

points toward the 9 o’clock position.

18. Position the oil pump and install the bolts loosely.
Tighten the bolts in the sequence shown.

21. Position the cylinder head over the dowels and

head gasket and install the cylinder head bolts
loosely.
RH is shown; LH is similar.
CAUTION: The cylinder head bolts
must be discarded and new bolts installed.
They are tighten-to-yield designed and
cannot be reused.
NOTE: NOTE: Do not turn the crankshaft until
instructed to do so.

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303-01b-78 Engine - 5.4L (3V) 303-01b-78

ASSEMBLY (Continued)

23. Install the oil level indicator tube.

Install a new O-ring seal on the oil level
indicator tube.
Install the oil level indicator tube.
Install the bolt and tighten to 10 Nm (89 lb-in).
24. Install the RH exhaust manifold gaskets and the
exhaust manifold. Tighten the nuts in the
sequence shown.

22. Tighten the bolts in three stages, in the sequence

shown.
RH is shown; LH is similar.
Stage 1: Tighten to 40 Nm (30 lb-ft).
Stage 2: Tighten an additional 90 degrees.
Stage 3: Tighten an additional 90 degrees.

25. Install the LH exhaust manifold and the exhaust

manifold gaskets. Tighten the nuts in the
sequence shown.

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303-01b-79 Engine - 5.4L (3V) 303-01b-79

ASSEMBLY (Continued)

26. Compress the tensioner plunger, using a vise. 30. Install the RH timing chain guide.
CAUTION: Timing chain procedures must
be followed exactly or damage to valves and
pistons will result.

31. Install the LH timing chain guide.

27. Install a retaining clip on the tensioner to hold the

plunger in during installation.

32. Pre-position the camshafts.

1. Rotate the LH camshaft until the timing mark
is approximately at 6 o’clock.
2. Rotate the RH camshaft until the timing mark
28. Remove the tensioner from the vise. is approximately at 12 o’clock.
29. If the copper links are not visible, mark two links
on one end and one link on the other end, and
use as timing marks.

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303-01b-80 Engine - 5.4L (3V) 303-01b-80

ASSEMBLY (Continued)

33. Remove the Crankshaft Holding Tool. 36. Position the timing chain on the camshaft
34. Install the crankshaft sprocket, making sure the sprocket with the camshaft sprocket timing mark
flange faces forward. positioned between the two copper (marked)
chain links.
NOTE: Make sure the upper half of the timing
chain is below the tensioner arm dowel.
NOTE: If necessary, use the Camshaft Alignment
Set to adjust the camshaft sprocket slightly to
obtain timing mark alignment.

35. Position the lower end of the LH (inner) timing

chain on the crankshaft sprocket, aligning the
timing mark on the outer flange of the crankshaft
sprocket with the single copper (marked) link on
the chain.

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303-01b-81 Engine - 5.4L (3V) 303-01b-81

ASSEMBLY (Continued)

37. Position the LH timing chain tensioner arm on the 40. Position the RH timing chain on the camshaft
dowel pin and install the LH timing chain sprocket. Make sure the camshaft sprocket timing
tensioner. mark is positioned between the two copper
NOTE: The LH timing chain tensioner arm has a (marked) chain links.
bump near the dowel hole for identification. NOTE: The lower half of the timing chain must be
positioned above the tensioner arm dowel.
NOTE: If necessary, use the Camshaft Alignment
Set to adjust the camshaft sprocket slightly to
obtain timing mark alignment.

38. Remove the retaining clip from the LH timing

chain tensioner.

41. Position the RH timing chain tensioner arm on the

dowel pin and install the RH timing chain
tensioner.

39. Position the lower end of the RH (outer) timing

chain on the crankshaft sprocket, aligning the
timing mark on the sprocket with the single copper
(marked) chain link.

42. Remove the retaining clip from the RH timing

chain tensioner.

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303-01b-82 Engine - 5.4L (3V) 303-01b-82

ASSEMBLY (Continued)

43. As a post-check, verify correct alignment of all

timing marks.

44. Install the camshaft roller followers.

1. Compress the valve spring.
2. Install the camshaft roller followers in their
original locations. 47. Install a new engine front cover gasket on the
NOTE: Lubricate the camshaft roller followers engine front cover. Position the engine front
using clean engine oil. cover. Install the fasteners finger-tight.
NOTE: The use of a special tool may be
required.
45. Install the crankshaft sensor ring on the
crankshaft.

48. Tighten the engine front cover fasteners in

sequence in three stages.
Stage 1: Tighten fasteners 1 through 5 to 25
Nm (18 lb-ft).
46. Apply a bead of silicone gasket and sealant along Stage 2: Tighten fasteners 6 and 7 to 48 Nm
the cylinder head-to-cylinder block surface at the (35 lb-ft).
locations shown. Stage 3: Tighten fasteners 8 through 15 to 48
NOTE: If the front cover is not secured within four Nm (35 lb-ft).
minutes, the sealant must be removed and the
sealing area cleaned. To clean the sealing area,
use silicone gasket remover and metal surface
prep. Follow the directions on the packaging.
Failure to follow this procedure can cause future
oil leakage.

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303-01b-83 Engine - 5.4L (3V) 303-01b-83

ASSEMBLY (Continued)

Item Description Item Description

1 N806177 Bolt, Hex Flange Head Pilot, M8 14 N808140 Stud and Washer, Hex Head
x 1.25 x 53 Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27
2 N806177 Bolt, Hex Flange Head Pilot, M8 15 N808140 Stud and Washer, Hex Head
x 1.25 x 53 Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27
3 N806177 Bolt, Hex Flange Head Pilot, M8 49. Install the oil pump screen and pickup tube
x 1.25 x 53 spacer.
4 N806177 Bolt, Hex Flange Head Pilot, M8
x 1.25 x 53
5 N806177 Bolt, Hex Flange Head Pilot, M8
x 1.25 x 53
6 N808529 Stud, Hex Head Pilot, M10 x 1.5
x 59 — M10 x 1.5 x 30
7 N808529 Stud, Hex Head Pilot, M10 x 1.5
x 59 — M10 x 1.5 x 30
8 N808142 Screw and Washer, Hex Pilot,
M10 x 1.5 x 57.5
9 N808142 Screw and Washer, Hex Pilot,
M10 x 1.5 x 57.5
10 N808142 Screw and Washer, Hex Pilot,
M10 x 1.5 x 57.5
11 N808140 Stud and Washer, Hex Head
Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27
12 N808140 Stud and Washer, Hex Head
Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27
13 N808140 Stud and Washer, Hex Head
Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27

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303-01b-84 Engine - 5.4L (3V) 303-01b-84

ASSEMBLY (Continued)

50. Position the oil pump screen and pickup tube and 53. Position the belt idler pulley and install the bolt.
install the bolts.
CAUTION: Make sure the O-ring is in
place and not damaged. A missing or
damaged O-ring can cause foam in the
lubrication system, low oil pressure and
severe engine damage.
NOTE: Clean and inspect the mating surfaces
and install a new O-ring. Lubricate with the O-ring
with clean engine oil.
51. Position the oil filter adapter and install the four
bolts.
NOTE: NOTE: Clean and inspect the mating
surfaces, and install new gaskets.
54. Install the coolant pump.
1. Lubricate the new O-ring seal using engine
coolant and install the O-ring seal onto the
coolant pump.
2. Position the coolant pump into the engine
block.
3. Install the bolts.
CAUTION: Do not rotate the coolant
pump housing once the coolant pump has
been positioned in the cylinder block.
Damage to the O-ring seal will occur.

52. Position the power steering pump and install the

three bolts.

55. Lubricate the engine front cover and the front oil
seal inner lip with clean engine oil.

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303-01b-85 Engine - 5.4L (3V) 303-01b-85

ASSEMBLY (Continued)

56. Use the special tools to install the crankshaft front 59. Tighten the new crankshaft pulley bolt in four
oil seal into the engine front cover. stages.
Stage 1: Tighten to 90 Nm (66 lb-ft).
Stage 2: Loosen 360 degrees.
Stage 3: Tighten to 50 Nm (37 lb-ft).
Stage 4: Tighten an additional 90 degrees.

57. Apply silicone gasket and sealant to the Woodruff

key slot on the crankshaft pulley.
NOTE: If not secured within four minutes, the
sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone
gasket remover and metal surface prep. Follow 60. Position the coolant pump pulley on the coolant
the directions on the packaging. Failure to follow pump and install the bolts.
this procedure can cause future oil leakage.

58. Use the special tool to install the crankshaft

pulley.

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303-01b-86 Engine - 5.4L (3V) 303-01b-86

ASSEMBLY (Continued)

61. Position the accessory drive belt tensioner and 64. Position the A/C compressor and install the bolts.
install the bolts.

65. Install the oil drain plug.

62. Install the crankshaft position (CKP) sensor and
the bolt.

66. If a new gasket is being installed, apply instant

adhesive completely around the gasket groove in
63. Position the A/C compressor bracket and install the RH valve cover. Install the new valve cover
the bolts. gasket.
NOTE: RH shown, LH similar.
67. Apply silicone gasket and sealant in two places
where the engine front cover meets the cylinder
head.
NOTE: RH is shown, LH is similar.
NOTE: If not secured within four minutes, the
sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone
gasket remover and metal surface prep. Follow
the directions on the packaging. Failure to follow
this procedure can cause future oil leakage.

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303-01b-87 Engine - 5.4L (3V) 303-01b-87

ASSEMBLY (Continued)

69. Position the LH valve cover and gasket on the

cylinder head and install the bolts loosely. Tighten
the bolts in the sequence shown.

68. Position the RH valve cover and gasket on the

cylinder head and install the bolts loosely. Tighten
the bolts in the sequence shown.

70. Install the eight ignition coils and bolts.

NOTE: NOTE: RH is shown, LH is similar.

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303-01b-88 Engine - 5.4L (3V) 303-01b-88

ASSEMBLY (Continued)

71. Position the water bypass tube assembly and 74. Position the generator support bracket and install
install the bolts. the bolts.

72. Install the bolt. 75. Install the intake manifold gaskets.

73. Position the generator and install the bolts.

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303-01b-89 Engine - 5.4L (3V) 303-01b-89

ASSEMBLY (Continued)

76. Install the intake manifold and tighten the bolts in 80. Install the special tool.
the sequence shown.

81. Install the special tool.

82. Install the special tool and remove the engine

77. Install the crankcase ventilation tube on the LH from the work stand.
valve cover.
78. Install the radio frequency interference capacitors.
NOTE: RH shown, LH similar.

83. Inspect the rear seal retainer plate. Clean the

mating surface for the rear seal retainer plate with
silicone gasket remover and metal surface prep.
Follow the directions on the packaging.
79. Install the engine control sensor wiring.
CAUTION: Do not use metal scrapers,
wire brushes, power abrasive discs or other
abrasive means to clean the aluminum
retainer plate. These tools cause scratches
and gouges, which make leak paths. Use a
plastic scraping tool to remove all traces of
old sealant.

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303-01b-90 Engine - 5.4L (3V) 303-01b-90

ASSEMBLY (Continued)

84. Apply a 4 mm (0.16 in) bead of silicone gasket 87. Inspect the oil pan. Clean the mating surface for
and sealant around the rear oil seal retainer the oil pan with silicone gasket remover and metal
sealing surface. surface prep. Follow the directions on the
NOTE: If not secured within four minutes, the packaging.
sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone CAUTION: Do not use metal scrapers,
gasket remover and metal surface prep. Follow wire brushes, power abrasive discs or other
the directions on the packaging. Failure to follow abrasive means to clean the sealing surfaces.
this procedure can cause future oil leakage. These tools cause scratches and gouges,
which make leak paths. Use a plastic scraping
tool to remove all traces of old sealant.
88. Apply silicone gasket and sealant at the rear oil
seal retainer-to-cylinder block sealing surface.
NOTE: If not secured within four minutes, the
sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone
gasket remover and metal surface prep. Follow
the directions on the packaging. Failure to follow
this procedure can cause future oil leakage.

85. Install the rear oil seal retainer plate and loosely
install the six bolts.

89. Apply silicone gasket and sealant at the engine

front cover-to-cylinder block sealing surface.
NOTE: If not secured within four minutes, the
sealant must be removed and the sealing area
cleaned. To clean the sealing area, use silicone
gasket remover and metal surface prep. Follow
the directions on the packaging. Failure to follow
86. Tighten the bolts in the sequence shown. this procedure can cause future oil leakage.

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303-01b-91 Engine - 5.4L (3V) 303-01b-91

ASSEMBLY (Continued)

90. Install the oil pan gasket and the oil pan and 91. Tighten the bolts in three stages, in the sequence
loosely install the bolts. shown.
Stage 1: Tighten to 2 Nm (18 lb-in).
Stage 2: Tighten to 20 Nm (15 lb-ft).
Stage 3: Tighten an additional 90 degrees.

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303-01b-92 Engine - 5.4L (3V) 303-01b-92

ASSEMBLY (Continued)

92. Using the special tools, install a new crankshaft 94. Install the flexplate or the flywheel and bolts.
rear oil seal. Tighten the bolts in the sequence shown.
CAUTION: Lubricate the inner lip of the
crankshaft rear oil seal with clean engine oil.

93. Using the special tools, install the crankshaft rear

oil slinger.

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