Part 2
Cylinder Head - 5.4LInstallation (Steps 37-72)
37. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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.
38. Position the LH valve cover and gasket on the cylinder head and install the fasteners loosely.
39. Tighten the fasteners in the sequence shown.
^ Tighten to 10 Nm (89 inch lbs).
40. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
41. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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.
42. Position the RH valve cover and gasket on the cylinder head and install the fasteners loosely.
43. Tighten the fasteners in the sequence shown.
^ ^ Tighten to 10 Nm (89 inch lbs).
44. Position the accessory drive belt idler pulley and install the bolt.
^ Tighten to 25 Nm (18 ft. lbs).
45. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Install the camshaft position (CMP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs).
46. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
47. Using the special tools, install a new crankshaft front seal.
48. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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 to the Woodruff key slot on the crankshaft pulley.
49. Using the special tool, install the crankshaft pulley.
50. NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.
Tighten the new crankshaft pulley bolt in 4 stages.
^ Stage 1: Tighten to 90 Nm (66 ft. lbs).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs).
^ Stage 4: Tighten an additional 90 degrees.
51. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Install the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 inch lbs).
52. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
53. NOTE: The front lower hole in the power steering pump is not used.
Position the power steering pump and install the 3 bolts.
^ Tighten to 25 Nm (18 ft. lbs).
54. NOTE: RH shown, LH similar.
Install the radio frequency interference capacitors and the nuts.
^ Tighten to 25 Nm (18 ft. lbs).
55. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
Using a new O-ring seal, install the oil level indicator tube and the bolt.
^ Tighten to 10 Nm (89 inch lbs).
56. Install the oil level indicator and tube support bracket nut.
^ Tighten to 25 Nm (18 ft. lbs).
57. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
58. Connect the CKP sensor electrical connector.
59. Connect the engine oil pressure (EOP) switch electrical connector.
60. Connect the KS electrical connector.
61. Connect the RH radio frequency interference capacitor electrical connector.
62. Connect the CMP sensor electrical connector.
63. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
64. NOTE: LH shown, RH similar.
Install the cylinder block drain plugs.
^ Tighten to 20 Nm (15 ft. lbs).
65. Position the RH engine support insulator and install the 3 bolts.
^ Tighten to 63 Nm (46 ft. lbs).
66. Install the special tool.
67. Install the special tool.
68. Install the special tool and remove the engine from the work stand.
69. Lower the engine onto wooden blocks.
70. Install the special tool and raise the engine.
71. Install the flexplate and the 8 bolts. Tighten the bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs).
^ Stage 2: Tighten to 80 Nm (59 ft. lbs).
72. Install the engine.