Part 1
Engine - 5.4L
Assembly (Steps 1-34)
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.
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 No. 1 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.
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.
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.
Install the crankshaft onto the upper crankshaft main bearings.
7. NOTE: If equipped, 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.
8. NOTE: If equipped, 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.
9. NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.
NOTE: If equipped, 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.
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.
11. Install the dowel pins so the flat sides face the crankshaft.
12. Tighten the vertical main bearing cap fasteners in the sequence shown, in 2 stages:
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.
13. Install the side bolts and tighten them in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 30 Nm (22 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.
14. Assemble the 8 pistons.
15. Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.
16. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
NOTE: The next 3 steps are for all 8 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.
Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place.
17. 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.
18. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly. Failure to follow these instructions may result in engine damage.
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.
Position the lower bearing and connecting rod, and install the new bolts loosely.
19. NOTE: Main bearing caps are removed for clarity.
Tighten the bolts in 2 stages, using the sequence shown.
^ Stage 1: Tighten to 43 Nm (32 lb-ft).
^ Stage 2: Tighten an additional 105 degrees.
20. Position the oil pump and tighten the bolts in the sequence shown.
^ Tighten to 10 Nm (89 lb-in).
21. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused. Failure to follow these instructions may result in engine damage.
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.
22. NOTE: LH shown, RH similar. Tighten the bolts in 3 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.
23. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
Install the hydraulic lash adjusters in their original locations.
24. Install 16 new exhaust manifold-to-cylinder head studs.
^ Tighten to 12 Nm (9 lb-ft).
25. Position the new gaskets and the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).
26. Position the new gaskets and the LH exhaust manifold and tighten the 8 new nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).
27. 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. Failure to follow these instructions may result in engine damage.
Compress the tensioner plunger, using a vise.
28. Install a retaining clip on the tensioner to hold the plunger in during installation.
29. 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.
30. Install the timing chain guides.
1 Position the LH timing chain guide.
2 Install the 2 LH bolts.
^ Tighten to 10 Nm (89 lb-in).
3 Position the RH timing chain guide.
4 Install the 2 RH bolts.
^ Tighten to 10 Nm (89 lb-in).
31. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
32. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and valve damage can occur.
NOTE: The No. 1 cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
Position the crankshaft so the No. 1 cylinder is at TDC with the special tool.
33. Install the crankshaft sprocket, making sure the flange faces forward.
34. 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.
