Engine-assembly.pdf

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303-01C-1

Engine — 5.4L (3V)

303-01C-1

ASSEMBLY Special Tool(s)

Engine

Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent

Special Tool(s) Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)

Installer, Crankshaft Rear Seal 303-518 (T95P-6701-DH) Installer, Connecting Rod 303-442 (T93P-6136-A)

Installer, Crankshaft Oil Slinger 303-517 (T95P-6701-CH) Compressor, Valve Spring 303-1039

Installer, Crankshaft Rear Seal 303-516 (T95P-6701-EH) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Holding Tool, Crankshaft 303-448 (T93P-6303-A) Installer, Crankshaft Front Seal 303-635

Alignment Pins, Cylinder Head 303-1040 (SR-015486) Installer, Front Cover Seal 303-335 (T88T-6701-A)

(Continued)

(Continued)

Copyright  2005, Ford Motor Company Last updated: 5/10/2006

2006 F-150, Mark LT, 9/2005

303-01C-2

Engine — 5.4L (3V)

303-01C-2

ASSEMBLY (Continued) Special Tool(s)

Material Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent

Locking Tool, Camshaft Phaser Sprocket 303-1046

Material Item Motorcraft Metal Surface Prep ZC-31 Silicone Gasket Remover ZC-30

Specification —



Item Silicone Gasket and Sealant TA-30 Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent Motorcraft Premium Gold Engine Coolant VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color) Threadlock 262 TA-26 or equivalent Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA

Specification WSE-M4G323-A4

WSS-M2C930-A

WSS-M97B51-A1

WSK-M2G351-A6 —

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-3

Engine — 5.4L (3V)

303-01C-3

ASSEMBLY (Continued) Engine — Upper End

2006 F-150, Mark LT, 9/2005

303-01C-4

Engine — 5.4L (3V)

303-01C-4

ASSEMBLY (Continued) Item

Part Number

Description

1 2 3 4 5 6

12B637 6A505 6750 N605892 6K873 N807834

7

6B280

8 9 10

6C255 6529 6518

11

6514

12 13 14

6513 6A517 6C501

15

6279

16

6C524

17 18 19 20

6B284 12405 12A366 6065

21

W707747

22

9Y431

23 24

9431 W701706

25 26 27 28

6507 6505 6083 W701520

29

6C261

30 31

6050 14B102

32

W701571

Engine wiring harness Valve cover — LH Oil level indicator Oil level indicator tube bolt Oil level indicator tube Camshaft bearing cap bolt (10 required) Camshaft bearing cap (4 required) Camshaft — LH Roller follower (24 required) Valve spring retainer key (48 required) Valve spring retainer (24 required) Valve spring (24 required) Valve stem seal (24 required) Hydraulic lash adjuster (24 required) Camshaft phaser sprocket bolt — LH Camshaft phaser sprocket — LH Camshaft bearing cap Spark plug (4 required) Ignition coil (4 required) Cylinder head bolt (20 required) Exhaust manifold stud (8 required) Exhaust manifold gasket (2 required) Exhaust manifold — LH Exhaust manifold nut (8 required) Intake valve (16 required) Exhaust valve (8 required) Cylinder head gasket — LH Variable camshaft timing (VCT) oil control solenoid assembly bolt (2 required) VCT oil control solenoid assembly Cylinder head — LH Cylinder head temperature (CHT) sensor jumper harness Heater outlet tube stud bolt

Item 33 34 35 36

Part Number 18663 6051 6049 9Y431

37 38

9430 W701706

39

W707747

40

6C260

41

W701520

42

6279

43

6C524

44 45

6B284 N807834

46

6B280

47 48 49 50 51 52 53 54 55

6251 12405 12A366 W706175 6582 6765 6766 6758 W503282

56

W503279

57 58 59 60 61 62

8594 N806807 8575 8C369 6N041 9A474

63

9S440

64

N811050

Description Heater outlet tube Cylinder head gasket — RH Cylinder head — RH Exhaust manifold gasket (2 required) Exhaust manifold — RH Exhaust manifold nut (8 required) Exhaust manifold stud (8 required) VCT oil control solenoid assembly VCT oil control solenoid assembly bolt (2 required) Camshaft phaser sprocket bolt — RH Camshaft phaser sprocket — RH Camshaft bearing cap Camshaft bearing cap bolt (10 required) Camshaft bearing cap (4 required) Camshaft — RH Spark plug (4 required) Ignition coil (4 required) Ignition coil bolt (8 required) Valve cover — RH Oil fill adapter Oil fill adapter cap Crankcase ventilation tube Coolant crossover tube bolt (3 required) Thermostat housing bolt (2 required) Thermostat housing Thermostat O-ring seal Thermostat Coolant crossover tube Intake manifold dust cover Intake manifold vacuum harness Intake manifold vacuum harness support bracket Intake manifold vacuum harness support bracket bolt

(Continued)

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-5

Engine — 5.4L (3V)

303-01C-5

ASSEMBLY (Continued) Item 65

Description Intake manifold bolt (10 required) Intake manifold assembly Positive crankcase ventilation (PCV) tube

Item 68

Part Number

Description

1

N804758

2

18801

3 4

6C086 W503282

5

6L266

6

N606543

7 8

6268 6M256

Radio ignition interference capacitor nut Radio ignition interference capacitor Engine front cover Timing chain guide bolt— RH (2 required) Timing chain tensioner — RH Timing chain tensioner bolt — RH (2 required) Timing chain — RH Timing chain guide — RH

Item 9

66 67

Part Number W709775 9Y451 6K817

69

Part Number W500204 9F624

Description PCV heater element assembly bolt (2 required) PCV heater element assembly

(Continued)

Engine — Front end

Item

(Continued)

Part Number N606543

10 11 12

6M269 6M274 N605892

13 14 15

6306 6B274 N606527

16 17 18

6268 6K255 12A227

Description Timing chain tensioner bolt — LH (2 required) Timing chain tensioner — LH Tensioner arm — LH Timing chain guide upper bolt — LH Crankshaft sprocket Timing chain guide — LH Timing chain guide lower bolt — LH Timing Chain — LH Tensioner arm — RH Ignition pulse wheel

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-6

Engine — 5.4L (3V)

303-01C-6

ASSEMBLY (Continued) Item 19

Part Number W707225

20

W706447

21

3A696

22 23

W706605 N808529

24

N806177

25

6C315

26 27

N806155 12A216

28

N808102

29

6700

Description Power steering pump stud bolt Power steering pump bolt (2 required) Power steering pump assembly Engine front cover bolt Engine front cover stud bolt (2 required) Engine front cover bolt (9 required) Crankshaft position (CKP) sensor CKP sensor bolt Accessory drive belt idler pulley Accessory drive belt idler pulley bolt Crankshaft front seal

Item 30 31 32 33 34

Part Number 6316 N806165 W701512 8A528 N806282

35

N806177

36 37

8501 N808102

38

12A216

39

N806155

40 41

6B288 W709573

Description Crankshaft pulley Crankshaft pulley washer Crankshaft pulley bolt Coolant pump pulley Coolant pump pulley bolt (4 required) Coolant pump bolt (4 required) Coolant pump Accessory drive belt idler pulley bolt Accessory drive belt idler pulley Camshaft position (CMP) sensor bolt (2 required) CMP sensor (2 required) Engine front cover stud bolt (3 required)

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-7

Engine — 5.4L (3V)

303-01C-7

ASSEMBLY (Continued) Engine — Lower end

Item

Part Number

Description

1

6150

2

6152

3

6159

4

6161

5

6159

Upper compression ring (8 required) Lower compression ring (8 required) Outer oil control ring (8 required) Inner oil control ring (8 required) Outer oil control ring (8 required)

Item 6

Part Number 6140

7 8 9

6135 6110 6200

10

6211

Description Piston pin retainer (16 required) Piston pin (8 required) Piston (8 required) Connecting rod assembly (8 required) Connecting rod bearing (8 required)

(Continued)

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-8

Engine — 5.4L (3V)

303-01C-8

ASSEMBLY (Continued) Item 11

Part Number 6K318

12

N806155

13 14 15 16 17 18 19

6310 6701 6375 N806168 6714 6890 N806156

20

9278

21 22 23 24 25

6881 6A636 W701605 6675 12A648

26 27

6710 N605904

28

N806155

29

6622

30

N806180

31

6K258

32

6345

33

6A346

34

6C357

35

6325

36

6A338

37

6K302

38 39

6303 N806201

Description Crankshaft rear seal retainer plate Crankshaft rear seal retainer plate bolt (6 required) Crankshaft rear seal Crankshaft oil slinger Flexplate Flexplate bolt (8 required) Oil filter Oil filter threaded adapter Oil filter adapter bolt (4 required) Engine oil pressure (EOP) sensor Oil filter adapter Oil filter adapter gasket Oil pan bolt (16 required) Oil pan Engine oil temperature (EOT) sensor Oil pan gasket Oil pump screen and pickup tube bolt Oil pump screen and pickup tube bolt (2 required) Oil pump screen and pickup tube Oil pump screen and pickup tube spacer Crankshaft main bearing cap stud Crankshaft main bearing cap bolt (9 required) Crankshaft main bearing dowel (10 required) Crankshaft main bearing cap bolt (10 required) Crankshaft main bearing cap (5 required) Crankshaft bearing — Lower (5 required) Crankshaft thrust washer — Lower Crankshaft Crankshaft key

Item 40

Part Number 6A341

41 42

6333 6333

43

6210

44

6211

45 46 47 48

6621 N806183 6010 W500225

49

12A699

Description Crankshaft thrust washer — Upper (2 required) Crankshaft bearing — Upper Crankshaft bearing — Upper (4 required) Connecting rod cap (8 required) Connecting rod bearing (8 required) Oil pump Oil pump bolt (3 required) Cylinder block Knock sensor bolt (2 required) Knock sensor (2 required)

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.

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-9

Engine — 5.4L (3V)

303-01C-9

ASSEMBLY (Continued) 3.

Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, 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 2 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 a ‘‘2.’’



Repeat this process for the remaining 4 main bearings.

2006 F-150, Mark LT, 9/2005

303-01C-10

Engine — 5.4L (3V)

303-01C-10

ASSEMBLY (Continued) 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.

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.

2006 F-150, Mark LT, 9/2005

303-01C-11

Engine — 5.4L (3V)

303-01C-11

ASSEMBLY (Continued) 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 2 steps.

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.

Install the crankshaft onto the upper crankshaft main bearings.

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.

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.

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, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.

2006 F-150, Mark LT, 9/2005

303-01C-12

Engine — 5.4L (3V)

303-01C-12

ASSEMBLY (Continued) 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.

2006 F-150, Mark LT, 9/2005

303-01C-13

Engine — 5.4L (3V)

303-01C-13

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. Assemble the 8 pistons. For additional information, refer to Piston in this section. 16. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.

14. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to Section 303-00.

2006 F-150, Mark LT, 9/2005

303-01C-14

Engine — 5.4L (3V)

303-01C-14

ASSEMBLY (Continued) 17.

18.

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

19.

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

NOTE: The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only 1 connecting rod, rod bearing and piston is shown.

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.

Use the special tools to install the connecting rod with the upper connecting rod bearing in place.

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



Lubricate the piston and ring with clean engine oil



Lubricate the rod bearings with clean engine oil.

20. NOTE: Main bearing caps are removed for clarity. Tighten the bolts in 2 stages, in the sequence shown. •

Stage 1: Tighten to 43 Nm (32 lb-ft).



Stage 2: Tighten an additional 105 degrees.

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 special tools.

2006 F-150, Mark LT, 9/2005

303-01C-15

Engine — 5.4L (3V)

303-01C-15

ASSEMBLY (Continued) 21. Position the oil pump and install the bolts. •

Tighten to 10 Nm (89 lb-in).

24. Position the crankshaft with the special tool, then remove the tool. 22. Install the oil pump screen and pickup tube spacer. •

23.

Tighten to 25 Nm (18 lb-ft).

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 the O-ring with clean engine oil prior to installation. Position the oil pump screen and pickup tube and install the bolts. •

Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in).



Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).

2006 F-150, Mark LT, 9/2005

303-01C-16

Engine — 5.4L (3V)

303-01C-16

ASSEMBLY (Continued) 25.

CAUTION: Make sure all coolant residue and foreign material are cleaned 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.

26. Tighten the bolts in 3 stages, in the sequence shown. RH shown, LH similar. •

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



Stage 2: Tighten an additional 90 degrees.



Stage 3: Tighten an additional 90 degrees.

CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused. NOTE: Do not turn the crankshaft until instructed to do so. NOTE: LH shown, RH similar. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.

27. Remove the special tool from the LH cylinder head.

2006 F-150, Mark LT, 9/2005

303-01C-17

Engine — 5.4L (3V)

303-01C-17

ASSEMBLY (Continued) 28. Remove the special tool from the RH cylinder head.

29. Install the hydraulic lash adjusters into the RH and LH cylinder heads. •

Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

32.

CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: LH shown, RH similar.

30. Install the LH and RH camshafts. •

Install the VCT phaser sprockets and new VCT phaser bolts finger tight.

Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.

31. NOTE: LH shown, RH similar. Install the LH and RH camshaft bearing caps in their original locations. •

Lubricate the camshaft bearing caps with clean engine oil.



Position the front camshaft bearing cap.



Position the remaining camshaft bearing caps.



Install the bolts loosely.



Tighten to 10 Nm (89 lb-in) in the sequence shown. 2006 F-150, Mark LT, 9/2005

303-01C-18

Engine — 5.4L (3V)

303-01C-18

ASSEMBLY (Continued) 33.

CAUTION: Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

35. Install a retaining clip on the tensioner to hold the plunger in during installation.

CAUTION: Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket. NOTE: LH shown, RH similar. Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages. •

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



Stage 2: Tighten an additional 90 degrees. 36. Remove the tensioner from the vise. 37. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.

34.

CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. CAUTION: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

38. Install the crankshaft sprocket, making sure the flange faces forward.

Compress the tensioner plunger, using a vise.

2006 F-150, Mark LT, 9/2005

303-01C-19

Engine — 5.4L (3V)

303-01C-19

ASSEMBLY (Continued) 39. Install the 4 bolts and the LH and RH timing chain guides. •

Tighten to 10 Nm (89 lb-in).

40. 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.

41. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 copper (marked) chain links.

2006 F-150, Mark LT, 9/2005

303-01C-20

Engine — 5.4L (3V)

303-01C-20

ASSEMBLY (Continued) 42. 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 and bolts. •

Tighten to 25 Nm (18 lb-ft).

45. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel. NOTE: The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft. 43. Remove the retaining clip from the LH timing chain tensioner.

Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 copper (marked) chain links.

44. 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.

2006 F-150, Mark LT, 9/2005

303-01C-21

Engine — 5.4L (3V)

303-01C-21

ASSEMBLY (Continued) 46. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts. •

Tighten to 25 Nm (18 lb-ft).

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

49. Install the crankshaft sensor ring on the crankshaft.

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

2006 F-150, Mark LT, 9/2005

303-01C-22

Engine — 5.4L (3V)

303-01C-22

ASSEMBLY (Continued) 50. Using the special tool, install all of the camshaft roller followers. •

Lubricate the camshaft roller followers with clean engine oil prior to installation.

2006 F-150, Mark LT, 9/2005

303-01C-23

Engine — 5.4L (3V)

303-01C-23

ASSEMBLY (Continued) 51.

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: If the engine front cover is not secured within 4 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.

2006 F-150, Mark LT, 9/2005

303-01C-24

Engine — 5.4L (3V)

303-01C-24

ASSEMBLY (Continued) 52. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.

Item

Part Number

9

N806177

Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

10

N806177

Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

11

N806177

Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

12

W709573

Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94

13

W709573

Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94

14

W709573

Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94

15

W706605

Bolt, Hex Head Pilot, M8 x 1.25 x 56

Description

53. Tighten the engine front cover fasteners in the sequence shown in 2 stages. Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Item

Part Number

1

N806177

Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

2

N806177

Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

3

N806177

Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

4

N806177

Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

5

N806177

Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

6

N808529

Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103

7

N808529

Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103

8

N806177

Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

Description

2006 F-150, Mark LT, 9/2005

303-01C-25

Engine — 5.4L (3V)

303-01C-25

ASSEMBLY (Continued) 54. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation. Install the LH camshaft position (CMP) sensor and the bolt. •

Tighten to 10 Nm (89 lb-in).

57. Tighten the 4 coolant pump bolts. •

Tighten to 25 Nm (18 lb-ft).

55. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation. Install the RH CMP sensor and the bolt. •

Tighten to 10 Nm (89 lb-in).

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

56.

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. Position the coolant pump and install the bolts loosely. •

Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.

2006 F-150, Mark LT, 9/2005

303-01C-26

Engine — 5.4L (3V)

303-01C-26

ASSEMBLY (Continued) 59. Using the special tools, install a new crankshaft seal into the engine front cover.

62. Tighten the new crankshaft pulley bolt in 4 stages. 60. NOTE: If not secured within 4 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.



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.

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

63. Position the crankshaft position (CKP) sensor and the bolt. •

Tighten to 10 Nm (89 lb-in).

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

2006 F-150, Mark LT, 9/2005

303-01C-27

Engine — 5.4L (3V)

303-01C-27

ASSEMBLY (Continued) 64. Position the accessory drive belt tensioner and install the 3 bolts. •

Tighten to 25 Nm (18 lb-ft).

65. Install the 3 accessory drive belt idler pulleys, the coolant pump pulley and the 7 bolts. •

Tighten to 25 Nm (18 lb-ft).

67. Install 8 new LH exhaust manifold-to-cylinder head studs. •

66.

Tighten to 12 Nm (9 lb-ft).

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: Clean and inspect the mating surfaces, and install new gaskets. Position the oil filter adapter and install the 4 bolts. •

Tighten to 25 Nm (18 lb-ft).

2006 F-150, Mark LT, 9/2005

303-01C-28

Engine — 5.4L (3V)

303-01C-28

ASSEMBLY (Continued) 68. Position a new gasket, the LH exhaust manifold and tighten the 8 new nuts in the sequence shown. •

69.

70. Install 8 new RH exhaust manifold-to-cylinder head studs. •

Tighten to 12 Nm (9 lb-ft).

Tighten to 25 Nm (18 lb-ft).

CAUTION: Clean the engine support insulator-to-cylinder block mating surface of any dirt or foreign material prior to installation.

71. Position a new gasket, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown. •

Tighten to 25 Nm (18 lb-ft).

Install the LH engine support insulator and the 3 bolts. •

Apply Threadlock 262 to the bolt threads prior to installation.



Tighten to 63 Nm (46 lb-ft).

2006 F-150, Mark LT, 9/2005

303-01C-29

Engine — 5.4L (3V)

303-01C-29

ASSEMBLY (Continued) 72.

CAUTION: Clean the engine support insulator-to-cylinder block mating surface of any dirt or foreign material prior to installation. Install the RH engine support insulator and the 3 bolts. •

Apply Threadlock 262 to the bolt threads prior to installation.



Tighten to 63 Nm (46 lb-ft).

75.

CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid. Position the RH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown. •

73.

Tighten to 10 Nm (89 lb-in).

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

74. NOTE: If not secured within 4 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

2006 F-150, Mark LT, 9/2005

303-01C-30

Engine — 5.4L (3V)

303-01C-30

ASSEMBLY (Continued) 76.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Clean the valve cover mating surface with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

77. NOTE: If not secured within 4 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

79. Install the oil level indicator tube and the bolt.

78.



Install a new O-ring seal and lubricate the O-ring seal with clean engine oil prior to installation.



Tighten to 10 Nm (89 lb-in).

CAUTION: When installing the valve cover, make sure to avoid damaging the VCT solenoid. Position the LH valve cover and gasket on the cylinder head and tighten the bolts in the sequence shown. •

Tighten to 10 Nm (89 lb-in).

2006 F-150, Mark LT, 9/2005

303-01C-31

Engine — 5.4L (3V)

303-01C-31

ASSEMBLY (Continued) 80. NOTE: Do not reuse the O-ring seals. NOTE: Lubricate the O-ring seals with clean engine coolant prior to installation. Slide the coolant tube forward with the new O-ring seals into the cylinder block.

81. Install the coolant tube stud bolt. •

Tighten to 10 Nm (89 lb-in).

82. Install the 2 knock sensors (KS) and the bolts. •

Tighten to 20 Nm (15 lb-ft).

83. Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs. 84. Connect the CKP sensor electrical connector.

85. NOTE: LH shown, RH similar. Install the 8 ignition coils and the 8 bolts. •

Tighten to 6 Nm (53 lb-in).

86. Install the LH radio ignition interference capacitor and the stud bolt. •

Tighten to 25 Nm (18 lb-ft).

2006 F-150, Mark LT, 9/2005

303-01C-32

Engine — 5.4L (3V)

303-01C-32

ASSEMBLY (Continued) 87. Connect the cylinder head temperature (CHT) sensor electrical connector.

91. Install the RH radio ignition interference capacitor and the stud bolt. 88. Connect the 4 RH ignition coil electrical connectors.

89. Connect the 2 engine wiring harness retainers from the RH valve cover studs.



Tighten to 25 Nm (18 lb-ft).

92. Position the upper radiator hose support bracket and install the nut. •

Tighten to 10 Nm (89 lb-in).

90. Connect the RH VCT solenoid electrical connector.

2006 F-150, Mark LT, 9/2005

303-01C-33

Engine — 5.4L (3V)

303-01C-33

ASSEMBLY (Continued) 93. Connect the RH CMP sensor electrical connector.

97. NOTE: If not secured within 4 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.

94. Install the special tool.

98. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.

95. Using a suitable floor crane, remove the engine from the engine stand. 96.

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 crankshaft 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.

2006 F-150, Mark LT, 9/2005

303-01C-34

Engine — 5.4L (3V)

303-01C-34

ASSEMBLY (Continued) 99. Tighten the bolts in the sequence shown. •

Tighten to 10 Nm (89 lb-in).

102. NOTE: If not secured within 4 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. 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.

100.

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.

101. NOTE: If not secured within 4 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. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.

103. Install the oil pan gasket and the oil pan and loosely install the bolts.

2006 F-150, Mark LT, 9/2005

303-01C-35

Engine — 5.4L (3V)

303-01C-35

ASSEMBLY (Continued) 104. Tighten the bolts in 3 stages, in the sequence shown. •

Stage 1: Tighten to 2 Nm (18 lb-in).



Stage 2: Tighten to 20 Nm (15 lb-ft).



Stage 3: Tighten an additional 60 degrees.

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

107. Install the flexplate and the 8 bolts in the sequence shown. •

Tighten to 80 Nm (59 lb-ft).

105. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil. Using the special tools, install a new crankshaft rear seal.

2006 F-150, Mark LT, 9/2005

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