Part 2

Engine - 5.4L















































Assembly (Steps 35-68)

35. 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 2 copper (marked) chain links.





36. 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.
^ Tighten to 25 Nm (18 lb-ft).





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





38. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.

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) link on the timing chain.





39. 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 2 copper (marked) chain links.





40. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
^ Tighten to 25 Nm (18 lb-ft).





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





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





43. Position the crankshaft sensor ring on the crankshaft.





44. NOTE: Camshaft roller follower is removed for clarity.

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





45. CAUTION: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in engine damage.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push the valve down while compressing the spring.

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

Use the special tool to compress the valve springs, and install the camshaft roller follower.





46. Repeat the previous 3 steps for each camshaft roller follower.

47. CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.

NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.

NOTE: If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder.

NOTE: Refer to specifications for correct spark plug identification.

Install the 8 spark plugs.
^ Tighten to 18 Nm (13 lb-ft).

48. 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 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.

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.





49. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.





50. Tighten the engine front cover fasteners in sequence in 3 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).








51. 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.

Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
52. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.





53. 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.





54. Position the LH valve cover and gasket on the cylinder head and install the fasteners loosely.





55. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).





56. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.





57. 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.





58. Position the RH valve cover and gasket on the cylinder head and install the fasteners loosely.





59. Tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).





60. NOTE: Lubricate the O-ring with clean engine oil prior to installation.

Install the camshaft position (CMP) sensor and bolt.
^ Tighten to 10 Nm (89 lb-in).





61. Position the accessory drive belt idler pulley and install the bolt.
^ Tighten to 25 Nm (18 lb-ft).





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





63. Using the special tools, install a new crankshaft front seal.





64. 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.





65. Using the special tool, install the crankshaft pulley.





66. 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 lb-ft).
^ Stage 2: Loosen one full turn.
^ Stage 3: Tighten to 50 Nm (37 lb-ft).
^ Stage 4: Tighten an additional 90 degrees.





67. NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.

Install the crankshaft position (CKP) sensor and the bolt.
^ Tighten to 10 Nm (89 lb-in).





68. 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 clean 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.
^ Tighten to 25 Nm (18 lb-ft).