Engine - 5.

4L
ASSEMBLY: ENGINE - 5.4L (ENGINE - 4.6L AND 5.4L) Procedure SGML ID: N839219
SECTION 303-01B: Engine - 4.6L and 5.4L 2000 F-150 Workshop Manual
ASSEMBLY Procedure revision date: 10/21/2003

Engine - 5.4L

Special Tool(s)
Installer, Connecting Rod
303-442 (T93P-6136-A)

Installer, Crankshaft Vibration Damper

303-102 (T74P-6316-B)

Installer, Crankshaft Front Oil Seal

303-635

Compressor, Piston Ring

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

Holding Tool, Crankshaft

303-448 (T93P-6303-A)

Compressor, Valve Spring

303-567 (T97P-6565-AH)

Compressor Spacer, Valve Spring

303-382 (T91P-6565-AH)

Installer, Front Cover Oil Seal

303-335 (T88T-6701-A)

Modular Engine Lift Bracket

303-F047 (014-00073) or equivalent
 Strap Wrench
303-D055 (D85L-6000-A)

Remover/Installer, Cylinder Head

303-572 (T97T-6000-A)

Installer, Crankshaft Rear Oil Seal

303-518 (T95P-6701-DH)

Installer, Crankshaft Rear Oil Seal

303-516 (T95P-6701-BH)

Installer, Crankshaft Rear Oil Slinger

303-517 (T95P-6701-CH)

Lifting Bracket Set, Engine

303-DS086 (D93P-6001-A)

Material
Item Specification
Motorcraft Silicone Gasket Remover --
ZC-30
Motorcraft Metal Surface Prep -
ZC-31
Silicone Gasket and Sealant WSE-M4G323-
F7AZ-19554-EA or equivalent A4
Instant Adhesive WSK-M2G402-
E8AZ-19554-A A4
SAE 5W-20 Premium Synthetic Blend WSS-M2C153-H
Engine Oil
XO-5W20-QSP or equivalent
Motorcraft Premium Engine Coolant ESE-M97B44-A
VC-4-A (in Canada CXC-10; in Oregon VC-5) (green in color)
or equivalent. Do not mix coolant types.
Motorcraft Premium Gold Engine Coolant WSS-M97B51-
VC-7-A (in Oregon VC-7-B) or equivalent. Do A1 (yellow in
not mix coolant types. color)

Assembly

All Engines

1. Record the main bearing code found on the front of the engine block.

2. Record the main bearing code found on the back of the crankshaft.

Bearing select fit chart, standard bearings

3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart determine the required bearing
grade for each main bearing.
Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main
bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main
bearing.
As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for
this main bearing is "2."
Repeat this process for the remaining four main bearings.
Bearing select fit chart, oversize bearings

4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize
Bearing Chart to determine the required grade for each main bearing.

5.

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.

Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.

6. 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.

Install the crankshaft onto the upper crankshaft main bearings.

7. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).

Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.

8. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface).

Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.

9. 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).

Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the
crankshaft surface.
10. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the
main bearing caps on the cylinder block and tap into place using a plastic or dead-blow hammer.

11. Install the dowel pins so the flat sides face the crankshaft.

12. Install the vertical main bearing cap fasteners and tighten in the sequence shown.
Tighten to 40 Nm (30 lb-ft).
Tighten an additional 90 degrees.
13. Install the side bolts and tighten in the sequence shown.
Tighten to 30 Nm (22 lb-ft).
Tighten an additional 90 degrees.

14. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

NOTE: The next three steps are for all eight connecting rods, rod caps and pistons. Only one connecting rod, rod cap and
piston is shown.

NOTE: Make sure the identification marks on the piston and connecting rod face toward the front of the engine.

Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place.
15. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.

Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.

16. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly.

NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing
clearance will result if not mated correctly.

Postion the lower bearing and connecting rod, and install the new bolts loosely.

17. NOTE: Main bearing caps are removed for clarity.

Tighten the bolts in two stages, using the sequence shown.

Stage 1: Tighten to 43 Nm (32 lb-ft).
Stage 2: Tighten an additional 105 degrees.
18. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.

19. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional
information, refer to Cylinder Heads - 5.4L in the Removal portion of this section.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must
be installed dry.

CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal properly. Do not
scratch the gasket.

NOTE: The RH head gasket shown; the LH head gasket similar.

Install the head gasket over the dowel pins.

 20. 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: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional
information, refer to Cylinder Heads - 5.4L in the Removal portion of this section.

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must
be installed dry.

CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head
installation.

NOTE: The new cylinder head bolts must be lightly oiled with a rag and allowed to drain for a few minutes prior to installation.

NOTE: The RH cylinder head is shown; the LH cylinder head is similar.

Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.

LH cylinder head

21.

NOTE: Make sure to tighten the bolts in sequence in three stages.

Tighten the LH bolts in the sequence shown.

Stage 1: Tighten to 40 Nm (30 lb-ft).

Stage 2: Tighten an additional 90 degrees.

Stage 3: tighten an additional 90 degrees.

RH cylinder head

22.

NOTE: Make sure to tighten the bolts in the following three stages.

Tighten the RH bolts in the sequence shown.

Stage 1: Tighten to 40 Nm (30 lb-ft).

Stage 2: Tighten an additional 90 degrees.

Stage 3: Tighten an additional 90 degrees.

All cylinder heads

23. Remove the special tools on both ends of the cylinder head.

24.

NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.

Install the hydraulic lash adjusters in their original locations.

RH cylinder head

25. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.

LH cylinder head

26.

NOTE: Lubricate the O-ring seal with clean engine oil.

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.

 27. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.

All cylinder heads

28.

CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly.

Compress the tensioner plunger, using an edge of a vise.

29. Using a small screwdriver or pick, push back and hold the ratchet mechanism.
30. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.

31. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.

32. Remove the tensioner from the vise.

33. 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.

34. Install the timing chain guides.

35. Pre-position the camshafts.
1. Rotate the LH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 12 o'clock.
2. Rotate the RH camshaft with the Camshaft Positioning Tool until the timing mark is approximately at 11 o'clock.

36. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and
valve damage can occur.

NOTE: The number one piston is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of
the special tool.

Position the crankshaft so the number one cylinder is at TDC with the special tool.
37. Remove the Crankshaft Holding Tool.

38. NOTE: Crankshaft sprockets are identical. They may only be installed one way. Refer to the following illustration for correct
crankshaft sprocket installation.

If removed, install the LH and RH crankshaft sprockets.

1. Timing marks aligned.
2. Keyways aligned.

39. 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.

40. 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.

Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper
(marked) chain links.

41. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.

42. Remove the retaining clip from the LH timing chain tensioner.

43. 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.
44. 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.

Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between
the two copper (marked) chain links.

45. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.

46. Remove the retaining clip from the RH timing chain tensioner.

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

48. Install the special tool between the valve spring coils to prevent valve stem seal damage.

49. NOTE: Lubricate the camshaft roller followers, using clean engine oil.

NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.

Install the camshaft roller followers.

1. Install the special tool.
2. Compress the valve spring.
3. Install the camshaft roller followers in their original locations.

50. Remove the special tool.

51. CAUTION: When installing the spark plugs, use care not to exceed the recommended torque.
 Install the eight spark plugs.
Tighten the spark plugs to 18 Nm (13 lb-ft).

52. Install the crankshaft sensor ring on the crankshaft.

53. NOTE: If the front cover is 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.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block
surface, at the locations shown.

54. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-
tight.
55. Tighten the engine front cover fasteners in sequence in three stages.
•Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).
•Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).
•Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).

Item Part Number Description

1 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53
2 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53
3 N806177 Bolt, hex flange head pilot, M8 x 1.25 x 53
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 M10 x 1.5 x 1.5 x 103.1
7 N808529 M10 x 1.5 x 1.5 x 103.1
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 M8 x 1.25 x 109.6
12 N808140 Stud and washer, hex-head pilot, M10 x 1.5 x M8 x 1.25 x 109.6
13 N808140 Stud and washer, hex-head pilot, M10 x 1.5 x M8 x 1.25 x 109.6
14 N808140 Stud and washer, hex-head pilot, M10 x 1.5 x M8 x 1.25 x 109.6
15 N808140 Stud and washer, hex-head pilot, M10 x 1.5 x M8 x 1.25 x 109.6

56. Position the belt idler pulley and install the bolt.
57. Lubricate the engine front cover and the front oil seal inner slip with clean engine oil.

58. Use the special tools to install the crankshaft front oil seal into the engine front cover.

59. 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.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

60. Use the special tool to install the crankshaft pulley.

61. NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.

Tighten the new crankshaft pulley bolt in four 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.

62. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the LH valve cover. Install
the new valve cover gasket.

63. 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.

Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
64. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.

65. Tighten the bolts in the sequence shown.

66. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the RH valve cover. Install
the new valve cover gasket.
67. NOTE: If not secured within four minutes, the selant must be removed and the sealing area cleaned, use silicone gasket
remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil
leakage.

Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.

68. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.

69. Tighten the bolts in the sequence shown.

70. Install the crankcase ventilation tube on the LH valve cover.

71. NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors and the hose support.

72. Roughtly position the engine control sensor wiring harness and mount it on the valve cover studs.

73. Connect the knock sensor electrical connector.

74. Connect the RH radio frequency interference capacitor electrical connector.

75. Connect the CMP sensor electrical connector.

76. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.

77. NOTE: LH shown, RH similar.

Install the cylinder block drain plugs.

78. NOTE: Clean and inspect the mating surfaces, and install new gaskets.

Position the oil filter adapter and install the four bolts.
79. Position the LH engine mount to the cylinder block and install the bolts.

80. Position the RH engine mount to the cylinder block and install the bolts.

81. 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.

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.
82. Position the coolant pump pulley on the coolant pump and install the bolts.

83. 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.

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.

84. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing
area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to
follow this procedure can cause future oil leakage.

Apply a 4 mm (0.15 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
85. Install the rear oil seal retainer plate and loosely install the six bolts.

86. Tighten the bolts in the sequence shown.

87. Install the oil drain plug.

88. Install the oil pump screen and pickup tube spacer.

89. 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.

Position the oil pump screen and pickup tube and install the bolts.
90. 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.

Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the
directions on the packaging.

91. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing areas cleaned. To clean
the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.

92. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing areas cleaned. To clean
the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep.
Failure to follow this procedure can cause future oil leakage.

Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.

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

95. Install the special tool.

96. Install the special tool.

 97. Install the special tool and remove the engine from the work stand.

98. Lower the engine onto wooden blocks.

99. Remove the special tool.

100. Remove the special tool.

101. Install the special tool and raise the engine.

102. Install the power steering reservoir lower mounting bracket.

103. NOTE: Lubricate the inner lip of the crankshaft rear oil seal with clean engine oil.

Using the special tools, install a new crankshaft rear oil seal.

104. Using the special tools, install the crankshaft rear oil slinger.

105. Install the flexplate and bolts. Tighten the bolts in the sequence shown.
106. Install the engine. For additional information, refer to Engine in this section.

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