Section 350 (Engine - 5.4L 2V): Assembly: Engine: Assembly
WARNING: This page is about a different car, the 2003 Ford Pickup, 2003 Ford Excursion, and 2003 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
All engines
- Record the main bearing code found on the front of the engine block.
- Record the main bearing code found on the back of the crankshaft.
Bearing Select Fit Chart, Standard Bearings
- 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 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 a "2".
- Repeat this process for the remaining four main bearings.
Bearing Select Fit Chart, Oversize Bearings
- 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.
All engines
- Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.
- Install the crankshaft onto the upper crankshaft main bearings.
- Push the crankshaft rearward and install the rear crankshaft upper thrust washer at the back of the No. 5 main boss.
- Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.
- Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft surface.
- 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.
- Install the dowel pins so the flat sides face the crankshaft.
- 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.
- Install the side bolts and tighten them in the sequence shown.
- Tighten to 30 Nm (22 lb-ft).
- Tighten an additional 90 degrees.
- Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place.
- Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.
- Position the lower bearing and connecting rod, and install the new bolts loosely.
- 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.
- Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
- Position the head gasket over the dowel pins.
- RH is shown; LH is similar.
- Rotate the crankshaft until the crankshaft keyway points toward the top of the engine (12 o'clock).
- Position the cylinder head over the dowels and head gasket and install the cylinder head bolts loosely.
- RH is shown; LH is similar.
- 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.
- 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.
- Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.
- Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
- Compress the tensioner plunger, using a vise.
- Install a retaining clip on the tensioner to hold the plunger in during installation.
- Remove the tensioner from the vise.
- 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.
- Install the timing chain guides.
- Install the special tool.
- Pre-position the camshafts.
- Rotate the LH camshaft until the timing mark is approximately at 12 o'clock.
- Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
- Position the crankshaft so the number one cylinder is at TDC with the special tool.
- Remove the Crankshaft Holding Tool.
- Install the crankshaft sprocket and make sure the flange faces forward.
- 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.
- Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
- Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
- Remove the retaining clip from the LH timing chain tensioner.
- 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.
- 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.
- Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
- Remove the retaining clip from the RH timing chain tensioner.
- As a post-check, verify correct alignment of all timing marks.
- Remove the special tool.
- Install the special tool between the valve spring coils to prevent valve stem seal damage.
- Install the camshaft roller followers.
- Install the special tool.
- Compress the valve springs.
- Install the camshaft roller followers in their original locations.
- Remove the special tool.
- Install the crankshaft sensor ring on the crankshaft.
- Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block sealing surfaces, at the locations shown.
- Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
- 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).
- Install the oil pump screen and pickup tube spacer.
- Position the oil pump screen and pickup tube and install the bolts.
- Position the oil filter adapter and install the four bolts.
- Install the rear nut.
- Position the engine mounts to the cylinder block and install the six bolts.
- Position the belt idler pulley and install the bolt.
- Install the coolant pump.
- Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the coolant pump.
- Position the coolant pump into the engine block.
- Install the bolts.
- Lubricate the engine front cover and the front seal inner lip with clean engine oil.
- Use the special tools to install the crankshaft front seal into the engine front cover.
- Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
- Use the special tool to install the crankshaft pulley.
- Install a new crankshaft pulley bolt and tighten the 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.
- Position the coolant pump pulley on the coolant pump and install the bolts.
- Install the oil drain plug.
- If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the valve cover. Install the new LH valve cover gasket.
- Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
- Position the LH valve cover and the valve cover gasket on the cylinder head and install the bolts loosely.
- Tighten the bolts in the sequence shown.
- If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the valve cover. Install the new RH valve cover gasket.
- Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
- Position the RH valve cover on the cylinder head and install the bolts loosely.
- Tighten the bolts in the sequence shown.
- Install the crankcase ventilation tube on the LH valve cover.
- Install the positive crankcase ventilation (PCV) valve and hose in the RH valve cover.
- Install the radio frequency interference capacitors.
- Install the engine control sensor wiring harness.
- Install the special tool.
- Install the special tool.
- Install the special tool and remove the engine from the work stand.
- 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.
- Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
- Install the rear oil seal retainer plate and loosely install the six bolts.
- Tighten the bolts in the sequence shown.
- 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.
- Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface.
- Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.
- Install the oil pan gasket and the oil pan and loosely install the bolts.
- Tighten the bolts in three 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 90 degrees.
- Lower the engine onto wooden blocks.
- Remove the special tool.
- Remove the special tool.
- Install the special tool and raise the engine.
- Using the special tools, install a new crankshaft rear oil seal.
- Using the special tools, install the crankshaft rear oil slinger.
- Install the flexplate and bolts. Tighten the bolts in the sequence shown.
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.
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.
NOTE:
The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface).
NOTE:
The oil groove on the thrust washer must face toward the front of the engine (against 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).
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.
CAUTION:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
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.
NOTE:
Main bearing caps are removed for clarity.
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.
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:
Lubricate the O-ring seal with clean engine oil.
CAUTION:
Timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION:
Do not turn the engine over with the special tool or damage to the camshaft sprocket or the bolt can occur.
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.
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.
NOTE:
The LH timing chain tensioner arm has a 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.
NOTE:
Lubricate the camshaft roller followers with clean engine oil.
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, 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.
Fig 46: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Sealing Surfaces
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.
NOTE:
Clean and inspect the mating surfaces, and install new gaskets.
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.
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.
NOTE:
If not secured within four minutes, 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.
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.
NOTE:
RH shown, LH similar.
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.
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.
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 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.
Fig 81: Applying Silicone Gasket And Sealant At Rear Oil Seal Retainer-To-Cylinder Block Sealing Surface
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.
Fig 82: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface
NOTE:
Lubricate the inner lip of the crankshaft rear oil seal with clean engine oil.