Section 253 (Engine-5.4L): Assembly: Engine: Assembly

WARNING: This page is about a different car, the 2003 Lincoln Navigator. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: During engine assembly it may become necessary to check bearing clearances, end play etc. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .

Read the first character code information on the cylinder block face (1) and record the information.

Fig 1: Identifying Character Code Information On Cylinder Block Face
Courtesy of FORD MOTOR CO.
Read the first character on the No. 7 crankshaft counterweight and note it.

Fig 2: Identifying Character On No. 7 Crankshaft Counterweight
Courtesy of FORD MOTOR CO.
Using the data recorded in the previous two steps, cross-reference using the chart to obtain bearing grade.

Fig 3: Bearing Grade Chart (Standard Bearing)
Courtesy of FORD MOTOR CO.

NOTE: Before assembling the cylinder block, all sealing surfaces must be free from chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

Fig 4: Installing Crankshaft Main Bearings Into Main Bearing Caps

Courtesy of FORD MOTOR CO.

Lubricate the crankshaft main bearings with clean engine oil and install into the cylinder block. Install the crankshaft main bearings into the main bearing caps.

NOTE: Do not install the upper thrust bearings until the crankshaft is installed.

Fig 5: Installing Crankshaft Onto Upper Main Bearings

Courtesy of FORD MOTOR CO.

Install the crankshaft onto the upper main bearings.

CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the crankshaft thrust surface.

Fig 6: Installing Crankshaft Thrust Washer At Back Of No. 5 Main Boss

Courtesy of FORD MOTOR CO.

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

CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the crankshaft thrust surface.

Fig 7: Installing Front Crankshaft Upper Thrust Washer At Front Of No. 5 Main Boss

Courtesy of FORD MOTOR CO.

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

CAUTION: Make sure the side of the thrust washer with three 5-mm wide oil grooves faces the rear of the engine.

NOTE: To aid in assembly apply petroleum jelly to the back of the crankshaft thrust washer.

Fig 8: Installing Lower Crankshaft Thrust Washer To Back Side Of No. 5 Main Bearing Cap

Courtesy of FORD MOTOR CO.

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

Fig 9: Installing Crankshaft Lower Main Bearings Into Main Bearing Caps
Courtesy of FORD MOTOR CO.

NOTE: Crankshaft not shown for clarity.

Fig 10: Installing Main Bearing Cap Dowel Pins

Courtesy of FORD MOTOR CO.

Install the main bearing cap dowel pins so the flat sides face the crankshaft.

NOTE: Crankshaft not shown for clarity.

Install and tighten the new bolts in two stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 11: Tightening Bolts In Two Stages
  Courtesy of FORD MOTOR CO.

NOTE: Crankshaft not shown for clarity.

Install and tighten the new cross-mounted bolts in two stages:
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 12: Tightening New Cross-Mounted Bolts In Two Stages
  Courtesy of FORD MOTOR CO.

NOTE: Verify the connecting rods and rod caps for correct orientation.

NOTE: Carefully tap the connecting rod bolts in. Avoid damaging the connecting rod.

Prepare the connecting rod and caps.
- Insert the bolts in the rod cap.
- Insert the upper and lower rod bearings into the rod and cap.
  
  Fig 13: Inserting Upper And Lower Rod Bearings Into Rod And Cap
  Courtesy of FORD MOTOR CO.

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

NOTE: Make sure the piston arrow is facing forward.

Using the special tools, install the No. 1 and No. 6 piston and connecting rod assemblies.
- Lubricate the piston and ring with clean engine oil.
- Lubricate the rod bearings with clean engine oil.
  
  Fig 14: Lubricating Piston And Ring With Clean Engine Oil
  Courtesy of FORD MOTOR CO.
Seat the connecting rods on the crankshaft journals and remove the special tools.

Fig 15: Seating Connecting Rods On Crankshaft Journals
Courtesy of FORD MOTOR CO.

CAUTION: The rod bearing caps must keep the same orientation as marked during disassembly.

NOTE: The rod bearing cap bolts are torque-to-yield. Install new bolts each time repaired.

Install the rod bearing caps and tighten the bolts in three stages:
- Stage 1: Tighten to 25 Nm (18 lb-ft).
- Stage 2: Tighten to 45 Nm (30 lb-ft).
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 16: Tightening Bolts In Three Stages
  Courtesy of FORD MOTOR CO.
Install the piston connecting rod assemblies 3 and 5, 4 and 7, 2 and 8, by turning the crankshaft 90 degrees and repeating the previous steps.
Position the oil pump and gasket and install the bolts in the sequence shown.

Fig 17: Installing Bolts In Sequence
Courtesy of FORD MOTOR CO.
Install and tighten the oil pump screen and cover spacer.

Fig 18: Tightening Oil Pump Screen And Cover Spacer
Courtesy of FORD MOTOR CO.

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 clean engine oil.

Fig 19: Installing Oil Pump Screen Cover And Tube, And Bolts

Courtesy of FORD MOTOR CO.

Install the oil pump screen cover and tube, and the bolts.
Install the cylinder head gaskets.

Fig 20: Installing Cylinder Head Gaskets
Courtesy of FORD MOTOR CO.
Install the LH and the RH cylinder heads. Loosely install the new bolts.

Fig 21: Installing LH And RH Cylinder Heads
Courtesy of FORD MOTOR CO.
Tighten the LH and RH bolts in three stages, 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.
  
  Fig 22: Tightening LH And RH Bolts In Sequence
  Courtesy of FORD MOTOR CO.
Install RH exhaust manifold gaskets and the exhaust manifold.
- Tighten the nuts in the sequence shown.
  
  Fig 23: Installing RH Exhaust Manifold Gaskets And Exhaust Manifold
  Courtesy of FORD MOTOR CO.

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

Fig 24: Compressing Tensioner Plunger

Courtesy of FORD MOTOR CO.

Compress the tensioner plunger, using the edge of a soft-jawed vise.
Install a paper clip into the hose in the tensioner housing to hold the ratchet assembly.
- Remove the tensioner from the vise.
  
  Fig 25: Installing Paper Clip Into Hose In Tensioner Housing
  Courtesy of FORD MOTOR CO.

NOTE: There are 61 links in the timing chain.

Fig 26: Locating Timing Marks On Timing Chain

Courtesy of FORD MOTOR CO.

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.

Fig 27: Installing Timing Chain Guides
Courtesy of FORD MOTOR CO.
Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position. Rotate the RH camshaft timing sprocket until the timing mark is approximately in the 11 o'clock position.

Fig 28: Identifying LH Camshaft Sprocket Timing Mark Position
Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 29: Installing Special Tools On LH And RH Cylinder Heads

Courtesy of FORD MOTOR CO.

Install the special tools on the LH and RH cylinder heads.
Using the special tool, position the crankshaft.

Fig 30: Positioning Crankshaft
Courtesy of FORD MOTOR CO.
Remove the special tool.
Install the crankshaft sprocket with the timing mark facing outward.

Fig 31: Identifying Crankshaft Sprocket Timing Mark Position
Courtesy of FORD MOTOR CO.
Install the LH and RH timing chain onto the crankshaft and camshaft sprockets.
- Align the two copper (marked) links with the timing mark on the camshaft sprocket.
- Align the one copper-colored link with the timing mark on the crankshaft sprocket.
  
  Fig 32: Installing LH And RH Timing Chain Onto Crankshaft And Camshaft Sprockets
  Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 33: Positioning Tensioner Arms And Tensioners

Courtesy of FORD MOTOR CO.

Position the tensioner arms and tensioners, and install the bolts.
Remove the paper clip.

Fig 34: Removing Paper Clip
Courtesy of FORD MOTOR CO.
Verify the camshaft and crankshaft sprocket to copper link alignment.

Fig 35: Identifying Crankshaft Sprocket Copper Link Alignment
Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 36: Removing Special Tools From LH And RH Cylinder Heads

Courtesy of FORD MOTOR CO.

Remove the special tools from the LH and RH cylinder heads.
Position the camshaft lobes at the base circle.
Using the special tool, compress the exhaust valve springs and install the roller followers.

Fig 37: Compressing Exhaust Valve Springs Using Special Tool
Courtesy of FORD MOTOR CO.
Using the special tool, compress the intake valve springs and install the roller followers.

Fig 38: Compressing Intake Valve Springs Using Special Tool
Courtesy of FORD MOTOR CO.
Repeat the previous steps to install all roller followers.
Position the crankshaft sensor ring on the crankshaft.

Fig 39: Positioning Crankshaft Sensor Ring On Crankshaft
Courtesy of FORD MOTOR CO.
Apply silicone gasket sealant in the locations shown.

Fig 40: Applying Silicone Gasket Sealant
Courtesy of FORD MOTOR CO.
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 (18 lb-ft).

Stage 2: Tighten numbers six and seven to 50 Nm (37 lb-ft).

Stage 3: Tighten numbers 11 through 15 to 25 Nm (18 lb-ft).

Fig 41: Tightening Specifications (1 Of 2)
Courtesy of FORD MOTOR CO.

Fig 42: Tightening Specifications (2 Of 2)
Courtesy of FORD MOTOR CO.
Apply silicone gasket sealant in the locations shown.

Fig 43: Applying Silicone Gasket Sealant
Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Install the valve covers, the bolts, and the studs.
1. Install the gaskets.
2. Install the valve covers.
  
  Fig 44: Installing Valve Covers, Bolts, And Studs
  Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 45: Installing Spark Plugs

Courtesy of FORD MOTOR CO.

Install the eight spark plugs.
Install the bolt and the belt idler pulley.

Fig 46: Installing Bolt And Belt Idler Pulley
Courtesy of FORD MOTOR CO.
Using the special tools, install the front crank seal.

Fig 47: Installing Front Crank Seal Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: The crankshaft pulley must be installed within four minutes after applying the silicone.

Fig 48: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
Using the special tool, install the crankshaft pulley.

Fig 49: Installing Crankshaft Pulley Using Special Tool
Courtesy of FORD MOTOR CO.
Install the bolt and washer. Tighten the bolt in four stages:
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen one full turn.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
  
  Fig 50: Installing Bolt And Washer
  Courtesy of FORD MOTOR CO.
Install the water pump.
- Inspect and lube the water pump O-ring seal before installation.
  
  Fig 51: Installing Water Pump
  Courtesy of FORD MOTOR CO.
Install the four bolts.

Fig 52: Installing Bolts
Courtesy of FORD MOTOR CO.
Install the water pump pulley and the bolts.

Fig 53: Installing Water Pump Pulley And Bolts
Courtesy of FORD MOTOR CO.
Install the heater return tube and the bolt.
- Inspect and lube the O-ring seals.
  
  Fig 54: Installing Heater Return Tube And Bolt
  Courtesy of FORD MOTOR CO.
Install the knock sensor (KS).

Fig 55: Installing Knock Sensor (KS)
Courtesy of FORD MOTOR CO.
Install the wiring and connect to the engine at six locations.

Fig 56: Installing Wiring And Connecting To Engine
Courtesy of FORD MOTOR CO.
Connect the KS.

Fig 57: Connecting KS
Courtesy of FORD MOTOR CO.
Install the RH ignition coils.

Fig 58: Installing RH Ignition Coils
Courtesy of FORD MOTOR CO.
Connect the RH ignition coils.

Fig 59: Connecting RH Ignition Coils
Courtesy of FORD MOTOR CO.
Install the RH ignition coil cover.

Fig 60: Installing RH Ignition Coil Cover
Courtesy of FORD MOTOR CO.
Position the bracket and the ground strap and install the nuts.

Fig 61: Installing Nuts
Courtesy of FORD MOTOR CO.
Connect the cylinder head temperature (CHT) sensor.

Fig 62: Connecting Cylinder Head Temperature (CHT) Sensor
Courtesy of FORD MOTOR CO.
Connect the camshaft position (CMP) sensor.

Fig 63: Connecting Camshaft Position (CMP) Sensor
Courtesy of FORD MOTOR CO.
Install the LH ignition coils.

Fig 64: Installing LH Ignition Coils
Courtesy of FORD MOTOR CO.
Connect the LH ignition coils.

Fig 65: Connecting LH Ignition Coils
Courtesy of FORD MOTOR CO.
Install the bolts and the LH ignition coil cover.

Fig 66: Installing Bolts And LH Ignition Coil Cover
Courtesy of FORD MOTOR CO.
Install the oil fill tube.

Fig 67: Installing Oil Fill Tube
Courtesy of FORD MOTOR CO.
Connect the oil pressure sender.

Fig 68: Connecting Oil Pressure Sender
Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Fig 69: Installing Cylinder Block Drain Plugs

Courtesy of FORD MOTOR CO.

Install the cylinder block drain plugs.

NOTE: RH shown, LH similar.

Fig 70: Installing Left And Right Engine Mounts

Courtesy of FORD MOTOR CO.

Install the left and right engine mounts.

NOTE: LH shown, RH similar.

Fig 71: Installing Special Tool

Courtesy of FORD MOTOR CO.

Install the special tool.
Remove the engine from the work stand.

Fig 72: Removing Engine From Work Stand
Courtesy of FORD MOTOR CO.

NOTE: If the rear crankshaft seal retaining plate is 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.

NOTE: The silicone must be applied on the groove along the retainer plate.

Fig 73: Applying Bead Of Silicone Gasket And Sealant Around Rear Oil Seal Retainer Sealing Surface

Courtesy of FORD MOTOR CO.

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 and loosely install the six bolts.

Fig 74: Installing Bolts
Courtesy of FORD MOTOR CO.
Tighten the bolts in the sequence shown.

Fig 75: Tightening Bolts In Sequence
Courtesy of FORD MOTOR CO.

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.

Fig 76: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface

Courtesy of FORD MOTOR CO.

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

Fig 77: Applying Silicone Gasket And Sealant At Engine Front Cover-To-Cylinder Block Sealing Surface

Courtesy of FORD MOTOR CO.

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 16 bolts.

Fig 78: Installing Oil Pan Gasket And Oil Pan And
Courtesy of FORD MOTOR CO.
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 60 degrees.
  
  Fig 79: Tightening Bolts In Sequence
  Courtesy of FORD MOTOR CO.
Lower the engine onto wooden blocks.
Remove the special tool.

Fig 80: Removing Special Tool
Courtesy of FORD MOTOR CO.
Install the oil level indicator and tube, and the stud.

Fig 81: Installing Oil Level Indicator And Tube, And Stud
Courtesy of FORD MOTOR CO.
Install the LH exhaust manifold and gaskets.
- Tighten the nuts in the sequence shown.
  
  Fig 82: Installing LH Exhaust Manifold And Gaskets
  Courtesy of FORD MOTOR CO.
Install the special tool and raise the engine.

Fig 83: Installing Special Tool
Courtesy of FORD MOTOR CO.
Using the special tool, install the crankshaft rear oil seal.

Fig 84: Installing Crankshaft Rear Oil Seal Using Special Tool
Courtesy of FORD MOTOR CO.
Using the special tool, install the crankshaft oil slinger.

Fig 85: Installing Crankshaft Oil Slinger Using Special Tool
Courtesy of FORD MOTOR CO.
Install the spacer plate.

Fig 86: Installing Spacer Plate
Courtesy of FORD MOTOR CO.
Install the bolts and the flywheel.

Fig 87: Installing Bolts And Flywheel
Courtesy of FORD MOTOR CO.