https://manualesdigitalesjc.

com

https://www.facebook.com/groups/ManualesDigitalesJC/
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

SPECIFICATIONS ................................................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

SPECIFICATIONS

Material
Item Specification Fill Capacity
Motorcraft Metal Surface Prep — —
ZC-31
Motorcraft Premium Gold Engine Coolant with WSS-M97B51-A1 23.5L (26 qt)
Bittering Agent (US only)
VC-7-B (US); CVC-7-A (Canada); or equivalent
(yellow color)
Motorcraft SAE 5W-20 Premium Synthetic Blend WSS-M2C930-A 6.6L (7.0 qt) with filter
Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super
Premium Motor Oil CXO-5W20-LSP12 (Canada); or
equivalent
Silicone Brake Caliper Grease and Dielectric ESE-M1C171-A —
Compound
XG-3-A
Silicone Gasket and Sealant WSE-M4G323-A4 —
TA-30
Silicone Gasket Remover — —
ZC-30

General Specifications

Item Specification
Engine
Displacement 5.4L (330 CID)
Number of cylinders 8
Bore 90.2 mm (3.55 in)
Stroke 105.8 mm (4.17 in)
Firing order 1-3-7-2-6-5-4-8
Spark plug (early build — black coil boot) PZT-14F
Spark plug (late build — brown coil boot) HJFS-24FP
Minimum oil pressure at idle (engine at normal operating temperature, 103 kPa (15 psi)
transmission in park)
Compression ratio 9.8:1
Engine weight (without accessory drive components and with flexplate) 247 kg (545 lb)
Engine weight (without accessory drive components and with flywheel) 260 kg (574 lb)
Cylinder Head and Valve Train
Combustion chamber volume 48.1-51.1 cc (2.94-3.12 cu in)
Head gasket surface flatness 0.025 mm (0.001 in) in any 25 mm (1 in) x 25 mm (1 in) area; 0.05 mm
(0.002 in) in any 150 mm (6 in) x 150 mm (6 in) area; 0.1 mm (0.004 in)
overall
Valve arrangement (front to rear) — LH I-E-I-I-E-I-I-E-I-I-E-I
Valve arrangement (front to rear) — RH I-E-I-I-E-I-I-E-I-I-E-I
Valve guide bore diameter 6.015-6.044 mm (0.237-0.238 in)
Valve stem diameter — intake 5.975-5.995 mm (0.235-0.236 in)
Valve stem diameter — exhaust 5.95-5.97 mm (0.234-0.235 in)
Valve stem-to-guide clearance — intake 0.020-0.045 mm (0.001-0.002 in)
Valve stem-to-guide clearance — exhaust 0.069-0.094 mm (0.003-0.004 in)
Valve head diameter — intake 33.62-33.98 mm (1.324-1.338 in)
Valve head diameter — exhaust 37.32-37.68 mm (1.469-1.483 in)
303-01A-3 Engine — 5.4L (3V) 303-01A-3
SPECIFICATIONS (Continued)

General Specifications (Continued)

Item Specification
Valve face runout 0.05 mm (0.002 in)
Valve face angle 45.5 degrees
Valve seat width — intake 1.2-1.4 mm (0.047-0.055 in)
Valve seat width — exhaust 1.4-1.6 mm (0.055-0.063 in)
Valve seat angle 44.5-45.0 degrees
Valve spring free length 55.7 mm (2.19 in)
Valve spring compression pressure 350 N (79 lbs) ± 17.5 N (4 lbs) @ 42.04 mm (1.66 in)
Valve spring installed height 42.04 mm (1.66 in)
Valve spring installed pressure 350 N (79 lbs) ± 17.5 N (4 lbs) @ 42.04 mm (1.66 in)
Roller follower ratio —
Hydraulic Lash Adjuster
Diameter 15.988-16.000 mm (0.6294-0.6299 in)
Clearance-to-bore 0.018-0.069 mm (0.0007-0.0027 in)
Service limit —
Hydraulic leakdown rate 5-25 seconds a
Collapsed lash adjuster gap 0.45-0.85 mm (0.017-0.033 in)
Camshaft
Theoretical valve lift @ 0 lash — intake 11.1 mm (0.437 in)
Theoretical valve lift @ 0 lash — exhaust 11.0 mm (0.433 in)
Lobe lift — intake 5.520 mm (0.217 in)
Lobe lift — exhaust 5.506 mm (0.217 in)
Allowable lobe lift loss 0.127 mm (0.005 in)
Journal diameter 28.607-28.633 mm (1.126-1.127 in)
Camshaft journal bore inside diameter 28.657-28.682 mm (1.128-1.129 in)
Camshaft journal-to-bearing clearance 0.024-0.075 mm (0.001-0.003 in)
Runout 0.03 mm (0.001 in)
End play 0.027-0.190 mm (0.001-0.007 in)
Cylinder Block
Cylinder bore diameter — grade 1 90.200-90.210 mm (3.5512-3.5516 in)
Cylinder bore diameter — grade 2 90.210-90.220 mm (3.5516-3.5520 in)
Cylinder bore diameter — grade 3 0.220-90.230 mm (3.5520-3.5524 in)
Cylinder bore maximum taper 0.006 mm (0.0002 in)
Cylinder bore maximum out-of-round 0.020 mm (0.0008 in)
Head gasket surface flatness 0.03 mm (0.001 in) in any 40 mm (1.5 in) x 40 mm (1.5 in) area; 0.05 mm
(0.002 in) in any 150 mm (6 in) x 150 mm (6 in) area; 0.15 mm (0.006 in)
overall
Main bearing bore inside diameter 72.400-72.424 mm (2.850-2.851 in)
Crankshaft
Main bearing journal diameter 67.481-67.505 mm (2.6568-2.6576 in)
Main bearing journal maximum taper 0.004 mm (0.0002 in)
Main bearing journal maximum out-of-round 0.0075 mm (0.0003 in) between cross sections
Main bearing journal-to-cylinder block clearance 0.048-0.024 mm (0.0019-0.0009 in)
Connecting rod journal diameter 53.003-52.983 mm (2.0867-2.0859 in)
Connecting rod journal maximum taper 0.004 mm (0.0002 in)
303-01A-4 Engine — 5.4L (3V) 303-01A-4
SPECIFICATIONS (Continued)

General Specifications (Continued)

Item Specification
Connecting rod journal maximum out-of-round 0.0075 mm (0.0003 in) between cross sections
Crankshaft maximum end play 0.075-0.377 mm (0.0030-0.0148 in)
Piston and Connecting Rod
Piston diameter — grade 1 (at right angle to pin bore) 90.175-90.165 mm (3.5502-3.5498 in)
Piston diameter — grade 2 (at right angle to pin bore) 90.185-90.175 mm (3.5506-3.5502 in)
Piston diameter — grade 3 (at right angle to pin bore) 90.195-90.185 mm (3.5510-3.5506 in)
Piston-to-cylinder bore clearance (at grade size) 0.025-0.045 mm (0.0010-0.0018 in)
Piston ring end gap — top 0.15-0.30 mm (0.006-0.012 in)
Piston ring end gap — intermediate 0.25-0.50 mm (0.0098-0.0197 in)
Piston ring end gap — oil control 0.15-0.65 mm (0.0059-0.0256 in)
Piston ring groove width — top 1.52-1.55 mm (0.0598-0.0610 in
Piston ring groove width — intermediate 1.52-1.54 mm (0.0598-0.0606 in)
Piston ring groove width — oil control 3.030-3.050 mm (0.1193-0.1201 in)
Piston ring width — top and intermediate 1.50-1.47 mm (0.0590-0.0578 in)
Piston ring-to-groove clearance — top 0.020-0.080 mm (0.0008-0.0031 in)
Piston ring-to-groove clearance — intermediate 0.030-0.070 mm (0.0012-0.0028 in)
Piston pin bore diameter 22.008-22.014 mm (0.8665-0.8667 in)
Piston pin diameter 22.0010-22.0030 mm (0.8662-0.8663 in)
Piston pin length 61.8 mm (2.433 in)
Piston pin-to-piston fit 0.005-0.0130 mm (0.0002-0.0005 in)
Connecting rod-to-pin clearance 0.009-0.0235 mm (0.0004-0.0093 in)
Connecting rod pin bore diameter 22.012-22.024 mm (0.8666-0.8671 in)
Connecting rod length (center-to-center) 169.1 mm (6.6575 in)
Connecting rod maximum allowed bend ± 0.038 mm (0.0015 in)

Connecting rod maximum allowed twist b ± 0.05 mm (0.0020 in)

Connecting rod bearing bore diameter (with assembled liners) 53.049-53.027 mm (2.0885-2.0877 in)
Connecting rod bearing-to-crankshaft clearance 0.064-0.026 mm (0.0025-0.0010 in)
Connecting rod side clearance 0.475-0.125 mm (0.0187-0.0049 in)

a The time required for the plunger to leak down 1.6 mm (0.062 in) of travel with 222 N force and leak-down fluid in the lash adjuster.

b The pin bore and crank bearing bore must be parallel and in the same vertical plane within the specified total difference when measured at the ends of a 203 mm bar, 105.5
mm on each side of rod centerline.
Torque Specifications

Description Nm lb-ft lb-in

A/C compressor bolts 25 18 —
A/C compressor nuts 20 15 —
Accessory drive belt idler pulley bolt 25 18 —
Accessory drive belt tensioner bolt 25 18 —
Air cleaner outlet pipe-to-throttle body (TB) adapter bolts 10 — 89

Camshaft bearing cap bolts a — — —

Camshaft phaser and sprocket bolt

a — — —

Camshaft position (CMP) sensor bolt 10 — 89

Canister purge valve bracket nuts 10 — 89
Charge motion control valve (CMCV) stud bolt 10 — 89
303-01A-5 Engine — 5.4L (3V) 303-01A-5
SPECIFICATIONS (Continued)

Torque Specifications (Continued)

Description Nm lb-ft lb-in
CMCV bolt 10 — 89

Connecting rod bolts

a — — —

Coolant pump bolts 25 18 —

Coolant pump pulley bolts 25 18 —
Cooling fan clutch hub-to-coolant pump nut 55 41 —
Coolant tube stud bolt 10 — 89

Crankshaft damper pulley bolt

a — — —

Crankshaft main bearing bolts (cross-mounted)

a — — —

Crankshaft main bearing bolts (vertical)

a — — —

Crankshaft position (CKP) sensor bolt 10 — 89

Crankshaft rear seal retainer plate bolts

a — — —

Cylinder block drain plug 24 18 —

Cylinder heads bolts

a — — —

Cylinder head temperature sensor (CHT) 10 — 89

Engine coolant crossover assembly bolts 10 — 89

Engine front cover bolts

a — — —

Engine oil pressure (EOP) switch 18 13 —

Engine support insulator bracket bolts

a — — —

Engine support insulator-to-crossmember nuts — LH 200 148 —

Engine support insulator-to-crossmember nuts — RH 115 85 —
Engine support insulator through bolt 350 258 —
Engine wiring harness retainer nut and bolts 10 — 89
Exhaust manifold flange nuts 40 30 —
Exhaust manifold heat shield bolts — RH 10 — 89
Exhaust manifold heat shield bolts — LH 14 10 —
Exhaust manifold nuts 25 18 —
Exhaust manifold-to-Y-pipe nuts 40 30 —
Exhaust manifold studs 12 9 —
Flexplate bolts 80 59 —
Flexplate inspection cover bolts 34 25 —
Flywheel bolts 80 59 —
Front oil level indicator tube bolt 25 18 —
Fuel rail bolts 10 — 89
Generator upper mounting bracket bolts 10 — 89
Generator lower mounting bolts 25 18 —
Ground strap stud bolt 10 — 89
Ignition coil 6 — 53

Intake manifold bolts

a — — —

Intake manifold-to-cylinder head bolts

a — — —

Intake manifold vacuum tube support bracket bolt 10 — 89

Knock sensor (KS) 20 15 —
303-01A-6 Engine — 5.4L (3V) 303-01A-6
SPECIFICATIONS (Continued)

Torque Specifications (Continued)

Description Nm lb-ft lb-in
Oil cooler 58 43 —
Oil filter 16 12 —
Oil filter adapter bolts 25 18 —
Oil filter adapter nut 48 35 —

Oil pan bolts

a — — —

Oil pan drain plug 14 10 —

Oil pump bolts 10 — 89
Oil pump screen and pickup tube-to-oil pump bolts 10 — 89
Oil pump screen and pickup tube spacer 25 18 —
Oil pump screen and pickup tube-to-spacer bolt 25 18 —
PCV heater element bolts 6 — 53
Power steering pump bolts 25 18 —
Radio ignition interference capacitor nut 10 — 89
Rear oil level indicator tube bolt 10 — 89
Spark plugs (early build — black coil boot) 34 25 —
Spark plug (late build — brown coil boot) 12 9 —
Starter wiring harness support bracket nut 10 — 89
Suction accumulator upper and lower nuts 7 — 62

TB bolts
a — — —

Timing chain guide bolts 10 — 89

Timing chain hydraulic tensioner bolts 25 18 —
Torque converter-to-flexplate nuts 35 26 —
Transmission auxiliary fluid cooler support bracket bolts 35 26 —
Transmission auxiliary fluid cooler tube support bracket nut 25 18 —
Transmission fluid filler tube bolt 10 — 89
Transmission mount-to-crossmember nuts 115 85 —
Transmission rear mount nuts 103 76 —
Transmission-to-engine bolts 48 35 —

Valve cover bolts

a 10 — 89

Wiring harness retainers 10 — 89

a Refer to the procedure in this section.

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

DESCRIPTION AND OPERATION

Engine .............................................................................................................................................................................. 303-01A-2
Engine Identification ................................................................................................................................................... 303-01A-2
Engine Code Information Label ........................................................................................................................... 303-01A-2
Engine Cylinder Identification .............................................................................................................................. 303-01A-3
Exhaust Emission Control System ............................................................................................................................. 303-01A-3
Induction System ........................................................................................................................................................ 303-01A-3
Valve Train ................................................................................................................................................................. 303-01A-3
Positive Crankcase Ventilation System ..................................................................................................................... 303-01A-3
Lubrication System ..................................................................................................................................................... 303-01A-3
Engine Oil Flow Illustrations ................................................................................................................................ 303-01A-4
Oil Pump .............................................................................................................................................................. 303-01A-8
303-01A-2 Engine — 5.4L (3V) 303-01A-2

DESCRIPTION AND OPERATION

Engine

NOTE:
Refer to the exploded view under the Assembly procedure in this section.

The 5.4L (3V) is a V-8 engine with the following features:

• Single overhead camshafts

• Three valves per cylinder
• Sequential Multi-Port Fuel Injection (SFI)
• Aluminum cylinder heads
• Cast iron, 90-degree V-cylinder block
• Variable Camshaft Timing (VCT)
• Individually chain-driven camshafts with a hydraulic timing chain tensioner on each timing chain
• Distributorless ignition system
• Electronic Returnless Fuel System (ERFS)

Engine Identification
Always refer to these labels when installation of new parts is necessary, or when checking engine calibrations. The engine parts often differ within a CID
family. Verification of the identification codes will make sure that the correct parts are obtained. These codes contain all the pertinent information relating to
the dates, optional equipment and revisions. The Ford Catalog Advantage™ or equivalent, contains a complete listing of the codes and their application.

Engine Code Information Label

The engine code information label, located on the front side of the valve cover, contains the following:

Item Description
1 Engine part number
2 Bar code
3 Running number
4 Engine build date (DDMMYY)
5 Windsor engine plant
6 Bar code
7 Engine displacement
303-01A-3 Engine — 5.4L (3V) 303-01A-3
DESCRIPTION AND OPERATION (Continued)

Engine Cylinder Identification

Exhaust Emission Control System

Operation and necessary maintenance of the exhaust emission control devices used on this engine are covered in the Powertrain Control/Emissions
Diagnosis (PC/ED) manual.

Induction System
The SFI system provides the fuel/air mixture needed for combustion in the cylinders. The 8 solenoid-operated fuel injectors:

• are mounted in the intake manifold.

• meter fuel into the air intake stream in accordance with engine demand.
• are positioned so that their tips direct fuel just ahead of the engine intake valves.
• supply fuel from the fuel tank with a fuel pump mounted in the fuel tank.

Valve Train
The valve train operates as follows:

• Ball-tip hydraulic lash adjusters provide automatic lash adjustment.

• Roller followers ride on the camshaft lobe, transferring the up-and-down motion of the camshafts to the valves in the cylinder heads.

Positive Crankcase Ventilation System

All engines are equipped with a closed-type positive crankcase ventilation system recycling the crankcase vapors to the upper intake manifold.

Lubrication System
The engine lubrication system operates as follows:

• Oil is drawn into the oil pump through the oil pump screen cover and tube in the sump of the oil pan.
• Oil is pumped through the oil filter on the left front side of the cylinder block.
• Oil enters the main gallery where it is distributed to the crankshaft main journals and to both cylinder heads.
• From the main journals, the oil is routed through cross-drilled passages in the crankshaft to lubricate the connecting rod bearings. Controlled leakage
through the crankshaft main bearings and connecting rod bearings is slung radially outward to cool and lubricate the cylinder walls as well as the entire
connecting rod, piston and piston ring assembly.
• The left cylinder head is fed from a drilling into the supply passage feeding the main gallery at the front of the cylinder block. The right cylinder head
is fed from a drilling into the rear of the main gallery. Main gallery pressure is reduced as it enters the cylinder head galleries through fixed serviceable
orifices, located at the upper part of the feed passages. It is this reduced pressure in the cylinder head galleries which feeds the camshaft journals, the
hydraulic lash adjusters and the primary and secondary timing chain tensioners.
303-01A-4 Engine — 5.4L (3V) 303-01A-4
DESCRIPTION AND OPERATION (Continued)

• The oil pressure feed for the VCT solenoids, VCT housings and camshaft phaser and sprockets is not reduced.
• The camshaft lobe and roller followers are lubricated by splash created through valve train operation.

Engine Oil Flow Illustrations

Engine Assembly

Item Part Number Description

1 6714 Oil filter
303-01A-5 Engine — 5.4L (3V) 303-01A-5
DESCRIPTION AND OPERATION (Continued)

Item Part Number Description

2 6A642 Oil cooler (if equipped)
3 9278 Engine Oil Pressure (EOP) switch
4 6884 Oil filter adapter
5 6622 Oil pump screen and pickup tube
6 6621 Oil pump
7 6L266A Timing chain tensioner — RH
8 6C260 Variable Camshaft Timing (VCT) housing — RH
9 6M280 VCT oil control solenoid assembly — RH
10 6B284 Front camshaft bearing cap — RH
11 6L266B Timing chain tensioner — LH
12 6C261 VCT housing — LH
13 6M280 VCT oil control solenoid assembly — LH
14 6B284 Front camshaft bearing cap — LH
15 6050 Cylinder head — LH

Camshaft Phaser and Sprocket, Camshaft Phaser and Sprocket Bolt and Camshaft

Item Part Number Description

1 6279 Camshaft phaser and sprocket bolt
2 6256 Camshaft phaser and sprocket
3 — Camshaft
303-01A-6 Engine — 5.4L (3V) 303-01A-6
DESCRIPTION AND OPERATION (Continued)

LH Variable Camshaft Timing (VCT) Housing, VCT Solenoid and Timing Chain Tensioner

Item Part Number Description

1 6L266B Timing chain tensioner — LH
2 6C261 Variable Camshaft Timing (VCT) housing — LH
3 6M280 VCT oil control solenoid assembly — LH
303-01A-7 Engine — 5.4L (3V) 303-01A-7
DESCRIPTION AND OPERATION (Continued)

RH Variable Camshaft Timing (VCT) Housing and VCT Solenoid

Item Part Number Description

1 6M280 Front camshaft bearing cap — RH
2 6C261 Variable Camshaft Timing (VCT) housing — RH
3 6C260 VCT oil control solenoid assembly — RH
303-01A-8 Engine — 5.4L (3V) 303-01A-8
DESCRIPTION AND OPERATION (Continued)

Variable Camshaft Timing (VCT) Housing

Item Part Number Description

1 — Variable Camshaft Timing (VCT) oil control solenoid assembly
2 — VCT housing

Oil Pump
The lubrication system of the 5.4L (3V) engine is designed to provide optimum oil flow to critical components of the engine through its entire operating
range. The heart of the system is a positive displacement internal gear oil pump using top seal rotors. Generically this design is known as a gerotor pump,
which operates as follows:

• The oil pump is mounted on the front face of the cylinder block.
• The inner rotor is piloted on the crankshaft post and is driven through flats on the crankshaft.
• System pressure is limited by an integral, internally-vented relief valve which directs the bypassed oil back to the inlet side of the oil pump.
• Oil pump displacement has been selected to provide adequate volume to make sure of correct oil pressure, both at hot idle and maximum speed.
• The relief valve calibration protects the system from excessive pressure during high viscosity conditions.
• The relief valve is designed to provide adequate connecting rod bearing lubrication under high-temperature and high-speed conditions.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Valve Cover — RH ............................................................................................................................................................ 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Valve Cover — RH

Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A
Silicone Brake Caliper Grease and Dielectric Compound ESE-M1C171-A
XG-3-A
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Motorcraft® Silicone Gasket Remover —
ZC-30

PCM Electrical Connectors

Item Part Number Description

1 — Transmission wiring harness electrical connector and wiring harness
retainer (part of 15525)
2 — Engine wiring harness electrical connector and wiring harness
retainer (part of 12B637)
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

Transmission Fluid Level Indicator Tube, Crankcase Vent Tube and Coolant Hose

Item Part Number Description

1 N859356 Transmission fluid level indicator tube support bracket bolt
2 7A228 Transmission fluid level indicator tube
3 9929 Heater coolant hose
4 — Heater coolant hose clamp
5 6758 Crankcase ventilation tube quick connect coupling
303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

Ignition Coils, RH Valve Cover and Gasket

Item Part Number Description

1 — Variable Camshaft Timing (VCT) solenoid electrical connector (part
of 12B637)
2 — Engine wiring harness retainers (part of 12B637)
3 — Engine wiring harness retainers (part of 12B637)
4 — RH ignition coil electrical connector (4 required) (part of 12B637)
5 W711062 RH ignition coil bolt (4 required)
6 12A366 RH ignition coil (4 required)
7 6582 RH valve cover
8 6584 RH valve cover gasket

Removal
1. Drain the engine cooling system. For additional information, refer to Section 303-03.
2. If equipped, remove the bolt and position the transmission filler tube aside.
3. Disconnect the quick connect coupling and position the crankcase vent tube aside. For additional information, refer to Section 310-00.
303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

4. Disconnect the heater coolant hose from the engine coolant crossover manifold assembly.
5. Disconnect the 2 PCM electrical connectors and the wiring harness retainers from the support bracket and position aside.
6. Disconnect the 4 RH ignition coil electrical connectors.
7. Remove the 4 RH bolts and the 4 RH ignition coils.
• Remove the ignition coil, using a twisting motion while pulling up on the ignition coil.
8. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector.
9. Disconnect the 4 wiring harness retainers from the valve cover and position the wiring harness aside.
10. NOTICE:
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. Failure to follow this procedure
may cause future oil leakage.

NOTICE:
When removing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.

NOTE:
The fasteners are part of the valve cover and should not be removed.

Fully loosen the 9 fasteners and remove the RH valve cover and gasket.
• Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the
packaging.
• Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Installation
1. NOTE:
If the valve 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 may cause future oil leakage.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

2. NOTICE:
When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.

Position the RH valve cover and new gasket on the cylinder head and tighten the 9 bolts in the sequence shown.
• Tighten to 10 Nm (89 lb-in).
303-01A-6 Engine — 5.4L (3V) 303-01A-6
IN-VEHICLE REPAIR (Continued)

3. Connect the wiring harness retainers to the valve cover.

4. Connect the VCT solenoid electrical connector.
5. NOTE:
Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.

Install the 4 RH ignition coils and the 4 bolts.

• Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.
• Tighten to 6 Nm (53 lb-in).
6. Connect the 4 RH ignition coil electrical connectors.
7. Connect the 2 PCM electrical connectors and the wiring harness retainers to the support bracket.
8. Position the crankcase vent tube and connect the quick connect couplings. For additional information, refer to Section 310-00.
9. Connect the heater coolant hose to the engine coolant crossover manifold assembly.
10. If equipped, position the transmission filler tube and install the bolt.
• Tighten to 10 Nm (89 lb-in).
11. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Intake Manifold ................................................................................................................................................................. 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Intake Manifold

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Silicone Gasket Remover —
ZC-30
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

Throttle Body (TB) Adapter, PCV Tube, Crankcase Vent Tube and Electrical Connectors

Item Part Number Description

1 W705800 Radiator hose clamp
2 9F792 Radiator hose
3 9229 Heater coolant hose
4 6K824 Crankcase ventilation tube
5 6K817 PCV tube
303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

Item Part Number Description

6 W505426 Air cleaner outlet pipe-to-throttle body (TB) adapter bolt (4 required)
7 9G651 Air cleaner outlet pipe-to-TB adapter
8 9B694 Air cleaner outlet pipe-to-TB adapter seal
9 — Fuel rail pressure and temperature sensor electrical connector (part
of 12B637)
10 — Fuel rail pressure and temperature sensor vacuum hose (part of
9D446)
11 — Electronic acceleration control electrical connector (part of 12B637)
12 — Throttle position (TP) sensor electrical connector (part of 12B637)
13 — Radio ignition interference capacitor electrical connector (part of
12B637)
14 — Variable camshaft timing (VCT) oil control solenoid electrical
connector (part of 12B637)
15 — Engine wiring harness retainers (part of 12B637)
16 — Fuel injector electrical connector (8 required) (part of 12B637)
303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

Intake Manifold and Gaskets

Item Part Number Description

1 N621903 Engine wiring harness retainer nut
2 — Engine wiring harness retainer (part of 12B637)
3 — Knock sensor (KS) electrical connector (2 required) (part of 12B637)
4 — Cylinder head temperature (CHT) sensor electrical connector (part of
12B637)
303-01A-6 Engine — 5.4L (3V) 303-01A-6
IN-VEHICLE REPAIR (Continued)

Item Part Number Description

5 — Charge motion control valve (CMCV) electrical connector (part of
12B637)
6 9J338 Fuel supply tube spring lock coupling
7 9A474 Vacuum tube
8 — Intake manifold vacuum tube-to-brake booster hose clamp (part of
9A474)
9 — Intake manifold vacuum tube-to-brake booster hose (part of 9A474)
10 — PCV intake fitting electrical connector (part of 12B637)
11 W709775 Intake manifold bolt (10 required)
12 9Y451 Intake manifold
13 9439 RH intake manifold gasket
14 9441 LH intake manifold gasket

Engine Coolant Crossover Manifold Assembly and Gaskets

303-01A-7 Engine — 5.4L (3V) 303-01A-7
IN-VEHICLE REPAIR (Continued)

Item Part Number Description

1 W503297 Engine coolant crossover manifold assembly bolt (3 required)
2 8C369 Engine coolant crossover manifold assembly
3 8C387 RH engine coolant crossover manifold assembly gasket
4 8C389 LH engine coolant crossover manifold assembly gasket

Removal

WARNING:
Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable
mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

WARNING:
Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying
of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in
serious personal injury.

1. Disconnect the fuel supply spring lock coupling from the fuel rail. For additional information, refer to Section 310-00.
2. Drain the cooling system. For additional information, refer to Section 303-03.
3. Remove the generator. For additional information, refer to Section 414-02.
4. Remove the air cleaner outlet pipe. For additional information, refer to Section 303-12.
5. Disconnect the upper radiator hose from the thermostat housing.
6. Disconnect the heater coolant hose from the engine coolant crossover manifold assembly.
7. Disconnect the evaporative emissions (EVAP) system tube from the intake manifold and position aside. For additional information, refer to Section
310-00.
8. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to Section 310-00.
9. Remove the 4 bolts and the air cleaner outlet pipe-to-throttle body (TB) adapter.
10. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
11. Disconnect the 8 fuel injector electrical connectors.
12. Disconnect the throttle position (TP) sensor and electronic acceleration control electrical connectors.
13. Disconnect the heated PCV intake fitting electrical connector.
14. Disconnect the LH variable camshaft timing (VCT) solenoid electrical connector.
15. Disconnect the LH radio ignition interference capacitor electrical connector.
16. Disconnect the wiring harness retainers from the LH valve cover studs and position the harness aside.
17. Disconnect the brake booster vacuum hose from the intake manifold vacuum tube.
18. Remove the 10 intake manifold bolts.
19. NOTICE:
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.

Remove the 3 bolts, the engine coolant crossover manifold assembly and discard the gaskets.
• Clean and inspect the sealing surfaces with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions on the packaging.
20. Disconnect the charge motion control valve (CMCV) electrical connector.
21. Disconnect the RH heated exhaust gas oxygen sensor (HO2S) electrical connector and detach the electrical connector retainers.
303-01A-8 Engine — 5.4L (3V) 303-01A-8
IN-VEHICLE REPAIR (Continued)

22. Disconnect the intake manifold vacuum tube from the valve cover stud and the support bracket.
23. Position the intake manifold assembly forward and disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector.
24. Disconnect the LH and RH knock sensor (KS) electrical connectors.
25. Remove the nut and disconnect the engine wiring harness retainer from the CMCV stud.
26. NOTICE:
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.

Remove the intake manifold and discard the gaskets.

• Clean and inspect the sealing surfaces with Motorcraft Metal Surface Prep and Silicone Gasket Remover. Follow the directions on the packaging.

Installation
1. NOTICE:
If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold
for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE:
Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at the rear of the intake manifold. Use extreme care on
installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses.

Using new intake manifold gaskets, position the intake manifold.

2. Using new gaskets, position the engine coolant crossover manifold assembly and install the 3 bolts
• Tighten to 10 Nm (89 lb-in).
3. Install the intake manifold bolts and tighten in 2 stages in the sequence shown.
• Stage 1: Tighten to 2 Nm (18 lb-in).
• Stage 2: Tighten to 10 Nm (89 lb-in).
303-01A-9 Engine — 5.4L (3V) 303-01A-9
IN-VEHICLE REPAIR (Continued)

4. Connect the engine wiring harness retainer to the CMCV stud and install the nut.
• Tighten to 10 Nm (89 lb-in).
5. Connect the CMCV electrical connector.
6. Connect the HO2S electrical connector and attach the electrical connector retainer.

7. Connect the CHT sensor jumper harness electrical connector.

8. Connect the LH and RH KS electrical connectors.
9. Connect the intake manifold vacuum tube to the support bracket and the valve cover stud.
10. Connect the brake booster vacuum hose to the intake manifold vacuum tube.
11. Position the engine wiring harness and connect the wiring harness retainers to the LH valve cover stud bolts.
12. Connect the LH radio ignition interference capacitor electrical connector.
13. Connect the LH VCT solenoid electrical connector.
14. Connect the heated PCV intake fitting electrical connector.
15. Connect the TP sensor and electronic acceleration control electrical connectors.
16. Connect the 8 fuel injector electrical connectors.
17. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
303-01A-10 Engine — 5.4L (3V) 303-01A-10
IN-VEHICLE REPAIR (Continued)

18. Position the air cleaner outlet pipe-to-throttle body (TB) adapter and install the 4 bolts.
• Tighten to 10 Nm (89 lb-in).
19. Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to Section 310-00.
20. Position the PCV tube and connect the quick connect couplings. For additional information, refer to Section 310-00.
21. Connect the EVAP tube quick connect coupling to the intake manifold. For additional information, refer to Section 310-00.
22. Connect the heater coolant hose to the engine coolant crossover manifold assembly.
23. Connect the upper radiator hose to the thermostat housing.
24. Install the generator. For additional information, refer to Section 414-02.
25. Install the air cleaner outlet pipe. For additional information, refer to Section 303-12.
26. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Valve Cover — LH ............................................................................................................................................................. 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Valve Cover — LH

Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A
Silicone Brake Caliper Grease and Dielectric Compound ESE-M1C171-A
XG-3-A
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Motorcraft® Silicone Gasket Remover —
ZC-30

Evaporative Emission (EVAP) Fuel Vapor Tube Quick Connect Fittings

Item Part Number Description

1 — Evaporative Emission (EVAP) fuel vapor tube quick connect fitting
2 — EVAP fuel vapor tube quick connect fitting
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

PCV Tube, Intake Manifold Vacuum Tube, Degas Bottle Coolant Outlet Hose and Electrical Connectors

Item Part Number Description

1 6K817 PCV tube
2 — Degas bottle coolant outlet hose clamp
3 — Degas bottle coolant outlet hose
4 — LH radio ignition interference capacitor electrical connector (part of
12B637)
5 — LH Variable Camshaft Timing (VCT) solenoid electrical connector
(part of 12B637)
6 — Engine wiring harness retainers (part of 12B637)
7 — Intake manifold vacuum tube-to-brake booster hose
8 9D446 Intake manifold vacuum tube
303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

LH Ignition Coils, Valve Cover and Gasket

Item Part Number Description

1 — Engine wiring harness retainers (part of 12B637)
2 — Camshaft Position (CMP) sensor electrical connector (part of
12B637)
3 — LH ignition coil electrical connector (4 required) (part of 12B637)
4 W711062 LH ignition coil bolt (4 required)
5 12A366 LH ignition coil (4 required)
6 6A505 LH valve cover
7 6A559 LH valve cover gasket

Removal
1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to Section 303-12.
2. Remove the degas bottle assembly. For additional information, refer to Section 303-03.
3. Remove the oil level indicator and tube. For additional information, refer to Oil Level Indicator and Tube in this section.
4. Disconnect the degas bottle coolant outlet hose.
303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

5. Disconnect the 2 Evaporative Emission (EVAP) system tube quick connect couplings and position the tubes aside. For additional information, refer to
Section 310-00.
6. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to Section 310-00.
7. Disconnect the 4 LH ignition coil electrical connectors.
8. Remove the 4 bolts and the 4 LH ignition coils.
• Remove the ignition coil, using a twisting motion while pulling up on the ignition coil.
9. Disconnect the intake manifold vacuum tube hose from the brake booster.
10. Disconnect the radio ignition interference capacitor electrical connector.
11. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector and the wiring harness retainers.
12. Disconnect the intake manifold vacuum tube from the support bracket and the valve cover stud.
13. NOTICE:
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. Failure to follow this procedure
may cause future oil leakage.

NOTICE:
When removing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.

NOTE:
The fasteners are part of the valve cover and should not be removed.

Fully loosen the 10 fasteners and remove the LH valve cover and gasket.
• Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the
packaging.
• Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Installation
1. NOTE:
If the valve 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 may cause future oil leakage.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

2. Position the LH valve cover and a new gasket on the cylinder head and tighten the 10 bolts in the sequence shown.
• Tighten to 10 Nm (89 lb-in).
303-01A-6 Engine — 5.4L (3V) 303-01A-6
IN-VEHICLE REPAIR (Continued)

3. Position the intake manifold vacuum tube assembly onto the support bracket and the valve cover stud.
4. Connect the VCT solenoid electrical connector and the wiring harness retainers.
5. Connect the radio ignition interference capacitor electrical connector.
6. Connect the intake manifold vacuum tube hose to the brake booster.
7. NOTE:
Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.

Install the 4 LH ignition coils and the 4 bolts.

• Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.
• Tighten to 6 Nm (53 lb-in).
8. Connect the 4 LH ignition coil electrical connectors.
9. Position the 2 EVAP system tubes and connect the quick connect couplings. For additional information, refer to Section 310-00.
10. Install the oil level indicator and tube. For additional information, refer to Oil Level Indicator and Tube in this section.
11. Position the PCV tube and connect the quick connect couplings. For additional information, refer to Section 310-00.
12. Connect the degas bottle coolant outlet hose.
13. Install the degas bottle assembly. For additional information, refer to Section 303-03.
14. Install the ACL outlet pipe. For additional information, refer to Section 303-12.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Crankshaft Pulley ............................................................................................................................................................. 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Crankshaft Pulley
Special Tool(s)

Remover, Crankshaft Vibration Damper

303-009 (T58P-6316-D)

Installer, Crankshaft Vibration Damper

303-102 (T74P-6316-B)

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil WSS-M2C930-A
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil
CXO-5W20-LSP12 (Canada); or equivalent
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Silicone Gasket Remover —
ZC-30

Item Part Number Description

1 8620 Accessory drive belt
2 W701512 Crankshaft pulley bolt
3 N806165 Crankshaft pulley bolt washer
4 6316 Crankshaft pulley
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Press the 5 position retaining tabs and rotate the lower cooling fan shroud upward until the position retainer tab locks into position.

3. Rotate the tensioner clockwise and remove the accessory drive belt.

4. Remove the crankshaft pulley bolt and washer.

• Discard the crankshaft pulley bolt.
5. Using the special tool, remove the crankshaft pulley.
303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

Installation
1. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep and Silicone Gasket
Remover. 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 may cause future oil leakage.

Apply Silicone Gasket and Sealant to the Woodruff key slot in the crankshaft pulley.

2. NOTE:
Lubricate the crankshaft front seal inner lip with clean engine oil prior to installing the crankshaft pulley.

Using the special tool, install the crankshaft pulley.

3. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 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.
303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

4. Rotate the tensioner clockwise and install the accessory drive belt.

5. Press the position retaining tab and rotate the lower cooling fan shroud downward until the position retainer tab locks into position.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Crankshaft Front Seal ...................................................................................................................................................... 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Crankshaft Front Seal
Special Tool(s)

Installer, Crankshaft Front Seal

303-635

Installer, Front Cover Seal

303-335 (T88T-6701-A)

Remover, Crankshaft Front Seal

303-107 (T74P-6700-A)

Installer, Crankshaft Vibration Damper

303-102 (T74P-6316-B)

Remover, Crankshaft Vibration Damper

303-009 (T58P-6316-D)

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil WSS-M2C930-A
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil
CXO-5W20-LSP12 (Canada); or equivalent
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Silicone Gasket Remover —
ZC-30
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

Item Part Number Description

1 8620 Accessory drive belt
2 W701512 Crankshaft pulley bolt
3 N806165 Crankshaft pulley bolt washer
4 6316 Crankshaft pulley
5 6700 Crankshaft front seal

Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Press the 5 position retaining tabs and rotate the lower cooling fan shroud upward until the position retainer tab locks into position.

3. Rotate the tensioner clockwise and remove the accessory drive belt.
303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

4. Remove the crankshaft pulley bolt and washer.

• Discard the crankshaft pulley bolt.
5. Using the special tool, remove the crankshaft pulley.

6. Using the special tool, remove and discard the crankshaft front seal.

Installation
1. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

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

3. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with Motorcraft Metal Surface Prep and Silicone Gasket
Remover. 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 may cause future oil leakage.

Apply Silicone Gasket and Sealant to the Woodruff key slot in the crankshaft pulley.

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

5. Using a new crankshaft pulley bolt, install the bolt and washer and tighten the bolt in 4 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.
303-01A-6 Engine — 5.4L (3V) 303-01A-6
IN-VEHICLE REPAIR (Continued)

6. Rotate the tensioner clockwise and install the accessory drive belt.

7. Press the position retaining tab and rotate the lower cooling fan shroud downward until the position retainer tab locks into position.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Engine Front Cover .......................................................................................................................................................... 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Engine Front Cover
Special Tool(s)

Installer, Crankshaft Front Seal

303-335 (T88T-6701-A)

Remover, Crankshaft Front Seal

303-107 (T74P-6700-A)

Installer, Crankshaft Front Seal

303-635

Remover, Crankshaft Vibration Damper

303-009 (T58P-6316-D)

Installer, Crankshaft Vibration Damper

303-102 (T74P-6316-B)

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil WSS-M2C930-A
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil
CXO-5W20-LSP12 (Canada); or equivalent
Silicone Gasket Remover —
ZC-30
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

Item Part Number Description

1 N808102 Accessory drive belt idler pulley bolt
2 19A216 Accessory drive belt idler pulley
3 N808920 Accessory drive belt tensioner bolt (3 required)
4 6B209 Accessory drive belt tensioner
5 W701512 Crankshaft pulley bolt
6 N806165 Crankshaft pulley bolt washer
7 6316 Crankshaft pulley
8 6700 Crankshaft front seal
9 W500315 Power steering pump bolt (2 required)
10 W701526 Power steering pump bolt
11 3A696 Power steering pump
303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

Item Part Number Description

12 N804758 RH radio ignition interference capacitor nut
13 18801 RH radio ignition interference capacitor
14 N804758 LH radio ignition interference capacitor nut
15 18801 LH radio ignition interference capacitor
16 — RH camshaft position (CMP) sensor electrical connector (part of
12B637)
303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

Item Part Number Description

17 N806155 RH CMP sensor bolt
18 6B288 RH CMP sensor
19 N806282 Coolant pump pulley bolt (4 required)
20 8A528 Coolant pump pulley
21 — Crankshaft position (CKP) sensor electrical connector (part of
12B637)
22 W605289 Transmission fluid cooler tube and battery wiring harness support
brackets nut
23 — Transmission fluid cooler tube support bracket
24 — Starter wiring harness support bracket
25 W701605 Oil pan bolt (4 required)
26 — LH CMP sensor electrical connector (part of 12B637)
27 N806155 LH CMP sensor bolt
28 6B288 LH CMP sensor

Item Part Number Description

29 N806155 CKP sensor bolt
30 6C315 CKP sensor
31 N808529 Engine front cover stud (2 required)
32 N806177 Engine front cover bolt (8 required)
33 N709573 Engine front cover stud (5 required)
34 6C086 Engine front cover
35 6D081 Engine front cover gasket (3 required)

Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Drain the engine oil.
303-01A-6 Engine — 5.4L (3V) 303-01A-6
IN-VEHICLE REPAIR (Continued)

3. Remove the engine cooling fan shroud. For additional information, refer to Section 303-03
4. Remove the engine cooling fan. For additional information, refer to Section 303-03.
5. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
6. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
7. Loosen the 4 coolant pump pulley bolts.
8. Rotate the tensioner clockwise and remove the accessory drive belt.

9. Remove the bolt and the accessory drive idler pulley.

10. Remove the 3 bolts and the accessory drive belt tensioner.
11. Remove the crankshaft pulley bolt and washer.
• Discard the crankshaft pulley bolt.
12. Using the special tool, remove the crankshaft pulley.

13. Using the special tool, remove and discard the crankshaft front seal.

14. Remove the 3 bolts and position the power steering pump assembly aside.
15. Remove the 2 nuts and the RH and LH radio ignition interference capacitors.
16. Disconnect the RH camshaft position (CMP) sensor electrical connector.
17. Remove the bolt and the RH CMP sensor.
303-01A-7 Engine — 5.4L (3V) 303-01A-7
IN-VEHICLE REPAIR (Continued)

18. Disconnect the LH CMP sensor electrical connector.

19. Remove the bolt and the LH CMP sensor.
20. Remove the 4 bolts and the coolant pump pulley.
21. Disconnect the crankshaft position (CKP) sensor electrical connector.
22. Remove the nut and the starter wiring harness and transmission cooler tube support brackets from the stud bolt.
23. Remove the 4 front oil pan bolts.
24. Remove the bolts and the studs.

25. NOTICE:
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. Failure to follow this procedure
may cause future oil leakage.

Remove the engine front cover from the front cover to cylinder block dowel.
• Remove the engine front cover gaskets.
• Clean the mating surfaces with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions on the packaging.
• Inspect the mating surfaces.

26. Remove the bolt and the CKP sensor.

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

Install the CKP sensor and the bolt.

• Tighten to 10 Nm (89 lb-in).
2. NOTICE:
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. To clean the sealing area, use
Silicone Gasket Remover and Motorcraft 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 may cause future oil leakage.
303-01A-8 Engine — 5.4L (3V) 303-01A-8
IN-VEHICLE REPAIR (Continued)

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 and the oil pan-to-cylinder block surface, at the
locations shown.

3. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.

4. Tighten the engine front cover fasteners in sequence in 2 stages.

Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

Item Part Number Description

1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
303-01A-9 Engine — 5.4L (3V) 303-01A-9
IN-VEHICLE REPAIR (Continued)

(Continued)
Item Part Number Description
7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
11 W709573 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
12 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
13 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
14 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
15 W709573 Bolt, Hex Head Pilot, M8 x 1.25 x 56

5. Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown.
• Stage 1: Tighten to 20 Nm (15 lb-ft).
• Stage 2: Tighten an additional 60 degrees.

6. Connect the CKP sensor electrical connector.

7. Position the starter wiring harness and transmission fluid cooler tubes support brackets and install the nut.
303-01A-10 Engine — 5.4L (3V) 303-01A-10
IN-VEHICLE REPAIR (Continued)

• Tighten to 25 Nm (18 lb-ft).

8. Position the power steering pump assembly and install the 3 bolts.
• Tighten to 25 Nm (18 lb-ft).
9. NOTE:
Lubricate the O-ring seal with clean engine oil prior to installation.

Install the RH CMP sensor and the bolt.

• Tighten to 10 Nm (89 lb-in).
10. Connect the RH CMP sensor electrical connector.
11. NOTE:
Lubricate the O-ring seal with clean engine oil prior to installation.

Install the LH CMP sensor and the bolt.

• Tighten to 10 Nm (89 lb-in).
12. Connect the LH CMP sensor electrical connector.
13. Install the RH and LH radio ignition interference capacitors and the 2 nuts.
• Tighten to 10 Nm (89 lb-in).
14. Install the accessory drive belt tensioner and the 3 bolts.
• Tighten to 25 Nm (18 lb-ft).
15. Install the coolant pump pulley and the 4 bolts finger tight.
16. Install the accessory drive idler pulley and the bolt.
• Tighten to 25 Nm (18 lb-ft).
17. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.

18. Using the special tools, install a new crankshaft front seal into the engine front cover.

19. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.
303-01A-11 Engine — 5.4L (3V) 303-01A-11
IN-VEHICLE REPAIR (Continued)

Apply Silicone Gasket and Sealant to the Woodruff key slot on the crankshaft pulley.

20. Use the special tool to install the crankshaft pulley.

21. Tighten the new crankshaft pulley bolt in 4 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.
22. Rotate the tensioner clockwise and install the accessory drive belt.

23. Tighten the 4 coolant pump pulley bolts.

• Tighten to 25 Nm (18 lb-ft).
24. Install the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
25. Install the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
26. Install the engine cooling fan. For additional information, refer to Section 303-03.
27. Install the engine cooling fan shroud. For additional information, refer to Section 303-03.
28. Fill the crankcase with clean engine oil.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Valve Train Components — Exploded View ..................................................................................................................... 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Valve Train Components — Exploded View

NOTE:
LH shown, RH similar.

Item Part Number Description

1 N807834 Camshaft bearing cap bolt (10 required)
2 6B284 Camshaft front bearing cap
3 6B280 Camshaft bearing cap (4 required)
4 6C255 Camshaft
5 6529 Camshaft roller follower (12 required)
6 6518 Valve spring retainer key (24 required)
7 6514 Valve spring retainer (12 required)
8 6513 Valve spring (12 required)
9 6A517 Valve seal (12 required)
10 6C501 Hydraulic lash adjuster (12 required)
11 6279 Camshaft phaser and sprocket bolt
12 6C524 Camshaft phaser and sprocket

1. For additional information, refer to the procedures in this section.

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Camshaft — LH ................................................................................................................................................................. 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Camshaft — LH
Special Tool(s)

Compressor, Valve Spring

303-1039

Locking Tool, Timing Chain

303-1175

Material
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal

NOTICE:
The camshaft procedure must be followed exactly or damage to the valves and pistons will result.

1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.

2. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
3. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and
sprocket.

Loosen and back off the LH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the LH Camshaft Position (CMP) sensor electrical connector.
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

5. Remove the bolt and the LH CMP sensor.

6. NOTE:
If the camshaft lobes are not exactly positioned as shown, the crankshaft keyway will require one full additional rotation to 12 o'clock.

The No. 5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the
exhaust lobe on the No. 5 cylinder.

7. Remove only the 3 camshaft roller followers shown in the illustration.

303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

8. NOTICE:
The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these
instructions may result in engine damage.

NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the previous step.
303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

9. NOTICE:
The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.

Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark
indentation at the 7 o'clock position.

10. NOTICE:
Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result.

NOTE:
The Timing Chain Locking Tool must be installed square to the timing chain and the engine block.

NOTE:
Engine front cover removed for clarity.

Install the Timing Chain Locking Tool in the LH timing chain as shown.
303-01A-6 Engine — 5.4L (3V) 303-01A-6
IN-VEHICLE REPAIR (Continued)

11. NOTICE:
Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of
placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive
Components in this section.

NOTICE:
The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to
valves and pistons will result.

NOTE:
RH shown, LH similar.

Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.

12. NOTICE:
Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side
loading.

Remove the 2 bolts and the camshaft front bearing cap.

303-01A-7 Engine — 5.4L (3V) 303-01A-7
IN-VEHICLE REPAIR (Continued)

13. NOTICE:
The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.

Remove the remaining 8 bolts in the sequence shown and remove the camshaft bearing caps.

14. Clean and inspect the LH camshaft bearing caps.

• The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
303-01A-8 Engine — 5.4L (3V) 303-01A-8
IN-VEHICLE REPAIR (Continued)

15. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket.

NOTICE:
Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of
placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive
Components in this section.

Remove the bolt and the camshaft phaser and sprocket assembly from the camshaft.
• Discard the bolt and washer.

16. Remove the camshaft.

17. Remove and inspect the camshaft phaser and sprocket for damage. For additional information, refer to Section 303-00.

Installation
1. NOTE:
Do not allow the camshaft roller followers to move out of position when installing the camshaft.

Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
2. NOTICE:
Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of
placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive
Components in this section.

NOTICE:
The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to
valves and pistons will result.

NOTE:
If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to the new camshaft phaser and sprocket.

Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in alignment.

3. NOTICE:
303-01A-9 Engine — 5.4L (3V) 303-01A-9
IN-VEHICLE REPAIR (Continued)

Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of
placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive
Components in this section.

NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to install the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket.

Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft phaser and sprocket bolt finger-tight.

4. NOTE:
Do not allow the camshaft roller followers to move out of position when installing the camshaft.

Install the 5 camshaft bearing caps in their original locations.

• Lubricate the camshaft bearing caps with clean engine oil.
• Position the front camshaft bearing cap.
• Position the remaining camshaft bearing caps.
• Install the 10 bolts loosely.
5. Tighten the 10 bolts in the sequence shown.
• Tighten to 10 Nm (89 lb-in).
303-01A-10 Engine — 5.4L (3V) 303-01A-10
IN-VEHICLE REPAIR (Continued)

6. NOTE:
Engine front cover removed for clarity.

Remove the Timing Chain Locking Tool.

7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark
indentation at the 1 o'clock position.
303-01A-11 Engine — 5.4L (3V) 303-01A-11
IN-VEHICLE REPAIR (Continued)

8. Verify correct camshaft position by noting the position of the No. 5 cylinder intake and exhaust camshaft lobes.

9. NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers.
303-01A-12 Engine — 5.4L (3V) 303-01A-12
IN-VEHICLE REPAIR (Continued)

10. Install the CMP sensor and the bolt.

• Tighten to 10 Nm (89 lb-in).

11. Connect the CMP electrical connector.

12. NOTICE:
Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and
sprocket.
303-01A-13 Engine — 5.4L (3V) 303-01A-13
IN-VEHICLE REPAIR (Continued)

NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

Tighten the camshaft phaser and sprocket bolt in 2 stages:

• Stage 1: Tighten to 40 Nm (30 lb-ft).
• Stage 2: Tighten an additional 90 degrees.

13. Install the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Timing Drive Components ................................................................................................................................................ 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Timing Drive Components
Special Tool(s)

Compressor, Valve Spring

303-1039

Holding Tool, Crankshaft

303-448 (T93P-6303-A)

Locking Tool, Cam Phaser

303-1046

General Equipment
Hydraulic Chain Tensioner Retaining Clip 1L3Z-6P250-AA

Material
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal
1. Remove the engine front cover. For additional information, refer to Engine Front Cover in this section.
2. Remove the crankshaft sensor ring from the crankshaft.

3. Position the crankshaft keyway at the 12 o'clock position.

303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

4. NOTE:
If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.

The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and
the exhaust lobe on the No. 1 cylinder.

5. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original
locations. Failure to follow these instructions may result in engine damage.

Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.
303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

6. NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

Using the Valve Spring Compressor, remove the 3 designated camshaft roller followers in the previous step from the RH cylinder head.

7. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original
locations. Failure to follow these instructions may result in engine damage.

Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head.
303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

8. NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

Using the Valve Spring Compressor, remove the 3 designated camshaft roller followers in the previous step from the LH cylinder head.
303-01A-6 Engine — 5.4L (3V) 303-01A-6
IN-VEHICLE REPAIR (Continued)

9. NOTICE:
The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.

Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.

10. NOTICE:
If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks,
tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage
may occur.

Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
303-01A-7 Engine — 5.4L (3V) 303-01A-7
IN-VEHICLE REPAIR (Continued)

11. NOTICE:
If one or both tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks,
tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage
may occur.

Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.

12. Remove the RH and LH timing chains and the crankshaft sprocket.
• Remove the RH timing chain from the camshaft sprocket.
• Remove the RH timing chain from the crankshaft sprocket.
• Remove the LH timing chain from the camshaft sprocket.
• Remove the LH timing chain and crankshaft sprocket.
303-01A-8 Engine — 5.4L (3V) 303-01A-8
IN-VEHICLE REPAIR (Continued)

13. NOTE:
RH shown, LH similar.

Remove the LH and RH timing chain guides.

• Remove the 4 bolts.
• Remove both timing chain guides.

14. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and
sprocket.

Using the Cam Phaser Locking Tool, remove the bolt and the RH camshaft phaser and sprocket assembly.
• Discard the camshaft phaser and sprocket bolt.
303-01A-9 Engine — 5.4L (3V) 303-01A-9
IN-VEHICLE REPAIR (Continued)

15. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and
sprocket.

Using the Cam Phaser Locking Tool, remove the bolt and the LH camshaft phaser and sprocket assembly.
• Discard the camshaft phaser and sprocket bolt.

16. NOTICE:
Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side
loading.

Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.

17. NOTICE:
The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.

Remove the remaining 8 bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.
303-01A-10 Engine — 5.4L (3V) 303-01A-10
IN-VEHICLE REPAIR (Continued)

18. Clean and inspect the RH camshaft bearing caps.

• The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.

19. Remove the RH camshaft.

20. NOTICE:
Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side
loading.

Remove the 2 bolts and the LH cylinder camshaft front bearing cap.
303-01A-11 Engine — 5.4L (3V) 303-01A-11
IN-VEHICLE REPAIR (Continued)

21. NOTICE:
The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.

Remove the remaining 8 bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps.

22. Clean and inspect the LH camshaft bearing caps.

• The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
303-01A-12 Engine — 5.4L (3V) 303-01A-12
IN-VEHICLE REPAIR (Continued)

23. Remove the LH camshaft.

24. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

Remove all of the remaining camshaft roller followers from the cylinder heads.

Installation
1. Install the LH and RH camshafts.
• Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
2. NOTE:
LH shown, RH similar.

Install the 5 LH and 5 RH camshaft bearing caps in their original locations.

• Lubricate the camshaft bearing caps with clean engine oil.
• Position the front camshaft bearing cap.
• Position the remaining camshaft bearing caps.
• Install the 20 bolts loosely.
• Tighten to 10 Nm (89 lb-in) in the sequence shown.

3. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE:
LH shown, RH similar.

Position the camshaft phaser and sprockets and install 2 new camshaft phaser and sprocket bolts finger-tight.
303-01A-13 Engine — 5.4L (3V) 303-01A-13
IN-VEHICLE REPAIR (Continued)

4. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and
sprocket.

NOTE:
LH shown, RH similar.

Using the Cam Phaser Locking Tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2 stages.
• Stage 1: Tighten to 40 Nm (30 lb-ft).
• Stage 2: Tighten an additional 90 degrees.

5. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.

6. NOTICE:
Timing chain procedures must be followed exactly or damage to valves and pistons will result.

NOTICE:
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 or engine damage may occur.

Compress the tensioner plunger, using a vise.

303-01A-14 Engine — 5.4L (3V) 303-01A-14
IN-VEHICLE REPAIR (Continued)

7. Install a retaining clip on the tensioner to hold the plunger in during installation.

8. Remove the tensioner from the vise.

9. 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.

10. Install the crankshaft sprocket, making sure the flange faces forward.

11. Position the LH and RH timing chain guides and install the 4 bolts.
• Tighten to 10 Nm (89 lb-in).
303-01A-15 Engine — 5.4L (3V) 303-01A-15
IN-VEHICLE REPAIR (Continued)

12. 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.

13. NOTE:
Make sure the upper half of the timing chain is below the tensioner arm dowel.

Position the timing chain on the camshaft phaser and sprocket with the timing mark positioned between the 2 copper (marked) chain links.

14. NOTE:
303-01A-16 Engine — 5.4L (3V) 303-01A-16
IN-VEHICLE REPAIR (Continued)

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 and the 2 bolts.
• Tighten to 25 Nm (18 lb-ft).

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

16. 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.

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

NOTE:
The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.

Position the RH timing chain on the camshaft phaser and sprocket. Make sure the timing mark is positioned between the 2 copper (marked) chain
links.
303-01A-17 Engine — 5.4L (3V) 303-01A-17
IN-VEHICLE REPAIR (Continued)

18. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts.
• Tighten to 25 Nm (18 lb-ft).

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

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

303-01A-18 Engine — 5.4L (3V) 303-01A-18
IN-VEHICLE REPAIR (Continued)

21. Install the crankshaft sensor ring on the crankshaft.

22. NOTICE:
If the components are to be reinstalled, they must be installed into their original locations. Failure to follow these instructions may result in
engine damage.

NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

Using the Valve Spring Compressor, install all of the camshaft roller followers.
• Lubricate the camshaft roller followers with clean engine oil prior to installation.
303-01A-19 Engine — 5.4L (3V) 303-01A-19
IN-VEHICLE REPAIR (Continued)

23. Install the engine front cover. For additional information, refer to Engine Front Cover in this section.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Camshaft — RH ................................................................................................................................................................ 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Camshaft — RH
Special Tool(s)

Compressor, Valve Spring

303-1039

Locking Tool, Timing Chain

303-1175

Material
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal

NOTICE:
The camshaft procedure must be followed exactly or damage to the valves and pistons will result.

1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.

2. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
3. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and
sprocket.

Loosen and backoff the RH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

5. Remove the bolt and the RH CMP sensor.

6. NOTE:
If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.

The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and
the exhaust lobe on the No. 1 cylinder.

7. Remove only the 3 camshaft roller followers shown in the illustration.

303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

8. NOTICE:
The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these
instructions may result in engine damage.

NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the previous step.

9. NOTICE:
The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.

Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark
indentation at the 7 o'clock position.
303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

10. NOTICE:
Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result.

NOTE:
The Timing Chain Locking Tool must be installed square to the timing chain and the engine block.

NOTE:
Engine front cover removed for clarity.

Install the Timing Chain Locking Tool in the RH timing chain as shown.

11. NOTICE:
Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of
placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive
Components in this section.

NOTICE:
The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to
valves and pistons will result.

Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
303-01A-6 Engine — 5.4L (3V) 303-01A-6
IN-VEHICLE REPAIR (Continued)

12. NOTICE:
Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side
loading.

Remove the 2 bolts and the camshaft front bearing cap.

13. NOTICE:
The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.

Remove the remaining 8 bolts in the sequence shown and remove the camshaft bearing caps.
303-01A-7 Engine — 5.4L (3V) 303-01A-7
IN-VEHICLE REPAIR (Continued)

14. Clean and inspect the RH camshaft bearing caps.

• The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.

15. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket.

NOTICE:
Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of
placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive
Components in this section.

Remove the bolt and the camshaft phaser and sprocket assembly from the camshaft.
• Discard the bolt and washer.
303-01A-8 Engine — 5.4L (3V) 303-01A-8
IN-VEHICLE REPAIR (Continued)

16. Remove the camshaft.

17. Remove and inspect the camshaft phaser and sprocket for damage. For additional information, refer to Section 303-00.

Installation
1. NOTE:
Do not allow the camshaft roller followers to move out of position when installing the camshaft.

Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
2. NOTICE:
Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of
placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive
Components in this section.

NOTICE:
The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to
valves and pistons will result.

NOTE:
If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to the new camshaft phaser and sprocket.

Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in alignment.

3. NOTICE:
Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of
placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive
Components in this section.

NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to install the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket.

Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft phaser and sprocket bolt finger-tight.
303-01A-9 Engine — 5.4L (3V) 303-01A-9
IN-VEHICLE REPAIR (Continued)

4. NOTE:
Do not allow the camshaft roller followers to move out of position when installing the camshaft.

Install the 5 camshaft bearing caps in their original locations.

• Lubricate the camshaft bearing caps with clean engine oil.
• Position the front camshaft bearing cap.
• Position the remaining camshaft bearing caps.
• Install the 10 bolts loosely.
5. Tighten the 10 bolts in the sequence shown.
• Tighten to 10 Nm (89 lb-in).

6. NOTE:
Engine front cover removed for clarity.

Remove the Timing Chain Locking Tool.

303-01A-10 Engine — 5.4L (3V) 303-01A-10
IN-VEHICLE REPAIR (Continued)

7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark
indentation at the 1 o'clock position.

8. Verify correct camshaft position by noting the position of the No. 1 cylinder intake and exhaust camshaft lobes.

9. NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

NOTE:
303-01A-11 Engine — 5.4L (3V) 303-01A-11
IN-VEHICLE REPAIR (Continued)

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

Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers.

10. Install the CMP sensor and the bolt.

• Tighten to 10 Nm (89 lb-in).

11. Connect the CMP electrical connector.

12. NOTICE:
Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and
sprocket.

NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

Tighten the new camshaft phaser and sprocket bolt in 2 stages:

• Stage 1: Tighten to 40 Nm (30 lb-ft).
• Stage 2: Tighten an additional 90 degrees.
303-01A-12 Engine — 5.4L (3V) 303-01A-12
IN-VEHICLE REPAIR (Continued)

13. Install the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Camshaft Phaser and Sprocket ....................................................................................................................................... 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Camshaft Phaser and Sprocket
Special Tool(s)

Locking Tool, Timing Chain

303-1175

Removal
1. If servicing the RH camshaft phaser and sprocket, remove the RH camshaft. For additional information, refer to Camshaft — RH in this section.
2. If servicing the LH camshaft phaser and sprocket, remove the LH camshaft. For additional information, refer to Camshaft — LH in this section.
3. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE:
Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the
engine front cover must be removed and the engine must be retimed. For additional information, refer to Timing Drive Components in this section.

Remove the camshaft phaser and sprocket from the timing chain.
4. Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.
• If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.

5. Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.
• If the location pin is deformed or damaged, a new camshaft phaser and sprocket must be installed.

6. Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or spring is deformed or damaged (B), install a new
camshaft phaser and sprocket.
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

Installation
1. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new camshaft phaser and sprocket.
2. NOTICE:
The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to
valves and pistons will result.

NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.

3. If servicing the RH camshaft phaser and sprocket, install the RH camshaft. For additional information, refer to Camshaft — RH in this section.
4. If servicing the LH camshaft phaser and sprocket, install the LH camshaft. For additional information, refer to Camshaft — LH in this section.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Variable Camshaft Timing (VCT) Housing ....................................................................................................................... 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Variable Camshaft Timing (VCT) Housing

Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A

Removal
All Variable Camshaft Timing (VCT) housings
1. Remove the timing drive components. For additional information, refer to Timing Drive Components in this section.
RH VCT housing
2. Remove the 2 bolts and the RH Variable Camshaft Timing (VCT) housing.

LH VCT housing
3. Remove the 2 bolts and the LH VCT housing.

All VCT housings

4. Remove and discard the VCT housing gasket.

5. NOTICE:
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

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.

Clean and inspect the cylinder head sealing surfaces with metal surface prep. Follow the directions on the packaging.
6. Clean and inspect the VCT housing. For additional information, refer to Section 303-00.

Installation
All VCT housing
1. Install a new gasket onto the VCT housing.

RH VCT housing
2. Position the RH VCT housing and install the 2 bolts.
• Tighten to 10 Nm (89 lb-in).

LH VCT housing
3. Position the LH VCT housing and install the 2 bolts.
• Tighten to 10 Nm (89 lb-in).

All VCT housings

4. Install the timing drive components. For additional information, refer to Timing Drive Components in this section.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Camshaft Roller Follower ................................................................................................................................................. 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Camshaft Roller Follower
Special Tool(s)

Compressor, Valve Spring

303-1039

Material
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal
LH cylinder head camshaft roller followers
1. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
RH cylinder head camshaft roller followers
2. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
All camshaft roller followers
3. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed.
4. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller follower.

5. Repeat the previous 2 steps for each camshaft roller follower being serviced.
6. Inspect the camshaft roller follower. For additional information, refer to Section 303-00.

Installation
All camshaft roller followers
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

1. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine
damage.

NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

NOTE:
Lubricate the camshaft roller followers with clean engine oil prior to installation.

Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller follower.

2. Repeat the previous step for each camshaft roller follower being serviced.
LH cylinder head camshaft roller followers
3. Install the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
RH cylinder head camshaft roller followers
4. Install the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Valve Springs ................................................................................................................................................................... 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Valve Springs
Special Tool(s)

Compressor, Valve Spring

303-1039

Material
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal
RH cylinder head valve springs
1. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
LH cylinder head valve springs
2. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
All valve springs
3. Remove the spark plug for the cylinder being serviced. For additional information, refer to Section 303-07A.
4. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed.
5. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller follower.

6. Use compressed air in the cylinder being serviced to hold both valves in position.
• Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
7. NOTICE:
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

NOTE:
If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure
must be removed, support the valve prior to removal. If a valve drops into the cylinder, remove the cylinder head. For additional information, refer to
Cylinder Head in this section.

Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer keys.

8. Remove the valve spring retainer and the valve spring.

9. Inspect the valve spring. For additional information, refer to Section 303-00.

Installation
All valve springs
1. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine
damage.

Using the Valve Spring Compressor, install the valve spring, the valve spring retainer and the valve spring retainer keys.

2. Relieve the air pressure from the cylinder.

3. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine
damage.

NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

NOTE:
Lubricate the camshaft roller followers with clean engine oil prior to installation.

Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller follower.
303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

4. Install the spark plug. For additional information, refer to Section 303-07A.
LH cylinder head valve springs
5. Install the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
RH cylinder head valve springs
6. Install the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Valve Seals ...................................................................................................................................................................... 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Valve Seals
Special Tool(s)

Compressor, Valve Spring

303-1039

Installer, Valve Stem Oil Seal

303-383 (T91P-6571-A)

Material
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal
RH cylinder head valve seals
1. Remove the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
LH cylinder head valve seals
2. Remove the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
All valve seals
3. Remove the spark plug for the cylinder being serviced. For additional information, refer to Section 303-07A.
4. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed.
5. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller follower.
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

6. Use compressed air in the cylinder being serviced to hold the valves in position.
• Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
7. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

NOTE:
If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure
must be removed, support the valve prior to removal. If a valve drops into the cylinder, remove the cylinder head. For additional information, refer to
Cylinder Head in this section.

Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer keys.

8. Remove the valve spring retainer, the valve spring and the valve seal.
• Discard the valve seal.
9. Inspect the components. For additional information, refer to Section 303-00.

Installation
All valve seals
1. NOTE:
Lubricate the valve seal and valve stem with clean engine oil prior to installation.

Position a new valve seal onto the valve stem.

2. Using the Valve Stem Oil Seal Installer, install the new valve seal.
303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

3. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine
damage.

Using the Valve Spring Compressor, install the valve spring, the valve spring retainer and the valve spring retainer keys.

4. Relieve the air pressure from the cylinder.

5. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine
damage.

NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head
must be removed. For additional information, refer to Cylinder Head in this section.

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

NOTE:
Lubricate the camshaft roller followers with clean engine oil prior to installation.

Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller follower.

6. Install the spark plug. For additional information, refer to Section 303-07A.
303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

LH cylinder head valve seals

7. Install the LH valve cover. For additional information, refer to Valve Cover — LH in this section.
RH cylinder head valve seals
8. Install the RH valve cover. For additional information, refer to Valve Cover — RH in this section.
303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Hydraulic Lash Adjuster ................................................................................................................................................... 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Hydraulic Lash Adjuster

Material
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal and Installation

1. Remove the camshafts. For additional information, refer to Camshaft — LH or Camshaft — RH in this section.
2. Remove the remaining roller followers from the cylinder head being serviced.
3. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

Remove the hydraulic lash adjusters that are being serviced.

4. Inspect the hydraulic lash adjusters. For additional information, refer to Section 303-00.
5. NOTE:
Lubricate each of the hydraulic lash adjusters with clean engine oil prior to installation.

To install, reverse the removal procedure.

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Exhaust Manifold — LH ..................................................................................................................................................... 303-01A-2
303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Exhaust Manifold — LH

Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A

RH and LH Exhaust Y-Pipe Flange Nuts

Item Part Number Description

1 W705443 RH exhaust Y-pipe flange nut (2 required)
2 5F250 RH exhaust Y-pipe flange
3 W705443 LH exhaust Y-pipe flange nut (2 required)
4 5F250 LH exhaust Y-pipe flange
303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

LH Exhaust Manifold Nuts, Studs, Heat Shield, Exhaust Manifold and Gaskets

Item Part Number Description

1 W714133 Exhaust manifold heat shield bolt (3 required)
2 9Y427 Exhaust manifold heat shield
3 W701706 Exhaust manifold nut (8 required)
4 W707747 Exhaust manifold-to-cylinder head stud (8 required)
5 9431 Exhaust manifold
6 9Y431 Exhaust manifold gaskets (2 required)

Removal
1. Remove the LH fender splash shield. For additional information, refer to Section 501-02.
2. Remove the degas bottle assembly. For additional information, refer to Section 303-03.
3. Remove the 4 exhaust Y-pipe flange nuts.
4. Remove the 3 bolts and the exhaust manifold heat shield.
5. Remove the 8 nuts, 8 exhaust manifold-to-cylinder head studs and the exhaust manifold.
303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

• Discard the 8 nuts and the 8 studs.

6. NOTICE:
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause
scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Remove and discard the exhaust manifold gaskets.

• Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
7. Inspect the exhaust manifold. For additional information, refer to Section 303-00.

Installation
1. Install 8 new exhaust manifold-to-cylinder head studs.
• Tighten to 12 Nm (106 lb-in).
2. Using new exhaust manifold gaskets, position the 2 gaskets and the exhaust manifold and install 8 new exhaust manifold nuts.
• Tighten to 25 Nm (18 lb-ft) in the sequence shown.

3. Position the exhaust manifold heat shield and install the 3 bolts.
• Tighten to 14 Nm (124 lb-in).
4. Install the 4 exhaust Y-pipe flange nuts.
• Tighten to 40 Nm (30 lb-ft).
5. Install the degas bottle assembly. For additional information, refer to Section 303-03.
6. Install the LH fender splash shield. For additional information, refer to Section 501-02.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Exhaust Manifold — RH .................................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Exhaust Manifold — RH

Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A

RH and LH Exhaust Y-Pipe Flange Nuts

Item Part Number Description

1 W705443 RH exhaust Y-pipe flange nut (2 required)
2 5F250 RH exhaust Y-pipe flange
3 W705443 LH exhaust Y-pipe flange nut (2 required)
4 5F250 LH exhaust Y-pipe flange

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

RH Exhaust Manifold Nuts, Studs, Exhaust Manifold and Gaskets

Item Part Number Description

1 W701706 Exhaust manifold nut (8 required)
2 W701706 Exhaust manifold-to-cylinder head stud (8 required)
3 9430 Exhaust manifold
4 9Y431 Exhaust manifold gasket (2 required)

Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Remove the RH engine support insulator. For additional information, refer to Engine Support Insulators in this section.
3. Remove the RH inner fenderwell. For additional information, refer to Section 501-02.
4. Remove the 4 exhaust Y-pipe flange nuts.
5. Remove the 8 nuts, 8 exhaust manifold-to-cylinder head studs and the exhaust manifold.
• Discard the 8 nuts and the 8 studs.
6. NOTICE:

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause
scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces.

Remove and discard the exhaust manifold gaskets.

• Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging.
7. Inspect the exhaust manifold. For additional information, refer to Section 303-00.

Installation
1. Install 8 new exhaust manifold-to-cylinder head studs.
• Tighten to 12 Nm (106 lb-in).
2. Using new exhaust manifold gaskets, position the gaskets and the exhaust manifold and install 8 new exhaust manifold nuts.
• Tighten to 25 Nm (18 lb-ft) in the sequence shown.

3. Install the RH inner fenderwell. For additional information, refer to Section 501-02.
4. Install the RH engine support insulator. For additional information, refer to Engine Support Insulators in this section.
5. Install the 4 exhaust Y-pipe flange nuts.
• Tighten to 40 Nm (30 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Engine Lubrication Components — Exploded View .......................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Engine Lubrication Components — Exploded View

Item Part Number Description

1 6758 Crankcase ventilation tube
2 — Vacuum hose (part of 9D446)
3 — Engine wiring harness retainer (part of 12B637)
4 W713555 Air Cleaner (ACL) outlet pipe-to-Throttle Body (TB) adapter bolt (4
required)
5 9A589 ACL outlet pipe-to-TB adapter
6 9B694 ACL outlet pipe-to-TB adapter seal (part of 9A589)

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

Item Part Number Description

7 W701605 Oil pan bolt (16 required)
8 6675 Oil pan
9 6710 Oil pan gasket
10 N605904 Oil pump screen and pickup tube-to-spacer bolt
11 N806155 Oil pump screen and pickup tube-to-oil pump bolts (2 required)
12 6622 Oil pump screen and pickup tube
13 N806180 Oil pump screen and pickup tube spacer
14 N806183 Oil pump bolt (3 required)
15 6621 Oil pump

1. For additional information, refer to the procedures in this section.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Oil Pan .............................................................................................................................................................................. 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Oil Pan
Special Tool(s)

Engine Support Bar, Heavy Duty

303-F070

Support Hook
303-F071

Engine Support Bracket

303-639

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil WSS-M2C930-A
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil
CXO-5W20-LSP12 (Canada); or equivalent
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Silicone Gasket Remover —
ZC-30

Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Remove the generator. For additional information, refer to Section 414-02.
3. Remove the engine cooling fan. For additional information, refer to Section 303-03.
4. Disconnect the crankcase vent tube quick connect coupling from the air cleaner outlet pipe-to-throttle body (TB) adapter. For additional information,
refer to Section 310-00.
5. Disconnect the vacuum hose from the air cleaner outlet pipe-to-TB adapter.
6. Disconnect the wiring harness retainer from the air cleaner outlet pipe-to-TB adapter.
7. Remove the 4 air cleaner outlet pipe-to-TB adapter bolts.
8. Remove the air cleaner outlet pipe-to-TB adapter.
9. Install the special tools.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

10. Drain the engine oil.

11. Remove and discard the engine oil filter.

12. NOTICE:
If metal foreign material is present in the oil cooler, mechanical concerns exist. To diagnose mechanical concerns, refer to Section 303-00.

Remove the threaded shaft and position the oil cooler aside. Inspect the engine oil cooler.

13. Press the position retaining tabs and rotate the lower cooling fan shroud upward until the position retainer tab locks into position.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

14. Remove the nut, the transmission auxiliary fluid cooler tube support bracket and the starter wiring harness support bracket from the engine front cover
stud bolt.

15. NOTE:
LH shown, RH similar.

Remove and discard the 7 engine support insulator-to-crossmember nuts.

16. Using the special tools, raise the engine assembly.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

Automatic transmission equipped vehicles

17. For early build vehicles, remove the transmission auxiliary fluid cooler assembly support bracket bolts.

18. For late build vehicles, remove the 2 bolts and the flexplate inspection cover.

All vehicles
19. Remove 16 oil pan bolts and position the oil pan onto the crossmember.
20. Remove the 3 bolts and position the oil pump screen and pickup tube into the oil pan.
Automatic transmission equipped vehicles
21. Remove the oil pan.
Manual transmission equipped vehicles
22. Position the oil pan onto the engine and install one bolt at the front and one bolt at the rear of the oil pan to hold it in position.
23. Using the special tools, align the engine support insulator studs and lower the engine.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-6 Engine — 5.4L (3V) 303-01A-6
IN-VEHICLE REPAIR (Continued)

24. Remove the flywheel. For additional information, refer to Flywheel in this section.
25. Remove the rear engine cover.
26. Remove the 2 bolts, the oil pan and the oil pump screen and pickup tube.
• Inspect the oil pan gasket for damage.
• Discard the oil pan gasket.
• Discard the oil pump screen and pickup tube O-ring seal.

Installation
All vehicles
1. NOTICE:
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. Failure to follow this procedure
may cause future oil leakage.

Inspect the oil pan. Clean the mating surface for the oil pan with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions
on the packaging.
2. Install a new O-ring seal onto the oil pump screen and pickup tube.
3. Position the oil pump screen and pickup tube in the oil pan and position the oil pan and new gasket into the vehicle.
Manual transmission equipped vehicles
4. Install the rear engine cover.
5. Install the flywheel. For additional information, refer to Flywheel in this section.
6. Using the special tools, raise the engine.

All vehicles
7. NOTICE:
Make sure to install a new O-ring seal. A missing or damaged O-ring seal can cause foam in the lubrication system and low oil pressure.
Failure to follow this instruction may result in engine damage.

NOTE:
Clean and inspect the mating surfaces and install a new O-ring seal. Lubricate the O-ring seal with clean engine oil prior to installation.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-7 Engine — 5.4L (3V) 303-01A-7
IN-VEHICLE REPAIR (Continued)

Position the oil pump screen and pickup tube and install the bolts.
• Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in).
• Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).
8. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.

Apply Silicone Gasket and Sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.

9. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.

Apply Silicone Gasket and Sealant at the engine front cover-to-cylinder block sealing surface.

10. Position the oil pan gasket and the oil pan and loosely install the 16 bolts.
11. Tighten the bolts in 3 stages, in the sequence shown.
• Stage 1: Tighten to 2 Nm (18 lb-in).
• Stage 2: Tighten to 20 Nm (15 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-8 Engine — 5.4L (3V) 303-01A-8
IN-VEHICLE REPAIR (Continued)

• Stage 3: Tighten an additional 60 degrees.

Automatic transmission equipped vehicles

12. For late build vehicles, position the flexplate inspection cover and install the 2 bolts.
• Tighten to 34 Nm (25 lb-ft).

13. For early build vehicles, install the 2 transmission auxiliary fluid cooler assembly support bracket bolts.
• Tighten to 35 Nm (26 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-9 Engine — 5.4L (3V) 303-01A-9
IN-VEHICLE REPAIR (Continued)

All vehicles
14. Using the special tools, align the engine support insulator studs and lower the engine.

15. NOTICE:
Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

Install 4 new RH engine support insulator nuts.

• Tighten to 115 Nm (85 lb-ft).

16. NOTICE:
Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

Install 3 new LH engine support insulator nuts.

• Tighten to 200 Nm (148 lb-ft).

17. Position the transmission auxiliary fluid cooler tube support bracket and the starter wiring harness support bracket onto the engine front cover stud
bolt and install the nut.
• Tighten to 25 Nm (18 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-10 Engine — 5.4L (3V) 303-01A-10
IN-VEHICLE REPAIR (Continued)

18. Press the position retaining tab and rotate the lower cooling fan downward until the position retainer tab locks into position.
19. Position the oil cooler and install the threaded shaft.
• Tighten to 58 Nm (43 lb-ft).

20. Install a new engine oil filter.

• Tighten to 16 Nm (142 lb-in).

21. Install the air cleaner outlet pipe-to-TB adapter.

22. Install the 4 air cleaner outlet pipe-to-TB adapter bolts.
• Tighten to 10 Nm (89 lb-in).
23. Connect the wiring harness retainer to the air cleaner outlet pipe-to-TB adapter.
24. Connect the vacuum hose to the air cleaner outlet pipe-to-TB adapter.
25. Connect the crankcase vent tube quick connect coupling to the air cleaner outlet pipe-to-TB adapter. For additional information, refer to Section
310-00.
26. Install the engine cooling fan. For additional information, refer to Section 303-03.
27. Install the generator. For additional information, refer to Section 414-02.
28. Fill the crankcase with clean engine oil.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Oil Pump ........................................................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Oil Pump

Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal
1. Remove the timing drive components. For additional information, refer to Timing Drive Components in this section.
2. Remove the oil pan. For additional information, refer to Oil Pan in this section.
3. Remove the 3 bolts and the oil pump.

Installation
1. NOTICE:
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.

Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.
2. Position the oil pump and install the 3 bolts.
• Tighten to 10 Nm (89 lb-in).

3. Install the oil pan. For additional information, refer to Oil Pan in this section.
4. Install the timing drive components. For additional information, refer to Timing Drive Components in this section.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Oil Pump Screen and Pickup Tube .................................................................................................................................. 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Oil Pump Screen and Pickup Tube
Removal and Installation
1. Remove the oil pan. For additional information, refer to Oil Pan in this section.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Oil Cooler ......................................................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Oil Cooler

Material
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Item Part Number Description

1 6714 Oil filter
2 — Oil cooler coolant hoses
3 — Oil cooler coolant hose clamps
4 62626 Oil cooler threaded shaft
5 6A642 Oil cooler

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Drain the engine cooling system. For additional information, refer to Section 303-03.
3. Remove and discard the oil filter.
• To install, tighten to 16 Nm (142 lb-in).
4. Disconnect the oil cooler coolant hoses and position aside.
5. NOTICE:
If metal foreign material is present in the oil cooler, mechanical concerns exist. To diagnose mechanical concerns, refer to Section 303-00.

Remove the threaded shaft and the oil cooler. Inspect the engine oil cooler.
• To install, tighten to 58 Nm (43 lb-ft).
6. To install, reverse the removal procedure.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Oil Filter Adapter .............................................................................................................................................................. 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Oil Filter Adapter

Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A
Motorcraft® Silicone Gasket Remover —
ZC-30

Lower Radiator Hose, Degas Bottle Coolant Hose, Engine Oil Pressure (EOP) Switch Electrical Connector and Power Steering Pump

Item Part Number Description

1 8B273 Lower radiator hose
2 15161 Lower radiator hose clamp
3 12B637 Degas bottle coolant hose clamp
4 8B273 Degas bottle coolant hose

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

Item Part Number Description

5 — Engine Oil Pressure (EOP) switch electrical connector (part of
12B637)
6 3A696 Power steering pump
7 W500315 Power steering pump bolts (2 required)
8 W701526 Power steering pump bolt

Oil Filter Adapter and Gasket

Item Part Number Description

1 N806156 Oil filter adapter bolt (4 required)
2 N620482 Oil filter adapter nut
3 6884 Oil filter adapter
4 6A636 Oil filter adapter gasket
5 W712913 Oil filter adapter stud

Removal and Installation

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Remove the LH engine mount. For additional information, refer to Engine Support Insulators in this section.
3. Remove the 3 bolts and position the power steering pump assembly aside.
• To install, tighten to 25 Nm (18 lb-ft).
4. Disconnect the lower radiator hose from the oil filter adapter and position it aside.
5. Disconnect the degas bottle hose from the oil filter adapter and position it aside.
6. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
7. Remove the EOP switch.
• To install, tighten to 18 Nm (159 lb-in).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

8. Remove the oil filter adapter nut.

• To install, tighten to 48 Nm (35 lb-ft).
9. Remove the 4 bolts and the oil filter adapter.
• To install, tighten to 25 Nm (18 lb-ft).
10. NOTICE:
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. Failure to follow this procedure
may cause future oil leakage.

Remove and discard the oil filter adapter gasket. Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions
on the packaging. Inspect the mating surfaces.
11. To install, reverse the removal procedure.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Engine Oil Pressure (EOP) Switch ................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Engine Oil Pressure (EOP) Switch

Item Part Number Description

1 — Engine Oil Pressure (EOP) switch electrical connector (part of
12C508)
2 9278 EOP switch

Removal
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
3. Remove the EOP switch.

Installation
1. Install the EOP switch and tighten in 2 stages.
• Stage 1: Tighten to 14 Nm (125 lb-in).
• Stage 2: Tighten an additional 180 degrees.
2. Connect the EOP switch electrical connector.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Oil Level Indicator and Tube ............................................................................................................................................ 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Oil Level Indicator and Tube

Material
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Item Part Number Description

1 W500224 Oil level indicator and tube bolt
2 N605892 Rear oil level indicator and tube bolt
3 6K873 Oil level indicator and tube
4 — Oil level indicator tube O-ring seal

Removal and Installation

1. Remove the front oil level indicator and tube bolt.
• To install, tighten to 25 Nm (18 lb-ft).
2. Remove the rear oil level indicator and tube bolt.
• To install, tighten to 10 Nm (89 lb-in).
3. Remove the oil level indicator and tube from the cylinder block.
• Discard the O-ring seal.
4. NOTE:
Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to installation.

To install, reverse the removal procedure.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Flexplate or Flywheel and Crankshaft Rear Seal — Exploded View ................................................................................. 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Flexplate or Flywheel and Crankshaft Rear Seal — Exploded View

Item Part Number Description

1 N806168 Flexplate bolt (automatic transmission) (8 required)
2 6375 Flexplate (automatic transmission)
3 N808139 Flywheel bolt (manual transmission) (8 required)
4 6375 Flywheel (manual transmission)
5 7120 Manual transmission input pilot bearing
6 6A373 Rear cover plate
7 6310 Crankshaft oil slinger
8 6701 Crankshaft rear seal
9 W701605 Oil pan bolts (2 required)
10 N806155 Crankshaft rear seal retainer plate bolt (6 required)
11 6K318 Crankshaft rear seal retainer plate

1. For additional information, refer to the procedures in this section.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Flexplate ........................................................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Flexplate
Removal and Installation
1. Remove the transmission. For additional information, refer to Section 307-01.
2. Remove the 8 bolts and the flexplate.
• To install, tighten to 80 Nm (59 lb-ft) in the sequence shown.

3. To install, reverse the removal procedure.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Flywheel ........................................................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Flywheel
Removal and Installation
1. Remove the clutch and pressure plate. For additional information, refer to Section 308-01.
2. Remove the 8 bolts and the flywheel.
• To install, tighten to 80 Nm (59 lb-ft) in the sequence shown.

3. To install, reverse the removal procedure.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Crankshaft Rear Seal ....................................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Crankshaft Rear Seal
Special Tool(s)

Installer, Crankshaft Rear Oil Seal

303-516 (T95P-6701-BH)

Installer, Crankshaft Rear Oil Seal

303-518 (T95P-6701-DH)

Installer, Crankshaft Rear Oil Slinger

303-517 (T95P-6701-CH)

Remover, Crankshaft Rear Oil Seal

303-519 (T95P-6701-EH)

Remover, Crankshaft Rear Oil Slinger

303-514 (T95P-6701-AH)

Slide Hammer
100-001 (T50T-100-A)

Material
Item Specification

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

Material (Continued)
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Removal
1. Remove the flexplate or flywheel. For additional information, refer to Flexplate or Flywheel in this section.
2. Remove the engine rear cover plate.
3. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger.

4. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.

Installation
1. NOTE:
Lubricate the crankshaft rear seal with clean engine oil prior to installation.

Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.

2. NOTE:
Lubricate the crankshaft oil slinger with clean engine oil prior to installation.

Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install a new crankshaft oil slinger.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

3. Install the engine rear cover plate.

4. Install the flexplate or flywheel. For additional information, refer to Flexplate or Flywheel in this section.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Crankshaft Rear Seal with Retainer Plate ........................................................................................................................ 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Crankshaft Rear Seal with Retainer Plate
Special Tool(s)

Installer, Crankshaft Rear Oil Seal

303-516 (T95P-6701-BH)

Installer, Crankshaft Rear Oil Seal

303-518 (T95P-6701-DH)

Installer, Crankshaft Rear Oil Slinger

303-517 (T95P-6701-CH)

Remover, Crankshaft Rear Oil Seal

303-519 (T95P-6701-EH)

Remover, Crankshaft Rear Oil Slinger

303-514 (T95P-6701-AH)

Slide Hammer
100-001 (T50T-100-A)

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

Support Bar, Engine

303-F070

Support Bracket, Engine

303-639

Support Hook
303-F071

Material
Item Specification
Motorcraft® Metal Surface Prep —
ZC-31-A
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Motorcraft® Silicone Gasket Remover —
ZC-30

Removal
Manual transmission equipped vehicles
1. Remove the oil pan. For additional information, refer to Oil Pan in this section.
Automatic transmission equipped vehicles
2. Remove the oil pan. For additional information, refer to Oil Pan in this section.
3. Using the Engine Support Bar, Support Hook and Engine Support Bracket, align the engine support insulator studs and lower the engine.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

4. Remove the flexplate. For additional information, refer to Flexplate in this section.
5. Remove the rear engine cover.
All vehicles
6. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger.

7. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.

8. Remove the 6 bolts and the crankshaft rear seal retainer plate.

Installation
All vehicles
1. NOTICE:
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:
Clean the sealing surfaces with silicone gasket remover and motorcraft metal surface prep. Follow the directions on the packaging.

Clean and inspect the mating surface.

2. NOTE:
If the rear crankshaft seal retaining plate 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 may cause future oil leaks.

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

Apply a 4.06 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer plate sealing surface.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

3. Install the crankshaft rear seal retainer plate and the 6 bolts in the sequence shown.
• Tighten to 10 Nm (89 lb-in).

4. NOTE:
Lubricate the crankshaft rear seal with clean engine oil prior to installation.

Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.

5. NOTE:
Lubricate the crankshaft oil slinger with clean engine oil prior to installation.

Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install a new crankshaft oil slinger.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-6 Engine — 5.4L (3V) 303-01A-6
IN-VEHICLE REPAIR (Continued)

Automatic transmission equipped vehicles

6. Install the rear engine cover.
7. Install the flexplate. For additional information, refer to Flexplate in this section.
8. Using the Engine Support Bar, Support Hook and Engine Support Bracket, align the engine support insulator studs and raise the engine.

9. Install the oil pan. For additional information, refer to Oil Pan in this section.
Manual transmission equipped vehicles
10. Install the oil pan. For additional information, refer to Oil Pan in this section.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

IN-VEHICLE REPAIR
Engine Support Insulators ................................................................................................................................................ 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

IN-VEHICLE REPAIR
Engine Support Insulators
Special Tool(s)

Support Bar, Engine

303-F070

Support Bracket, Engine

303-639

Support Hook
303-F071

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
IN-VEHICLE REPAIR (Continued)

RH Engine Support Insulator

Item Part Number Description

1 W709771 RH engine support insulator nut (4 required)
2 W711959 RH engine support insulator through bolt
3 6038 RH engine support
4 W712861 RH engine support insulator bracket bolt (3 required)
5 6046 RH engine support insulator bracket
6 W790018 RH engine support insulator stud (2 required)

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
IN-VEHICLE REPAIR (Continued)

LH Engine Support Insulator

Item Part Number Description

1 W711336 LH engine support insulator nut (3 required)
2 W711959 LH engine support insulator through bolt
3 6B032 LH engine support
4 W712860 LH engine support insulator bracket bolt (3 required)
5 6B033 LH engine support insulator bracket

Removal
All vehicles
1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.
2. Disconnect the battery ground cable. For additional information, refer to Section 414-01.
3. Remove the ACL outlet pipe. For additional information, refer to Section 303-12.
4. Remove the Throttle Body (TB). For additional information, refer to Section 303-04A.
5. Remove the generator. For additional information, refer to Section 414-02.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-5 Engine — 5.4L (3V) 303-01A-5
IN-VEHICLE REPAIR (Continued)

6. Remove the engine cooling fan. For additional information, refer to Section 303-03.
7. Install the Engine Support Bar, Support Hook and Engine Support Bracket.

8. Remove the 4 exhaust Y-pipe nuts.

9. Remove and discard the 2 transmission mount-to-crossmember nuts.

RH engine support insulator

10. Remove the A/C compressor. For additional information, refer to Section 412-01.
11. Remove the starter. For additional information, refer to Section 303-06A.
12. Remove and discard the RH engine support insulator through bolt.
13. Loosen the LH engine support insulator through bolt.
14. Remove and discard the 3 LH engine support insulator nuts.
15. Remove and discard the 4 RH engine support insulator nuts.
LH engine support insulator
16. Remove the oil cooler. For additional information, refer to Oil Cooler in this section.
17. Loosen the RH engine support insulator through bolt.
18. Remove and discard the LH engine support insulator through bolt.
19. Loosen the 4 RH engine support insulator nuts.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-6 Engine — 5.4L (3V) 303-01A-6
IN-VEHICLE REPAIR (Continued)

20. Remove and discard the 3 LH engine support insulator nuts.

All engine support insulators
21. Using the Engine Support Bar, Support Hook and Engine Support Bracket, raise the engine assembly.

RH engine support insulator

22. Remove the RH engine support insulator.
23. NOTICE:
The engine support insulator bracket bolts must be discarded and new bolts installed, or damage to the vehicle may occur. They are a
tighten-to-yield design and cannot be reused.

If servicing the RH engine support insulator bracket, remove the 3 bolts and the RH engine mount bracket.
• Discard the 3 engine support insulator bracket bolts.
LH engine support insulator
24. Remove the LH engine support insulator.
25. NOTICE:
The engine support insulator bracket bolts must be discarded and new bolts installed, or damage to the vehicle may occur. They are a
tighten-to-yield design and cannot be reused.

If servicing the LH engine support insulator bracket, remove the 3 bolts and the LH engine mount bracket.
• Discard the 3 engine support insulator bracket bolts.

Installation
All engine support insulators
1. Clean the engine support insulator-to-cylinder block and engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to
installation.
LH engine support insulator
2. NOTICE:
The engine support insulator bracket bolts must be discarded and new bolts installed, or damage to the vehicle may occur. They are a
tighten-to-yield design and cannot be reused.

NOTICE:
The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque, or damage to the bolts may occur.

NOTE:
Place a visible mark on the engine support insulator bracket and the bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

If servicing the LH engine support insulator bracket, position the engine support insulator bracket and install 3 new bolts in 2 stages.
• Stage 1: Tighten to 30 Nm (22 lb-ft).
• Stage 2: Tighten an additional minimum of 60 degrees.
3. Position the LH engine support insulator into the vehicle.
RH engine support insulator
4. NOTICE:
The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be
reused.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-7 Engine — 5.4L (3V) 303-01A-7
IN-VEHICLE REPAIR (Continued)

NOTICE:
The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque, or damage to the bolts may occur.

NOTE:
Place a visible mark on the engine support insulator bracket and the bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

If servicing the RH engine support insulator bracket, position the engine support insulator bracket and install 3 new bolts in 2 stages.
• Stage 1: Tighten to 30 Nm (22 lb-ft).
• Stage 2: Tighten an additional minimum of 60 degrees.
5. Position the RH engine support insulator into the vehicle.
All engine support insulators
6. Using the Engine Support Bar, Support Hook and Engine Support Bracket, and lower the engine.

LH engine support insulator

7. NOTICE:
Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

Install 3 new LH engine support insulator nuts.

• Tighten to 200 Nm (148 lb-ft).
8. NOTICE:
Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

Install 4 new RH engine support insulator nuts.

• Tighten to 115 Nm (85 lb-ft).
9. NOTICE:
Only use hand tools when installing the engine support through bolt or damage to the engine support insulator may occur.

Install a new LH engine support insulator through bolt.

• Tighten to 350 Nm (258 lb-ft).
10. NOTICE:
Only use hand tools when installing the engine support through bolt or damage to the engine support insulator may occur.

Install a new RH engine support insulator through bolt.

• Tighten to 350 Nm (258 lb-ft).
11. Install the oil cooler. For additional information, refer to Oil Cooler in this section.
RH engine support insulator
12. NOTICE:
Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

Install 4 new RH engine support insulator nuts.

• Tighten to 115 Nm (85 lb-ft).
13. NOTICE:
Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-8 Engine — 5.4L (3V) 303-01A-8
IN-VEHICLE REPAIR (Continued)

Install 3 new LH engine support insulator nuts.

• Tighten to 200 Nm (148 lb-ft).
14. NOTICE:
Only use hand tools when installing the engine support through bolt or damage to the engine support insulator may occur.

Install a new LH engine support insulator through bolt.

• Tighten to 350 Nm (258 lb-ft).
15. NOTICE:
Only use hand tools when installing the engine support through bolt or damage to the engine support insulator may occur.

Install a new RH engine support insulator through bolt.

• Tighten to 350 Nm (258 lb-ft).
16. Install the starter. For additional information, refer to Section 303-06A.
17. Install the A/C compressor. For additional information, refer to Section 412-01.
All vehicles
18. NOTICE:
Only use hand tools when installing the transmission mount-to-crossmember nuts or damage to the transmission mount may occur.

Install 2 new transmission mount-to-crossmember nuts.

• Tighten to 115 Nm (85 lb-ft).

19. NOTE:
RH shown, LH similar.

Install the 4 exhaust Y-pipe flange nuts.

• Tighten to 40 Nm (30 lb-ft).

20. Install the engine cooling fan. For additional information, refer to Section 303-03.
21. Install the generator. For additional information, refer to Section 414-02.
22. Install the TB. For additional information, refer to Section 303-04A.
23. Install the ACL outlet pipe. For additional information, refer to Section 303-12.
24. Connect the battery ground cable. For additional information, refer to Section 414-01.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-9 Engine — 5.4L (3V) 303-01A-9
IN-VEHICLE REPAIR (Continued)

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

Engine .............................................................................................................................................................................. 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

Engine
Special Tool(s)

Modular Engine Lift Bracket

303-F047 (014-00073) or equivalent

Disconnect Tool, Transmission Cooler Line

303-F047 (014-00073) or equivalent

Retainer, Torque Converter

307-346 (T97T-7902-A) or equivalent

All vehicles
1. Release the fuel pressure. For additional information, refer to Section 310-00.
2. Remove the engine cooling module. For additional information, refer to Section 303-03.
3. NOTICE:
If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold
for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Remove the intake manifold. For additional information, refer to Intake Manifold in this section.
4. Remove the degas bottle. For additional information, refer to Section 303-03.
5. Remove the PCM. For additional information, refer to Section 303-14A.
6. Remove the accessory drive belt.
7. Disconnect the lower radiator hose to the oil filter adapter.

8. Disconnect the degas bottle coolant hose.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
(Continued)

9. Disconnect the engine wiring harness electrical connector located below the PCM.

10. Disconnect the generator wiring harness position retainers from the engine front cover studs.

11. Disconnect the A/C compressor and crankshaft position (CKP) sensor electrical connectors and position the generator wiring harness aside.

12. Remove the bolt and the transmission fluid level indicator tube.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
(Continued)

13. Remove the 2 nuts and disconnect the 2 A/C compressor manifold tube assemblies from the A/C compressor.
• Discard the O-rings seals.

14. Disconnect the coolant hose from the coolant tube.

Manual transmission equipped vehicles

15. Remove the clutch and pressure plate. For additional information, refer to Section 308-01.
Early build automatic transmission equipped vehicles
16. Remove the 2 transmission auxiliary fluid cooler outlet tube secondary latches.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-5 Engine — 5.4L (3V) 303-01A-5
(Continued)

17. Using the special tool, disconnect the 2 transmission auxiliary fluid cooler inlet tubes.

18. Disconnect the 2 transmission auxiliary fluid cooler outlet tubes.

19. Remove the 2 bolts and the transmission auxiliary fluid cooler assembly.

Late build automatic transmission equipped vehicles

20. Remove the 2 bolts and the flexplate inspection cover.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-6 Engine — 5.4L (3V) 303-01A-6
(Continued)

All automatic transmission equipped vehicles

21. Remove the starter. For additional information, refer to Section 303-06A.
22. Remove the cylinder block opening cover.

23. Remove the 6 torque converter-to-flexplate nuts.

• Discard the nuts.

24. Install the special tool.

25. Loosen the 2 transmission rear mount nuts.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-7 Engine — 5.4L (3V) 303-01A-7
(Continued)

26. NOTE:
The upper 2 transmission-to-engine bolts will be removed later.

Remove the 5 transmission-to-engine bolts.

All vehicles
27. If equipped, disconnect the block heater electrical connector.

28. Remove the bolt and the transmission wiring harness support bracket.

29. Remove the nut and the 2 engine wiring harness ground straps.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-8 Engine — 5.4L (3V) 303-01A-8
(Continued)

30. Remove the bolt and position the ground strap aside.

31. Remove the 3 bolts and position the power steering pump aside.

32. Remove the nut, the transmission auxiliary fluid cooler tube support bracket and the starter wiring harness support bracket from the engine front cover
stud bolt.

33. Remove the 3 bolts and the A/C compressor.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-9 Engine — 5.4L (3V) 303-01A-9
(Continued)

34. Disconnect the RH heated oxygen sensor (HO2S) wiring harness retainers.

35. Disconnect the 2 HO2S electrical connectors.

36. Remove the 4 exhaust manifold flange nuts.

37. Remove and discard the engine oil filter.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-10 Engine — 5.4L (3V) 303-01A-10
(Continued)

38. Disconnect the oil cooler coolant hoses.

39. NOTICE:
If metal foreign material is present in the oil cooler, mechanical concerns exist. To diagnose mechanical concerns, refer to Section 303-00.

Remove and inspect the engine oil cooler.

40. Remove the LH engine support insulator through bolt.

41. Remove the RH engine support insulator through bolt.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-11 Engine — 5.4L (3V) 303-01A-11
(Continued)

Automatic transmission vehicles

42. Remove the upper 2 transmission-to-engine bolts.

All vehicles
43. Install the special tool.

44. Using a suitable floor crane, remove the engine assembly from the vehicle.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

Cylinder Head ................................................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

Cylinder Head
Special Tool(s)

Compressor, Valve Spring

303-1039

Installer, Valve Stem Oil Seal

303-383 (T91T-6571-A)

Material
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
(Continued)

Item Part Number Description

1 W701520 Variable Camshaft Timing (VCT) housing assembly bolts (2
required)
2 6C261 VCT housing assembly
3 N807834 Camshaft bearing cap bolt (10 required)
4 6B284 Camshaft front bearing cap
5 6B280 Camshaft bearing cap (4 required)
6 6C255 Camshaft
7 6518 Valve spring retainer key (24 required)
8 6514 Valve spring retainer (12 required)
9 6513 Valve spring (12 required)
10 6A517 Valve seal (12 required)
11 6507 Intake valves (8 required)
12 6505 Exhaust valve (4 required)
13 6050 Cylinder head

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
(Continued)

Disassembly
1. Remove the 2 bolts and the Variable Camshaft Timing (VCT) housing.
• Discard the gasket.
2. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
3. Install the camshaft bearing caps in their original locations.
• Lubricate the camshaft bearing caps with clean engine oil.
• Position the front camshaft bearing cap.
• Position the remaining camshaft bearing caps.
• Install the 10 bolts finger-tight.
4. Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer keys.

5. Remove the valve spring retainer, the valve spring and the valve seal.
• Discard the valve seal.
6. Remove the valve from the cylinder head.
7. Repeat the previous 3 steps for each valve.
8. Inspect the components. For additional information, refer to Section 303-00.
9. NOTICE:
Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side
loading.

Remove the 10 bolts, the front camshaft bearing cap and then the remaining bearing caps.
10. Remove the camshaft.
11. Check the cylinder head for distortion. For additional information, refer to Section 303-00.

Assembly
1. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
2. Install the camshaft bearing caps in their original locations.
• Lubricate the camshaft bearing caps with clean engine oil.
• Position the front camshaft bearing cap.
• Position the remaining camshaft bearing caps.
• Install the 10 bolts finger-tight.
3. NOTE:
Lubricate the valve stem with clean engine oil prior to installation.

Install the valve into the cylinder head.

4. NOTE:
Lubricate the valve seal and valve stem with clean engine oil prior to installation.

Position a new valve seal onto the valve stem.

5. Using the Valve Stem Oil Seal Installer, install the new valve seal.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-5 Engine — 5.4L (3V) 303-01A-5
(Continued)

6. NOTICE:
If the components are to be reinstalled, they must be installed into their original locations.

Using the Valve Spring Compressor, install the valve spring, the valve spring retainer and the valve spring retainer keys.

7. Repeat the previous 2 steps for each valve.

8. Remove the 8 bolts, the front camshaft bearing cap and then the remaining bearing caps.
9. Remove the camshaft.
10. Install a new gasket, the VCT housing and the 2 bolts.
• Tighten to 10 Nm (89 lb-in).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

Piston ............................................................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

Piston

Material
Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); WSS-M2C945-A
Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)

Item Part Number Description

1 6150 Piston compression upper ring
2 6152 Piston compression lower ring
3 6159 Piston oil control upper segment ring
4 6161 Piston oil control spacer
5 6159 Piston oil control lower segment ring
6 6140 Piston pin retainer
7 6140 Piston pin retainer
8 6135 Piston pin
9 6200 Connecting rod
10 — Connecting rod bearing cap (part of 6200)
11 6414 Connecting rod bearing cap bolt (2 required)
12 6110 Piston

Disassembly

WARNING:
Since the retainer ring has a tendency to spring out, cover the end of the pin bore with a hand or shop rag when removing the ring. Wear eye
protection. Failure to follow these instructions may result in serious personal injury.

1. Remove the piston rings from the piston.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
(Continued)

• Discard the piston rings.

2. Mark the piston and connecting rod on the same side for assembly reference.

3. Remove the 2 piston pin retainers and the piston pin.

4. Separate the piston from the connecting rod.
5. Clean and inspect the piston and connecting rod. For additional information, refer to Section 303-00.

Assembly
1. NOTE:
The connecting rod must be installed into the piston with the marks made during disassembly on the same side. If a new piston or connecting rod is
being installed, it can be installed in either direction.

Position the connecting rod in the piston.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
(Continued)

2. Lubricate the piston pin and pin bore with clean engine oil.
3. Install the piston pin in the piston and connecting rod assembly.
4. Install the 2 piston pin retaining clips in the piston.
5. Lubricate the piston and the new piston rings with clean engine oil.
6. Install the piston rings onto the piston.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

Intake Manifold Assembly ................................................................................................................................................ 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

Intake Manifold Assembly

Material
Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil WSS-M2C930-A
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil
CXO-5W20-LSP12 (Canada); or equivalent

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
(Continued)

Item Part Number Description

1 N705438 Throttle body (TB) bolt (4 required)
2 9F991 TB assembly
3 N705800 Fuel rail bolt (4 required)
4 9F792 Fuel rail
5 9F907 Fuel injector-to-fuel rail locking clip (8 required)
6 — Fuel injector-to-fuel rail O-ring seal (8 required)
7 9F593 Fuel injector (8 required)
8 — Fuel injector-to-intake manifold O-ring seal (8 required)
9 9D446 Intake manifold vacuum tube assembly
10 — Charge motion control valve (CMCV) rod locking clip (2 required)
11 W708165 CMCV stud bolt
12 W709184 CMCV bolts (2 required)
13 9L490 CMCV
14 W500204 PCV heater element bolts (2 required)
15 9F624 PCV heater element
16 — PCV heater element O-ring seal
17 6N041 Engine noise shield insulator

Disassembly
1. Remove the 4 bolts and the throttle body (TB).
2. Remove the 4 bolts and the fuel rail.
3. Remove the fuel injector-to-fuel rail locking clips and separate the fuel injectors from the fuel rail.
• Discard the 2 O-ring seals from each fuel injector.
4. Remove the vacuum tube assembly from the intake manifold.
5. Remove the charge motion control valve (CMCV) rod locking clips.
6. Remove the stud bolt, the 2 bolts and the CMCV.
7. Remove the 2 bolts and the PCV heater element.
• Discard the O-ring seal.
8. Remove the engine noise shield insulator from the intake manifold.

Assembly
1. NOTICE:
If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold
for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Install the engine noise shield insulator onto the intake manifold.
2. NOTE:
Lubricate the new O-ring seal with clean engine oil prior to installation.

Using a new O-ring seal, install the PCV heater element and the 2 bolts.
• Tighten to 6 Nm (53 lb-in).
3. Position the CMCV and install the stud bolt and the 2 bolts.
• Tighten to 10 Nm (89 lb-in).
4. Install the CMCV rod locking clips.
5. Install the vacuum tube assembly onto the intake manifold.
6. NOTE:
Lubricate the new O-ring seals with clean engine oil prior to installation.

Install new O-ring seals on each of the fuel injectors.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
(Continued)

7. Assemble the fuel injectors onto the fuel rail and install the locking clips.
8. Install the fuel rail and fuel injector assembly onto the intake manifold.
9. Install the 4 fuel rail bolts.
• Tighten to 10 Nm (89 lb-in).
10. Install the TB and tighten the bolts in 2 stages.
• Stage 1: Tighten to 9 Nm (80 lb-in).
• Stage 2: Tighten an additional 90 degrees.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

Cylinder Head ................................................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

Cylinder Head
Special Tool(s)

Remover/Installer, Cylinder Head

303-572 (T97T-6000-A)

Locking Tool, Camshaft Phaser Sprocket

303-1046

Compressor, Valve Spring

303-1039

Remover, Crankshaft Vibration Damper

303-009 (T58P-6316-D)

Remover, Crankshaft Front Seal

303-107 (T74P-6700-A)

Modular Engine Lift Bracket

303-F047 (014-00073) or equivalent

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
(Continued)

Fan Pulley Holding Wrench

303-239 (T84T-6312-C)

Fan Clutch Nut Wrench

303-240 (T84T-6312-D)

Material
Item Specification
Metal Surface Prep —
ZC-31
Silicone Gasket Remover —
ZC-30

All cylinder heads

1. Remove the engine. For additional information, refer to Engine in this section.
2. NOTE:
Flexplate shown, flywheel similar.

Remove the bolts and the flexplate or flywheel.

3. Install the engine onto a suitable engine stand.

4. Remove the special tool.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
(Continued)

5. Remove the 3 bolts and the RH engine support insulator bracket.

• Discard the bolts.

6. NOTE:
LH shown, RH similar.

Remove the cylinder block drain plugs and drain the coolant into a suitable container.

7. NOTE:
LH shown, RH similar.

Install the cylinder block drain plugs.

• Tighten to 24 Nm (18 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-5 Engine — 5.4L (3V) 303-01A-5
(Continued)

8. NOTE:
The large clutch assembly nut has a RH thread and must be rotated counterclockwise to remove it.

Using the special tools, remove the engine cooling fan from the coolant pump pulley.

9. Disconnect the RH camshaft position (CMP) sensor electrical connector.

10. Remove the stud bolt and the RH radio ignition interference capacitor.

11. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-6 Engine — 5.4L (3V) 303-01A-6
(Continued)

12. NOTE:
RH shown, LH similar.

Disconnect the 8 ignition coil electrical connectors.

13. Disconnect the cylinder head temperature (CHT) sensor electrical connector.

14. Remove the stud bolt and the LH radio ignition interference capacitor.

15. Disconnect the engine wiring harness position retainers from the front of the RH valve cover.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-7 Engine — 5.4L (3V) 303-01A-7
(Continued)

16. Disconnect the engine wiring harness position retainers from the front of the LH valve cover and the LH CMP sensor electrical connector.

17. Disconnect the engine oil pressure (EOP) switch electrical connector.

18. Disconnect the 2 engine wiring harness retainers from the LH valve cover studs.

19. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-8 Engine — 5.4L (3V) 303-01A-8
(Continued)

20. Remove the engine wiring harness from the engine assembly.
21. NOTE:
RH shown, LH similar.

Remove the 8 bolts and the 8 ignition coils.

• Remove the ignition coil, using a twisting motion while pulling up on the ignition coil.

22. Remove the 2 bolts and the oil level indicator tube.
• Discard the O-ring seal.

23. Remove the bolt and the RH CMP sensor.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-9 Engine — 5.4L (3V) 303-01A-9
(Continued)

24. Remove the bolt and the LH CMP sensor.

25. Remove the bolt and the CKP sensor.

26. Disconnect the intake manifold vacuum tube from the valve cover stud and the support bracket.

27. NOTICE:
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. Failure to follow this procedure
can cause future oil leakage.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-10 Engine — 5.4L (3V) 303-01A-10
(Continued)

NOTICE:
When removing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

NOTE:
The fasteners are part of the valve cover and should not be removed.

NOTE:
LH shown, RH similar.

Remove the valve covers.

• Fully loosen the fasteners and remove the valve covers.
• Clean the valve cover mating surface of the cylinder head with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the
directions on the packaging.
• Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water
or a suitable solvent.

28. Remove the bolts, coolant pump pulley and accessory drive belt idler pulley.

29. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.

30. Using the special tool, remove and discard the crankshaft front seal.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-11 Engine — 5.4L (3V) 303-01A-11
(Continued)

31. NOTE:
Correct fastener location is essential for assembly procedure. Record fastener location.

Remove the fasteners.

32. Remove the 4 front oil pan bolts.

33. Remove the engine front cover from the cylinder block.

34. Remove the crankshaft sensor ring from the crankshaft.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-12 Engine — 5.4L (3V) 303-01A-12
(Continued)

35. Position the crankshaft keyway at the 12 o'clock position.

36. NOTE:
If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.

The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and
the exhaust lobe on the No. 1 cylinder.

37. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original
locations. Failure to follow these instructions may result in engine damage.

Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-13 Engine — 5.4L (3V) 303-01A-13
(Continued)

38. NOTE:
Do not allow the valve keepers to fall off of 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.

Using the special tool, remove the 3 camshaft roller followers designated in the previous step from the RH cylinder head.

39. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original
locations. Failure to follow these instructions may result in engine damage.

Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-14 Engine — 5.4L (3V) 303-01A-14
(Continued)

40. NOTE:
Do not allow the valve keepers to fall off of 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.

Using the special tool, remove the 3 camshaft roller followers designated in the previous step from the LH cylinder head.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-15 Engine — 5.4L (3V) 303-01A-15
(Continued)

41. NOTICE:
The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.

Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.

42. NOTICE:
If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If
cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine
damage may occur.

Remove the bolts, the LH timing chain tensioner and tensioner arm.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-16 Engine — 5.4L (3V) 303-01A-16
(Continued)

43. NOTICE:
If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If
cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine
damage may occur.

Remove the bolts, the RH timing chain tensioner and tensioner arm.

44. Remove the RH and LH timing chains and the crankshaft sprocket.
• Remove the RH timing chain from the camshaft sprocket.
• Remove the RH timing chain from the crankshaft sprocket.
• Remove the LH timing chain from the camshaft sprocket.
• Remove the LH timing chain and crankshaft sprocket.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-17 Engine — 5.4L (3V) 303-01A-17
(Continued)

45. NOTE:
RH shown, LH similar.

Remove the LH and RH timing chain guides.

• Remove the bolts.
• Remove both timing chain guides.

46. NOTICE:
Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the variable camshaft timing (VCT) phaser sprocket assembly or damage may occur to the camshaft or VCT
phaser sprocket.

Using the special tool, remove the bolt and the RH VCT phaser sprocket assembly.
• Discard the VCT phaser sprocket bolt.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-18 Engine — 5.4L (3V) 303-01A-18
(Continued)

47. NOTICE:
Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the variable camshaft timing (VCT) phaser sprocket assembly or damage may occur to the camshaft or VCT
phaser sprocket.

Using the special tool, remove the bolt and the LH VCT phaser sprocket assembly.
• Discard the VCT phaser sprocket bolt.

48. NOTICE:
Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from
sideloading.

Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.

49. NOTICE:
The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.

Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-19 Engine — 5.4L (3V) 303-01A-19
(Continued)

50. Clean and inspect the RH camshaft bearing caps.

• The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.

51. Remove the RH camshaft.

52. NOTICE:
Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from
sideloading.

Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-20 Engine — 5.4L (3V) 303-01A-20
(Continued)

53. NOTICE:
The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.

Remove the remaining bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps.

54. Clean and inspect the LH camshaft bearing caps.

• The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-21 Engine — 5.4L (3V) 303-01A-21
(Continued)

55. Remove the LH camshaft.

56. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original
locations. Failure to follow these instructions may result in engine damage.

Remove the all of the remaining camshaft roller followers from the cylinder heads.
LH cylinder head
57. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original
locations. Failure to follow these instructions may result in engine damage.

Remove the hydraulic lash adjusters from the LH cylinder head.

58. Remove the bolt and the intake manifold vacuum tube support bracket.

59. Install the special tool onto the LH cylinder head.

60. Remove the 3 bolts and the LH exhaust manifold shield.

61. Remove the 8 nuts, the 8 studs and the LH exhaust manifold.
• Discard the gaskets, the 8 studs and the 8 nuts.
• Inspect the exhaust manifold. For additional information, refer to Section 303-00.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-22 Engine — 5.4L (3V) 303-01A-22
(Continued)

RH cylinder head
62. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original
locations. Failure to follow these instructions may result in engine damage.

Remove the hydraulic lash adjusters from the RH cylinder heads.

63. Remove the stud bolt and the coolant tube.
• Discard the O-ring seals.

64. Install the special tool onto the RH cylinder head.

65. Remove the 2 bolts and the RH exhaust manifold heat shield.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-23 Engine — 5.4L (3V) 303-01A-23
(Continued)

66. Remove the 8 nuts, the 8 studs and the RH exhaust manifold.
• Discard the gaskets, the 8 studs and the 8 nuts.
• Inspect the exhaust manifold. For additional information, refer to Section 303-00.

All cylinder heads

67. NOTICE:
The cylinder head must be cool before removing it from the engine. Cylinder head warpage may result if a warm or hot cylinder head is
removed.

NOTICE:
Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.

NOTICE:
The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

NOTICE:
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. Failure to follow this procedure
may cause future oil leakage.

NOTICE:
Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE:
RH shown, LH similar.

Remove the bolts and the cylinder head.

• Discard the cylinder head gasket.
• Discard the cylinder head bolts.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-24 Engine — 5.4L (3V) 303-01A-24
(Continued)

68. NOTICE:
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. Failure to follow this procedure
may cause future oil leakage.

NOTICE:
Observe all warnings or cautions and follow all application directions contained on the packaging of the Silicone Gasket Remover and the
Motorcraft Metal Surface Prep.

NOTE:
If there is no residual gasket material present, Motorcraft Metal Surface Prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
1 Remove any large deposits of silicone or gasket material with a plastic scraper.
2 Apply Silicone Gasket Remover, following package directions, and allow to set for several minutes.
3 Remove the Silicone Gasket Remover with a plastic scraper. A second application of Silicone Gasket Remover may be required if residual traces
of silicone or gasket material remain.
4 Apply Motorcraft Metal Surface Prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces
to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
69. NOTE:
Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before
running a flatness check.

NOTE:
Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in) per running foot length, such as Snap-On® GA438A
or equivalent. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat within 0.010 mm (0.0004 in) from end to end.

NOTE:
LH shown, RH similar.

Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to
the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or
scratches longer than 0.0254 mm (0.001 in).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-25 Engine — 5.4L (3V) 303-01A-25
(Continued)

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

Engine .............................................................................................................................................................................. 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

Engine
Special Tool(s)

Remover, Crankshaft Rear Oil Slinger

303-514 (T95P-6701-AH)

Slide Hammer
100-001 (T50T-100-A)

Installer, Connecting Rod

303-442 (T93P-6136-A)

Lifting Bracket, Engine

303-F047 (014-00073) or equivalent

Remover, Crankshaft Vibration Damper

303-009 (T58P-6316-D)

Remover/Installer, Cylinder Head

303-572 (T97T-6000-A)

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
(Continued)

Remover, Crankshaft Front Oil Seal

303-107 (T74P-6700-A)

Remover, Crankshaft Rear Seal

303-519 (T95P-6701-DH)

Compressor, Valve Spring

303-1039

Locking Tool, Cam Phaser Sprocket

303-1046

Fan Pulley Holding Wrench

303-239 (T84T-6312-C)

Fan Clutch Nut Wrench

303-240 (T84T-6312-D)

Material
Item Specification
Motorcraft Metal Surface Prep —
ZC-31
Silicone Gasket Remover —
ZC-30

NOTICE:

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
(Continued)

Remove the cylinder heads before removing the crankshaft. Failure to do so may result in engine damage.

NOTICE:
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket
surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTE:
The flexplate or flywheel, crankshaft rear seal and the crankshaft rear oil slinger must be removed before mounting the engine on the engine stand.

NOTE:
For additional information, refer to the exploded view under the Assembly procedure in this section.

1. Remove the bolts and the flexplate or flywheel.

2. Using the special tools, remove and discard the crankshaft rear oil slinger.

3. Using the special tools, remove and discard the crankshaft rear seal.

4. Remove the bolts and the crankshaft rear seal retainer plate.
• NOTICE:
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.

Clean and inspect the sealing surfaces.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-5 Engine — 5.4L (3V) 303-01A-5
(Continued)

5. Mount the engine on a suitable work stand.

6. Remove the special tool.

7. Remove the 3 bolts and the RH engine support insulator bracket.

• Discard the bolts.

8. NOTE:
LH shown, RH similar.

If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-6 Engine — 5.4L (3V) 303-01A-6
(Continued)

9. NOTE:
LH shown, RH similar.

If equipped, install the cylinder block drain plugs.

• Tighten to 24 Nm (18 lb-ft).

10. NOTE:
The large clutch assembly nut has a RH thread and must be rotated counterclockwise to remove it.

Using the special tools, remove the engine cooling fan from the coolant pump pulley.

11. Disconnect the RH camshaft position (CMP) sensor electrical connector.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-7 Engine — 5.4L (3V) 303-01A-7
(Continued)

12. Remove the stud bolt and the RH radio ignition interference capacitor.

13. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.

14. NOTE:
RH shown, LH similar.

Disconnect the 8 ignition coil electrical connectors.

15. Disconnect the cylinder head temperature (CHT) sensor electrical connector.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-8 Engine — 5.4L (3V) 303-01A-8
(Continued)

16. Remove the stud bolt and the LH radio ignition interference capacitor.

17. Disconnect the engine wiring harness position retainers from the front of the RH valve cover.

18. Disconnect the engine wiring harness position retainers from the front of the LH valve cover and the LH CMP sensor electrical connector.

19. Disconnect the engine oil pressure (EOP) switch electrical connector.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-9 Engine — 5.4L (3V) 303-01A-9
(Continued)

20. Disconnect the 2 engine wiring harness retainers from the LH valve cover studs.

21. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs.

22. Remove the engine wiring harness from the engine assembly.
23. NOTE:
RH shown, LH similar.

Remove the 8 bolts and the 8 ignition coils.

• Remove the ignition coil, using a twisting motion while pulling up on the ignition coil.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-10 Engine — 5.4L (3V) 303-01A-10
(Continued)

24. Remove the 2 bolts and the 2 knock sensors (KS).

25. Remove the stud bolt and the coolant tube.

• Discard the O-ring seal.

26. Remove the 2 bolts and the oil level indicator tube.
• Discard the O-ring seal.

27. Remove the bolt and the RH CMP sensor.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-11 Engine — 5.4L (3V) 303-01A-11
(Continued)

28. Remove the bolt and the LH CMP sensor.

29. Remove the bolt and the CKP sensor.

30. Disconnect the intake manifold vacuum tube from the valve cover stud and the support bracket.

31. Remove the bolt and the intake manifold vacuum tube support bracket.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-12 Engine — 5.4L (3V) 303-01A-12
(Continued)

32. NOTICE:
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.

NOTICE:
When removing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

NOTE:
The fasteners are part of the valve cover and should not be removed.

NOTE:
LH shown, RH similar.

Remove the valve covers.

• Fully loosen the fasteners and remove the valve cover.
• Clean the valve cover mating surface of the cylinder head with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the
directions on the packaging.
• Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water
or a suitable solvent.

33. Remove the 2 bolts and the RH exhaust manifold heat shield.

34. Remove the 8 nuts, the 8 studs and the RH exhaust manifold.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-13 Engine — 5.4L (3V) 303-01A-13
(Continued)

• Discard the gaskets, nuts and studs.

• Inspect the exhaust manifold. For additional information, refer to Section 303-00.

35. Remove the 3 bolts and the LH exhaust manifold shield.

36. Remove the 8 nuts, the 8 studs and the LH exhaust manifold.
• Discard the gaskets, nuts and studs.
• Inspect the exhaust manifold. For additional information, refer to Section 303-00.

37. Remove the 3 bolts and the LH engine support insulator.

• Discard the bolts.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-14 Engine — 5.4L (3V) 303-01A-14
(Continued)

38. Remove the nut, the 4 bolts and the oil filter adapter and gasket.
• Discard the gasket.

39. Remove the bolts, coolant pump pulley and accessory drive belt idler pulley.

40. Remove the bolts and the accessory drive belt tensioner.

41. Remove the bolts.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-15 Engine — 5.4L (3V) 303-01A-15
(Continued)

42. Remove the coolant pump from the cylinder block.

• Discard the O-ring seal.

43. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.

44. Using the special tool, remove and discard the crankshaft front seal.

45. Remove the bolts, oil pan and oil pan gasket.
• NOTICE:

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-16 Engine — 5.4L (3V) 303-01A-16
(Continued)

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.

Clean and inspect the sealing surfaces.

46. NOTE:
Correct fastener location is essential for assembly procedure. Record fastener location.

Remove the fasteners.

47. Remove the engine front cover from the cylinder block.

48. Remove the crankshaft sensor ring from the crankshaft.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-17 Engine — 5.4L (3V) 303-01A-17
(Continued)

49. Position the crankshaft keyway at the 12 o'clock position.

50. NOTE:
If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.

The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and
the exhaust lobe on the No. 1 cylinder.

51. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-18 Engine — 5.4L (3V) 303-01A-18
(Continued)

52. NOTE:
Do not allow the valve keepers to fall off of 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.

Using the special tool, remove the 3 camshaft roller followers designated in the previous step from the RH cylinder head.

53. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-19 Engine — 5.4L (3V) 303-01A-19
(Continued)

54. NOTE:
Do not allow the valve keepers to fall off of 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.

Using the special tool, remove the 3 camshaft roller followers designated in the previous step from the LH cylinder head.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-20 Engine — 5.4L (3V) 303-01A-20
(Continued)

55. NOTICE:
The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.

Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.

56. NOTICE:
If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If
cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine
damage may occur.

Remove the bolts, the LH timing chain tensioner and tensioner arm.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-21 Engine — 5.4L (3V) 303-01A-21
(Continued)

57. NOTICE:
If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If
cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine
damage may occur.

Remove the bolts, the RH timing chain tensioner and tensioner arm.

58. Remove the RH and LH timing chains and the crankshaft sprocket.
• Remove the RH timing chain from the camshaft sprocket.
• Remove the RH timing chain from the crankshaft sprocket.
• Remove the LH timing chain from the camshaft sprocket.
• Remove the LH timing chain and crankshaft sprocket.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-22 Engine — 5.4L (3V) 303-01A-22
(Continued)

59. NOTE:
RH shown, LH similar.

Remove the LH and RH timing chain guides.

• Remove the bolts.
• Remove both timing chain guides.

60. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and
sprocket.

Using the special tool, remove the bolt and the RH camshaft phaser and sprocket assembly.
• Discard the camshaft phaser and sprocket bolt.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-23 Engine — 5.4L (3V) 303-01A-23
(Continued)

61. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and
sprocket.

Using the special tool, remove the bolt and the LH camshaft phaser and sprocket assembly.
• Discard the camshaft phaser and sprocket bolt.

62. Install the special tool onto the LH cylinder head.

63. Install the special tool onto the RH cylinder head.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-24 Engine — 5.4L (3V) 303-01A-24
(Continued)

64. NOTICE:
Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from
sideloading.

Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.

65. NOTICE:
The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.

Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-25 Engine — 5.4L (3V) 303-01A-25
(Continued)

66. Clean and inspect the RH camshaft bearing caps.

• The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.

67. Remove the RH camshaft.

68. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

Remove the remaining camshaft roller followers from the RH cylinder head.
69. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

Remove the hydraulic lash adjusters from the RH cylinder head.

70. NOTICE:
Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from
sideloading.

Remove the 2 bolts and the LH cylinder head camshaft bearing cap.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-26 Engine — 5.4L (3V) 303-01A-26
(Continued)

71. NOTICE:
The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these
instructions may result in engine damage.

Remove the remaining bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps.

72. Clean and inspect the LH camshaft bearing caps.

• The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-27 Engine — 5.4L (3V) 303-01A-27
(Continued)

73. Remove the LH camshaft.

74. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original
locations. Failure to follow these instructions may result in engine damage.

Remove the remaining camshaft roller followers from the LH cylinder head.
75. NOTICE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original
locations. Failure to follow these instructions may result in engine damage.

Remove the hydraulic lash adjusters from the LH cylinder head.

76. NOTICE:
The cylinder head must be cool before removing it from the engine. Cylinder head warpage may result if a warm or hot cylinder head is
removed.

NOTICE:
Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Failure
to follow this procedure may cause engine damage.

NOTICE:
The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused.

NOTICE:
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.

NOTICE:
Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
Failure to follow this procedure may cause engine damage.

NOTE:
RH shown, LH similar.

Remove the bolts and the cylinder head.

• Discard the cylinder head gasket.
• Discard the cylinder head bolts.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-28 Engine — 5.4L (3V) 303-01A-28
(Continued)

77. NOTICE:
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.

NOTICE:
Observe all warnings or cautions and follow all application directions contained on the packaging of the Silicone Gasket Remover and the
Motorcraft Metal Surface Prep. Failure to follow this procedure may cause engine damage.

NOTE:
If there is no residual gasket material present, Motorcraft Metal Surface Prep can be used to clean and prepare the surfaces.

Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
1 Remove any large deposits of silicone or gasket material with a plastic scraper.
2 Apply Silicone Gasket Remover, following package directions, and allow to set for several minutes.
3 Remove the Silicone Gasket Remover with a plastic scraper. A second application of Silicone Gasket Remover may be required if residual traces
of silicone or gasket material remain.
4 Apply Motorcraft Metal Surface Prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces
to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
78. NOTE:
LH shown, RH similar.

Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying
particular attention to the oil pressure feed area. For additional information, refer to Section 303-00.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-29 Engine — 5.4L (3V) 303-01A-29
(Continued)

79. Remove the bolts, the oil pump screen and pickup tube and the spacer.

80. Remove the 3 bolts and the oil pump.

81. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an
abrasive pad or equivalent, following the manufacturer instructions.
82. NOTICE:
Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for
correct orientation. Failure to follow these instructions may result in engine damage.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-30 Engine — 5.4L (3V) 303-01A-30
(Continued)

Remove the bolts and the connecting rod caps. Discard the bolts.

83. NOTICE:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow these instructions may result in engine
damage.

Use the special tool to push the piston through the top of the cylinder block.

84. Disassemble the 8 pistons. For additional information, refer to Piston in this section.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-31 Engine — 5.4L (3V) 303-01A-31
(Continued)

85. Remove the fasteners.

1 Remove and discard the cross-mounted main cap bolts.
2 Remove the dowels.
3 Remove and discard the main bearing cap bolts.

86. Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.

87. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-32 Engine — 5.4L (3V) 303-01A-32
(Continued)

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

Engine .............................................................................................................................................................................. 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

Engine
Special Tool(s)

Modular Engine Lift Bracket

303-F047 (014-00073) or equivalent

Material
Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil WSS-M2C930-A
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil
CXO-5W20-LSP12 (Canada); or equivalent

All vehicles
1. Using a suitable floor crane, position the engine assembly into the vehicle.
2. NOTICE:
Only use hand tools when installing the RH engine through bolt or damage to the engine support insulator may occur.

Install the LH engine support insulator through bolt.

• Tighten to 350 Nm (258 lb-ft).

3. NOTICE:
Only use hand tools when installing the LH engine through bolt or damage to the engine support insulator may occur.

Install the RH engine support insulator through bolt.

• Tighten to 350 Nm (258 lb-ft).

Manual transmission equipped vehicles

4. Install the clutch and pressure plate. For additional information, refer to Section 308-01.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
(Continued)

All automatic transmission equipped vehicles

5. NOTE:
The upper 2 transmission-to-engine bolts will be installed later.

Install the lower 5 transmission-to-engine bolts.

• Tighten to 48 Nm (35 lb-ft).

6. Install 6 new torque converter-to-flexplate nuts.

• Tighten to 35 Nm (26 lb-ft).

7. Install the cylinder block opening cover.

8. Install the 2 transmission rear mount nuts.

• Tighten to 103 Nm (76 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
(Continued)

9. Install the starter. For additional information, refer to Section 303-06A.

Late build automatic transmission equipped vehicles
10. Install the flexplate inspection cover and the 2 bolts.
• Tighten to 34 Nm (25 lb-ft).

Early build automatic transmission equipped vehicles

11. Position the transmission auxiliary fluid cooler assembly and install the 2 bolts.
• Tighten to 35 Nm (26 lb-ft).

12. Connect the 2 transmission auxiliary fluid cooler outlet tubes.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-5 Engine — 5.4L (3V) 303-01A-5
(Continued)

13. Connect the 2 transmission auxiliary fluid cooler inlet tubes.

14. Install the 2 transmission auxiliary fluid cooler outlet tube secondary latches.

All vehicles
15. If equipped, connect the block heater electrical connector.

16. Position the transmission wiring harness support bracket and install the bolt.
• Tighten to 10 Nm (89 lb-in).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-6 Engine — 5.4L (3V) 303-01A-6
(Continued)

17. Connect the 2 engine wiring harness ground straps and install the nut.
• Tighten to 10 Nm (89 lb-in).

18. Connect the RH heated oxygen sensor (HO2S) wiring harness retainers.

19. Position the ground strap and install the bolt.

• Tighten to 10 Nm (89 lb-in).

20. Position the power steering pump and install the 3 bolts.
• Tighten to 25 Nm (18 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-7 Engine — 5.4L (3V) 303-01A-7
(Continued)

21. Position the A/C compressor and install the 3 bolts.

• Tighten to 25 Nm (18 lb-ft).

22. Position the transmission auxiliary fluid cooler tube support bracket and the starter wiring harness support bracket on the engine front cover stud bolt
and install the nut.
• Tighten to 25 Nm (18 lb-ft).

23. Install the 4 exhaust manifold flange nuts.

• Tighten to 40 Nm (30 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-8 Engine — 5.4L (3V) 303-01A-8
(Continued)

24. Connect the 2 heated HO2S electrical connectors.

25. Position the oil cooler and install the threaded shaft.
• Tighten to 58 Nm (43 lb-ft).

26. Connect the oil cooler coolant hoses.

27. Install a new engine oil filter.

• Tighten to 16 Nm (12 lb-ft).

Automatic transmission vehicles

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-9 Engine — 5.4L (3V) 303-01A-9
(Continued)

28. Install the upper 2 transmission-to-engine bolts.

• Tighten to 48 Nm (35 lb-ft).

All vehicles
29. Using new O-ring seals, connect the 2 A/C compressor manifold tube assemblies to the A/C compressor and install the 2 nuts.
• Tighten to 20 Nm (15 lb-ft).

30. Position the transmission fluid level indicator tube and install the bolt.
• Tighten to 10 Nm (89 lb-in).

31. Position the generator wiring harness and connect the A/C compressor and crankshaft position (CKP) sensor electrical connectors.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-10 Engine — 5.4L (3V) 303-01A-10
(Continued)

32. Connect the generator wiring harness position retainers to the engine front cover studs.

33. Connect the engine wiring harness electrical connector located below the PCM.

34. Connect the coolant hose to the coolant tube.

35. Connect the lower radiator hose to the oil filter adapter.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-11 Engine — 5.4L (3V) 303-01A-11
(Continued)

36. Connect the degas bottle coolant hose.

37. Position the accessory drive belt onto the accessory drive pulleys.
38. NOTICE:
If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold
for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Install the intake manifold. For additional information, refer to Intake Manifold in this section.
39. Install the PCM. For additional information, refer to Section 303-14A.
40. Install the degas bottle. For additional information, refer to Section 303-03.
41. Fill the crankcase with clean engine oil.
42. Install the engine cooling module. For additional information, refer to Section 303-03.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

Cylinder Head ................................................................................................................................................................... 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

Cylinder Head
Special Tool(s)

Lifting Bracket, Engine

303-F047 (014-00073) or equivalent

Remover/Installer, Cylinder Head

303-572 (T97T-6000-A)

Compressor, Valve Spring

303-1039

Alignment Pins, Cylinder Head

303-1040 (SR-015486)

Locking Tool, Cam Phaser Sprocket

303-1046

Installer, Crankshaft Vibration Damper

303-102 (T74P-6316-B)

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
(Continued)

Installer, Crankshaft Front Seal

303-635

Installer, Front Cover Seal

303-335 (T88T-6701-A)

Holding Tool, Crankshaft

303-448 (T93P-6303-A)

Fan Pulley Holding Wrench

303-239 (T84T-6312-C)

Fan Clutch Nut Wrench

303-240 (T84T-6312-D)

Material
Item Specification
Hydraulic Chain Tensioner Retaining Clip —
1L3Z-6P250-AA
Motorcraft Metal Surface Prep —
ZC-31
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) WSS-M97B51-A1
VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil WSS-M2C930-A
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil
CXO-5W20-LSP12 (Canada); or equivalent
Silicone Brake Caliper Grease and Dielectric Compound ESE-M1C171-A
XG-3-A
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
(Continued)

Material (Continued)
Item Specification
Silicone Gasket Remover —
ZC-30

All cylinder heads

1. NOTICE:
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.

NOTICE:
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 future oil leakage.

NOTICE:
The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

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.

2. NOTE:
Tighten the bolts in 3 stages, in the sequence shown.

NOTE:
RH shown, LH similar.

• Stage 1: Tighten to 40 Nm (30 lb-ft).

• Stage 2: Tighten an additional 90 degrees.
• Stage 3: Tighten an additional 90 degrees.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-5 Engine — 5.4L (3V) 303-01A-5
(Continued)

LH cylinder head
3. Remove the special tool from the LH cylinder head.

4. Install the hydraulic lash adjusters into the LH cylinder head.

• Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

5. Install 8 new exhaust manifold studs.

• tighten to 12 Nm (9 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-6 Engine — 5.4L (3V) 303-01A-6
(Continued)

6. Position a new gasket and the LH exhaust manifold and tighten the 8 new nuts in the sequence shown.
• Tighten to 25 Nm (18 lb-ft).

7. Position the LH exhaust manifold heat shield and install the 3 nuts.
• Tighten to 14 Nm (10 lb-ft).

8. Position the intake manifold vacuum tube support bracket and install the bolt.
• Tighten to 10 Nm (89 lb-in).

RH cylinder head

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-7 Engine — 5.4L (3V) 303-01A-7
(Continued)

9. Remove the special tool from the RH cylinder head.

10. Install the hydraulic lash adjusters into the RH cylinder head.
• Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

11. Install 8 new exhaust manifold studs.

• Tighten to 12 Nm (9 lb-ft).

12. Position a new gasket and the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
• Tighten to 25 Nm (18 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-8 Engine — 5.4L (3V) 303-01A-8
(Continued)

13. Position the RH exhaust manifold heat shield and install the 2 bolts.
• Tighten to 10 Nm (89 lb-in).

14. Install the coolant tube and the stud bolt.

• Tighten to 10 Nm (89 lb-in).

All cylinder heads

15. Position the crankshaft with the special tool, then remove the tool.

16. Install the LH and RH camshafts.

• Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
17. NOTE:
LH shown, RH similar.

Install the LH and RH camshaft bearing caps in their original locations.

• Lubricate the camshaft bearing caps with clean engine oil.
• Position the front camshaft bearing cap.
• Position the remaining camshaft bearing caps.
• Install the bolts loosely.
• Tighten to 10 Nm (89 lb-in) in the sequence shown.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-9 Engine — 5.4L (3V) 303-01A-9
(Continued)

18. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE:
LH shown, RH similar.

Install the camshaft phaser and sprocket and new camshaft phaser and sprocket bolts finger tight.

19. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and
sprocket.

NOTE:
LH shown, RH similar.

Using the special tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2 stages.
• Stage 1: Tighten to 40 Nm (30 lb-ft).
• Stage 2: Tighten an additional 90 degrees.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-10 Engine — 5.4L (3V) 303-01A-10
(Continued)

20. NOTICE:
Timing chain procedures must be followed exactly or damage to valves and pistons will result.

NOTICE:
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 or engine damage may occur.

Compress the tensioner plunger, using a vise.

21. Install a retaining clip on the tensioner to hold the plunger in during installation.

22. Remove the tensioner from the vise.

23. 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.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-11 Engine — 5.4L (3V) 303-01A-11
(Continued)

24. Install the crankshaft sprocket, making sure the flange faces forward.

25. Install the 4 bolts and the LH and RH timing chain guides.
• Tighten to 10 Nm (89 lb-in).

26. 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.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-12 Engine — 5.4L (3V) 303-01A-12
(Continued)

27. NOTE:
Make sure the upper half of the timing chain is below the tensioner arm dowel.

Position the timing chain on the camshaft phaser and sprocket with the timing mark positioned between the 2 copper (marked) chain links.

28. 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 and bolts.
• Tighten to 25 Nm (18 lb-ft).

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

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-13 Engine — 5.4L (3V) 303-01A-13
(Continued)

30. 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.

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

NOTE:
The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.

Position the RH timing chain on the camshaft phaser and sprocket. Make sure the timing mark is positioned between the 2 copper (marked) chain
links.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-14 Engine — 5.4L (3V) 303-01A-14
(Continued)

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

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

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

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-15 Engine — 5.4L (3V) 303-01A-15
(Continued)

35. Install the crankshaft sensor ring on the crankshaft.

36. NOTE:
Do not allow the valve keepers to fall off of 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.

Using the special tool, install all of the camshaft roller followers.
• Lubricate the camshaft roller followers with clean engine oil prior to installation.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-16 Engine — 5.4L (3V) 303-01A-16
(Continued)

37. NOTICE:
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. To clean the sealing area, use
Silicone Gasket Remover and Motorcraft 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 may 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 and the oil pan-to-cylinder block surface, at the
locations shown.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-17 Engine — 5.4L (3V) 303-01A-17
(Continued)

38. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.

39. Tighten the engine front cover fasteners in sequence in 2 stages.

Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

Item Part Number Description

1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-18 Engine — 5.4L (3V) 303-01A-18
(Continued)

(Continued)
Item Part Number Description
10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
11 W709573 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
12 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
13 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
14 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
15 W709573 Bolt, Hex Head Pilot, M8 x 1.25 x 56

40. Install the 4 front oil pan bolts in the sequence shown in 2 stages:
• Stage 1: Tighten to 20 Nm (15 lb-ft).
• Stage 2: Tighten an additional 60 degrees.

41. NOTICE:
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. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions on the packaging.
42. NOTE:

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-19 Engine — 5.4L (3V) 303-01A-19
(Continued)

If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.

Apply Silicone Gasket and Sealant in 2 places where the engine front cover meets the cylinder head.

43. NOTICE:
When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

Position the RH valve cover and gasket on the cylinder head and tighten the fasteners in the sequence shown.
• Tighten to 10 Nm (89 lb-in).

44. NOTICE:
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. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions on the packaging.
45. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.

Apply Silicone Gasket and Sealant in 2 places where the engine front cover meets the cylinder head.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-20 Engine — 5.4L (3V) 303-01A-20
(Continued)

46. NOTICE:
When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

Position the LH valve cover and gasket on the cylinder head and tighten the fasteners in the sequence shown.
• Tighten to 10 Nm (89 lb-in).

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

48. Use the special tools to install a new crankshaft front seal into the engine front cover.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-21 Engine — 5.4L (3V) 303-01A-21
(Continued)

49. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.

Apply Silicone Gasket and Sealant to the Woodruff key slot on the crankshaft pulley.

50. Use the special tool to install the crankshaft pulley.

51. Tighten the new crankshaft pulley bolt in 4 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.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-22 Engine — 5.4L (3V) 303-01A-22
(Continued)

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

Install the LH camshaft position (CMP) sensor and the bolt.

• Tighten to 10 Nm (89 lb-in).

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

Install the RH CMP sensor and the bolt.

• Tighten to 10 Nm (89 lb-in).

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

Position the crankshaft position (CKP) sensor and the bolt.

• Tighten to 10 Nm (89 lb-in).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-23 Engine — 5.4L (3V) 303-01A-23
(Continued)

55. Connect the intake manifold vacuum tube to the valve cover stud and the support bracket.

56. Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
• Tighten to 25 Nm (18 lb-ft).

57. Position the oil level indicator and tube and install the bolt.
• Install a new O-ring seal and lubricate with clean engine oil prior to installation.
• Tighten to 10 Nm (89 lb-in).

58. Install the oil level indicator and tube front bolt.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-24 Engine — 5.4L (3V) 303-01A-24
(Continued)

• Tighten to 25 Nm (18 lb-ft).

59. NOTE:
Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.

NOTE:
LH shown, RH similar.

Install the 8 ignition coils and the 8 bolts.

• Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.
• Tighten to 6 Nm (53 lb-in).

60. Position the electrical harness on the engine assembly.

61. Connect the engine oil pressure (EOP) switch electrical connector.

62. Connect the 2 engine wiring harness retainers to the LH valve cover studs.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-25 Engine — 5.4L (3V) 303-01A-25
(Continued)

63. Connect the engine wiring harness position retainers to the front of the RH valve cover.

64. Connect the engine wiring harness position retainers to the front of the LH valve cover and the LH CMP sensor electrical connector.

65. Install the LH radio ignition interference capacitor and the stud bolt.
• Tighten to 25 Nm (18 lb-ft).

66. Connect the cylinder head temperature (CHT) sensor electrical connector.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-26 Engine — 5.4L (3V) 303-01A-26
(Continued)

67. NOTE:
RH shown, LH similar.

Connect the 8 ignition coil electrical connectors.

68. Connect the 2 engine wiring harness retainers from the RH valve cover studs.

69. Connect the RH VCT solenoid electrical connector.

70. Install the RH radio ignition interference capacitor and the stud bolt.
• Tighten to 25 Nm (18 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-27 Engine — 5.4L (3V) 303-01A-27
(Continued)

71. Connect the RH CMP sensor electrical connector.

72. NOTICE:
The engine support insulator bracket bolts must be discarded and new bolts installed, or damage to the vehicle may occur. They are a
tighten-to-yield design and cannot be reused.

NOTICE:
Clean the engine support insulator bracket mounting surfaces of any dirt or foreign material prior to installation. Failure to follow these
instructions may result in engine support insulator damage.

NOTE:
The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.

NOTE:
Place a visible mark on the engine support insulator bracket and the bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

If equipped with cylinder block drain plugs, position the RH engine support insulator bracket, position the engine support insulator bracket and install
3 new bolts in 2 stages.
• Stage 1: Tighten to 30 Nm (22 lb-ft).
• Stage 2: Tighten an additional minimum of 60 degrees.

73. NOTE:
The large clutch assembly nut has a RH thread and must be rotated clockwise to remove it.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-28 Engine — 5.4L (3V) 303-01A-28
(Continued)

Using the special tool, install the engine cooling fan onto the coolant pump pulley.
• Tighten to 55 Nm (41 lb-ft).

74. Install the special tool.

75. Using a suitable floor crane, remove the engine from the engine stand.
76. Install the flexplate or flywheel and the 8 bolts in the sequence shown.
• Tighten to 80 Nm (59 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-29 Engine — 5.4L (3V) 303-01A-29
(Continued)

77. Install the engine. For additional information, refer to Engine in this section.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-i Engine — 5.4L (3V) 303-01A-i

SECTION 303-01A Engine — 5.4L (3V)

CONTENTS PAGE

Engine .............................................................................................................................................................................. 303-01A-2

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-2 Engine — 5.4L (3V) 303-01A-2

Engine
Special Tool(s)

Remover/Installer, Cylinder Head

303-572 (T97T-6000-A)

Installer, Connecting Rod

303-442 (T93P-6136-A)

Compressor, Valve Spring

303-1039

Installer, Crankshaft Vibration Damper

303-102 (T74P-6316-B)

Installer, Crankshaft Front Seal

303-635

Installer, Front Cover Seal

303-335 (T88T-6701-A)

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-3 Engine — 5.4L (3V) 303-01A-3
(Continued)

Compressor, Piston Ring

303-D032 (D81L-6002-C) or equivalent

Installer, Crankshaft Rear Seal

303-518 (T95P-6701-DH)

Installer, Crankshaft Oil Slinger

303-517 (T95P-6701-CH)

Installer, Crankshaft Rear Seal

303-516 (T95P-6701-EH)

Alignment Pins, Cylinder Head

303-1040 (SR-015486)

Lifting Bracket, Engine

303-F047 (014-00073) or equivalent

Locking Tool, Cam Phaser Sprocket

303-1046

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-4 Engine — 5.4L (3V) 303-01A-4
(Continued)

Holding Tool, Crankshaft

303-448 (T93P-6303-A)

Fan Pulley Holding Wrench

303-239 (T84T-6312-C)

Fan Clutch Nut Wrench

303-240 (T84T-6312-D)

Material
Item Specification
Hydraulic Chain Tensioner Retaining Clip —
1L3Z-6P250-AA
Motorcraft Metal Surface Prep —
ZC-31
Motorcraft Premium Gold Engine Coolant with Bittering Agent (US only) WSS-M97B51-A1
VC-7-B (US); CVC-7-A (Canada); or equivalent (yellow color)
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil WSS-M2C930-A
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil
CXO-5W20-LSP12 (Canada); or equivalent
Silicone Brake Caliper Grease and Dielectric Compound ESE-M1C171-A
XG-3-A
Silicone Gasket and Sealant WSE-M4G323-A4
TA-30
Silicone Gasket Remover —
ZC-30

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-5 Engine — 5.4L (3V) 303-01A-5
(Continued)

Engine — Upper End

Item Part Number Description

1 12B637 Engine wiring harness
2 6A505 Valve cover — LH
3 6750 Oil level indicator
4 N605892 Oil level indicator tube bolt
5 6K873 Oil level indicator tube

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-6 Engine — 5.4L (3V) 303-01A-6
(Continued)

Item Part Number Description

6 N807834 Camshaft bearing cap bolt (10 required)
7 6B280 Camshaft bearing cap (4 required)
8 6C255 Camshaft — LH
9 6529 Roller follower (24 required)
10 6518 Valve spring retainer key (48 required)
11 6514 Valve spring retainer (24 required)
12 6513 Valve spring (24 required)
13 6A517 Valve stem seal (24 required)
14 6C501 Hydraulic lash adjuster (24 required)
15 6279 Camshaft phaser sprocket bolt — LH
16 6C524 Camshaft phaser sprocket — LH
17 6B284 Camshaft bearing cap
18 12405 Spark plug (4 required)
19 12A366 Ignition coil (4 required)
20 6065 Cylinder head bolt (20 required)
21 W707747 Exhaust manifold stud (8 required)
22 9Y431 Exhaust manifold gaskets (2 required)
23 9431 Exhaust manifold — LH
24 W701706 Exhaust manifold nut (8 required)
25 6507 Intake valve (16 required)
26 6505 Exhaust valve (8 required)
27 6083 Cylinder head gasket — LH
28 W701520 Variable camshaft timing (VCT) oil control solenoid assembly bolt
(2 required)
29 6C261 VCT oil control solenoid assembly
30 6050 Cylinder head — LH
31 14B102 Cylinder head temperature (CHT) sensor jumper harness
32 W701571 Heater outlet tube stud bolt
33 18663 Heater outlet tube
34 6051 Cylinder head gasket — RH
35 6049 Cylinder head — RH
36 9Y431 Exhaust manifold gaskets (2 required)
37 9430 Exhaust manifold — RH
38 W701706 Exhaust manifold nut (8 required)
39 W707747 Exhaust manifold stud (8 required)
40 6C260 VCT oil control solenoid assembly
41 W701520 VCT oil control solenoid assembly bolt (2 required)
42 6279 Camshaft phaser sprocket bolt — RH
43 6C524 Camshaft phaser sprocket — RH
44 6B284 Camshaft bearing cap
45 N807834 Camshaft bearing cap bolt (10 required)
46 6B280 Camshaft bearing cap (4 required)
47 6251 Camshaft — RH
48 12405 Spark plug (4 required)
49 12A366 Ignition coil (4 required)
50 W706175 Ignition coil bolt (8 required)
51 6582 Valve cover — RH

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-7 Engine — 5.4L (3V) 303-01A-7
(Continued)

Item Part Number Description

52 6765 Oil fill adapter
53 6766 Oil fill adapter cap
54 6758 Crankcase ventilation tube
55 W503282 Coolant crossover tube bolt (3 required)
56 W503279 Thermostat housing bolt (2 required)
57 8594 Thermostat housing
58 N806807 Thermostat O-ring seal
59 8575 Thermostat
60 8C369 Coolant crossover tube
61 9A474 Intake manifold vacuum harness and support bracket assembly
62 W709775 Intake manifold bolt (10 required)
63 9Y451 Intake manifold assembly
64 6K817 PCV tube
65 W500204 PCV heater element assembly bolt (2 required)
66 9F624 PCV heater element assembly

Engine — Front End

Item Part Number Description

1 6306 Crankshaft sprocket
2 6B274 Timing chain guide — LH
3 N606527 Timing chain guide lower bolt — LH
4 6268 Timing chain — LH
5 6K255 Tensioner arm — RH
6 12A227 Ignition pulse wheel
7 W706447 Power steering pump bolt (2 required)
8 3A696 Power steering pump assembly

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-8 Engine — 5.4L (3V) 303-01A-8
(Continued)

Item Part Number Description

9 N808529 Engine front cover stud bolt (2 required)
10 N806177 Engine front cover bolt (10 required)
11 6C315 Crankshaft position (CKP) sensor
12 N806155 CKP sensor bolt
13 6700 Crankshaft front seal
14 6316 Crankshaft pulley
15 N806165 Crankshaft pulley washer
16 W701512 Crankshaft pulley bolt
17 8A528 Coolant pump pulley
18 N806282 Coolant pump pulley bolt (4 required)
19 N806177 Coolant pump bolt (4 required)
20 8501 Coolant pump
21 N808102 Accessory drive belt idler pulley bolt
22 12A216 Accessory drive belt idler pulley
23 N806155 Camshaft position (CMP) sensor bolt (2 required)
24 6B288 CMP sensor (2 required)
25 W709573 Engine front cover stud bolt (3 required)
26 N804758 Radio ignition interference capacitor nuts (2 required)
27 18801 Radio ignition interference capacitors (2 required)
28 6C086 Engine front cover
29 N606543 Timing chain tensioner bolt — RH (2 required)
30 6L266 Timing chain tensioner — RH
31 W503282 Timing chain guide bolt — RH (2 required)
32 6268 Timing chain — RH
33 6M256 Timing chain guide — RH
34 N606543 Timing chain tensioner bolt — LH (2 required)
35 6M269 Timing chain tensioner — LH
36 6M274 Tensioner arm — LH
37 N605892 Timing chain guide upper bolt — LH

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-9 Engine — 5.4L (3V) 303-01A-9
(Continued)

Engine — Lower End

Item Part Number Description

1 6010 Cylinder block
2 W500225 Knock sensor (KS) bolt (2 required)
3 12A699 KS (2 required)
4 6211 Upper connecting rod bearing (8 required)
5 6135 Piston pin (8 required)
6 6159 Outer oil control ring (8 required)
7 6161 Inner oil control ring (8 required)
8 6150 Upper compression ring (8 required)
9 6152 Lower compression ring (8 required)
10 6159 Outer oil control ring (8 required)
11 6140 Piston pin retainer (16 required)
12 6110 Piston (8 required)
13 6200 Connecting rod assembly (8 required)

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-10 Engine — 5.4L (3V) 303-01A-10
(Continued)

Item Part Number Description

14 6K318 Crankshaft rear seal retainer plate
15 6375 Flexplate
16 N806168 Flexplate bolt (8 required)
17 N806168 Flywheel bolt (8 required)
18 6375 Flywheel
19 N806168 Pilot bearing
20 6310 Crankshaft oil slinger
21 6701 Crankshaft rear seal
22 N806155 Crankshaft rear seal retainer plate bolt (6 required)
23 6714 Oil filter
24 6A642 Oil cooler
25 N620482 Oil filter adapter nut
26 6881 Oil filter adapter
27 W704787 Oil filter adapter stud
28 9278 Engine oil pressure (EOP) switch
29 N620482 Oil filter adapter bolt (4 required)
30 6A636 Oil filter adapter gasket
31 W701605 Oil pan bolt (16 required)
32 6675 Oil pan
33 12A648 Engine oil temperature (EOT) sensor
34 6710 Oil pan gasket
35 N605904 Oil pump screen and pickup tube bolt
36 N806155 Oil pump screen and pickup tube bolt (2 required)
37 6622 Oil pump screen and pickup tube
38 N806180 Oil pump screen and pickup tube spacer
39 6345 Crankshaft main bearing cap bolt (9 required)
40 6C357 Crankshaft main bearing cap stud
41 6A346 Crankshaft main bearing dowel (10 required)
42 6325 Crankshaft main bearing cap (5 required)
43 6K302 Crankshaft thrust washer — lower
44 6A338 Crankshaft bearing — lower (5 required)
45 6303 Crankshaft
46 N806201 Crankshaft key
47 6333 Crankshaft bearing — upper (4 required)
48 6A341 Crankshaft thrust washer — upper (2 required)
49 6333 Crankshaft bearing — upper
50 6210 Connecting rod cap (8 required)
51 6211 Connecting rod bearing (8 required)
52 6621 Oil pump
53 N806183 Oil pump bolt (3 required)

1. Record the main bearing code found on the front of the engine block.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-11 Engine — 5.4L (3V) 303-01A-11
(Continued)

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.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-12 Engine — 5.4L (3V) 303-01A-12
(Continued)

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.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-13 Engine — 5.4L (3V) 303-01A-13
(Continued)

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:
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:
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.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-14 Engine — 5.4L (3V) 303-01A-14
(Continued)

9. 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).

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.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-15 Engine — 5.4L (3V) 303-01A-15
(Continued)

12. Install the vertical main bearing cap fasteners and tighten in 2 stages, in the sequence shown.
• 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).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-16 Engine — 5.4L (3V) 303-01A-16
(Continued)

• Stage 2: Tighten an additional 90 degrees.

14. Assemble the 8 pistons. For additional information, refer to Piston in this section.
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. Make sure the dimple in the piston faces the front of the engine.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-17 Engine — 5.4L (3V) 303-01A-17
(Continued)

17. NOTICE:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

NOTE:
The following piston installation steps are for all 8 connecting rods, rod bearings and pistons. Only one connecting rod, rod bearing and piston is
shown.

Use the special tools to install the connecting rod with the upper connecting rod bearing in place.
• Lubricate the piston and ring with clean engine oil.
• Lubricate the rod bearings with clean engine oil.

18. NOTICE:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod or engine damage may occur.

Once the connecting rod is seated on the crankshaft journal, remove the special tool.

19. NOTICE:
The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

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.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-18 Engine — 5.4L (3V) 303-01A-18
(Continued)

20. Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to Section 303-00.
21. NOTE:
Main bearing caps are removed for clarity.

Tighten the bolts in 2 stages, in the sequence shown.

• Stage 1: Tighten to 43 Nm (32 lb-ft).
• Stage 2: Tighten an additional 105 degrees.

22. Position the oil pump and install the bolts.

• Tighten to 10 Nm (89 lb-in).

23. Install the oil pump screen and pickup tube spacer.
• Tighten to 25 Nm (18 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-19 Engine — 5.4L (3V) 303-01A-19
(Continued)

24. NOTICE:
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 the O-ring with clean engine oil prior to installation.

Position the oil pump screen and pickup tube and install the bolts.
• Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in).
• Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).

25. Position the crankshaft with the special tool, then remove the tool.

26. NOTICE:
Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.

NOTICE:
The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry or engine damage may
occur.

NOTICE:
The cylinder head bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

NOTE:

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-20 Engine — 5.4L (3V) 303-01A-20
(Continued)

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.

27. NOTE:
Tighten the bolts in 3 stages, in the sequence shown.

NOTE:
RH shown, LH similar.

• Stage 1: Tighten to 40 Nm (30 lb-ft).

• Stage 2: Tighten an additional 90 degrees.
• Stage 3: Tighten an additional 90 degrees.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-21 Engine — 5.4L (3V) 303-01A-21
(Continued)

28. Remove the special tool from the LH cylinder head.

29. Remove the special tool from the RH cylinder head.

30. Install the hydraulic lash adjusters into the RH and LH cylinder heads.
• Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-22 Engine — 5.4L (3V) 303-01A-22
(Continued)

31. Install the LH and RH camshafts.

• Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
32. NOTE:
LH shown, RH similar.

Install the LH and RH camshaft bearing caps in their original locations.

• Lubricate the camshaft bearing caps with clean engine oil.
• Position the front camshaft bearing cap.
• Position the remaining camshaft bearing caps.
• Install the bolts loosely.
• Tighten to 10 Nm (89 lb-in) in the sequence shown.

33. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTE:
LH shown, RH similar.

Install the camshaft phaser and sprockets, new camshaft phaser and sprocket bolts finger tight.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-23 Engine — 5.4L (3V) 303-01A-23
(Continued)

34. NOTICE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

NOTICE:
Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and
sprocket.

NOTE:
LH shown, RH similar.

Using the special tool, tighten the LH and RH camshaft phaser and sprocket bolts in 2 stages.
• Stage 1: Tighten to 40 Nm (30 lb-ft).
• Stage 2: Tighten an additional 90 degrees.

35. NOTICE:
Timing chain procedures must be followed exactly or damage to valves and pistons may result.

NOTICE:
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 or engine damage may occur.

Compress the tensioner plunger, using a vise.

36. Install a retaining clip on the tensioner to hold the plunger in during installation.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-24 Engine — 5.4L (3V) 303-01A-24
(Continued)

37. Remove the tensioner from the vise.

38. 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.

39. Install the crankshaft sprocket, making sure the flange faces forward.

40. Install the 4 bolts and the LH and RH timing chain guides.
• Tighten to 10 Nm (89 lb-in).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-25 Engine — 5.4L (3V) 303-01A-25
(Continued)

41. 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.

42. NOTE:
Make sure the upper half of the timing chain is below the tensioner arm dowel.

Position the timing chain on the VCT phaser sprocket with the timing mark positioned between the 2 copper (marked) chain links.

43. NOTE:

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-26 Engine — 5.4L (3V) 303-01A-26
(Continued)

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 and bolts.
• Tighten to 25 Nm (18 lb-ft).

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

45. 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.

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

NOTE:
The camshaft phaser and sprocket will be stamped with one of the illustrated timing marks for the RH camshaft.

Position the RH timing chain on the camshaft phaser and sprocket. Make sure the timing mark is positioned between the 2 copper (marked) chain
links.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-27 Engine — 5.4L (3V) 303-01A-27
(Continued)

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

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

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

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-28 Engine — 5.4L (3V) 303-01A-28
(Continued)

50. Install the crankshaft sensor ring on the crankshaft.

51. NOTE:
Do not allow the valve keepers to fall off of 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.

Using the special tool, install all of the camshaft roller followers.
• Lubricate the camshaft roller followers with clean engine oil prior to installation.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-29 Engine — 5.4L (3V) 303-01A-29
(Continued)

52. NOTICE:
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. To clean the sealing area, use
Silicone Gasket Remover and Motorcraft 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 may 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.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-30 Engine — 5.4L (3V) 303-01A-30
(Continued)

53. Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight.

54. Tighten the engine front cover fasteners in sequence in 2 stages.

Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

Item Part Number Description

1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
5 N806177 Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
6 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
8 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
9 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-31 Engine — 5.4L (3V) 303-01A-31
(Continued)

(Continued)
Item Part Number Description
10 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
11 W709573 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
12 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
13 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
14 W709573 Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
15 W709573 Bolt, Hex Head Pilot, M8 x 1.25 x 56

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

Install the LH camshaft position (CMP) sensor and the bolt.

• Tighten to 10 Nm (89 lb-in).

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

Install the RH CMP sensor and the bolt.

• Tighten to 10 Nm (89 lb-in).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-32 Engine — 5.4L (3V) 303-01A-32
(Continued)

57. NOTICE:
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.

Using a new O-ring seal, position the coolant pump and install the bolts loosely.
• Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.

58. Tighten the 4 coolant pump bolts.

• Tighten to 25 Nm (18 lb-ft).

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

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-33 Engine — 5.4L (3V) 303-01A-33
(Continued)

60. Using the special tools, install a new crankshaft front seal into the engine front cover.

61. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.

Apply Silicone Gasket and Sealant to the Woodruff key slot on the crankshaft pulley.

62. Use the special tool to install the crankshaft pulley.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-34 Engine — 5.4L (3V) 303-01A-34
(Continued)

63. Tighten the new crankshaft pulley bolt in 4 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.

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

Position the crankshaft position (CKP) sensor and the bolt.

• Tighten to 10 Nm (89 lb-in).

65. Position the accessory drive belt tensioner and install the 3 bolts.
• Tighten to 25 Nm (18 lb-ft).

66. Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
• Tighten to 25 Nm (18 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-35 Engine — 5.4L (3V) 303-01A-35
(Continued)

67. NOTICE:
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:
Clean and inspect the mating surfaces, and install a new gasket.

Position the oil filter adapter and install the 4 bolts and the nut.
• Tighten the bolts to 25 Nm (18 lb-ft).
• Tighten the nut to 48 Nm (35 lb-ft).

68. NOTE:
RH shown, LH similar.

Install 16 new exhaust manifold studs.

• Tighten to 12 Nm (9 lb-ft).

69. Position a new gasket, the LH exhaust manifold and tighten the 8 new nuts in the sequence shown.
• Tighten to 25 Nm (18 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-36 Engine — 5.4L (3V) 303-01A-36
(Continued)

70. Position the LH exhaust manifold shield and install the 3 bolts.
• Tighten to 14 Nm (10 lb-ft).

71. NOTICE:
The engine support insulator bracket bolts must be discarded and new bolts installed, or damage to the vehicle may occur. They are a
tighten-to-yield design and cannot be reused.

NOTICE:
Clean the engine support insulator bracket mounting surfaces of any dirt or foreign material prior to installation. Failure to follow these
instructions may result in engine support insulator damage.

NOTE:
The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.

NOTE:
Place a visible mark on the engine support insulator bracket and the bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

Position the LH engine support insulator bracket and install 3 new bolts in 2 stages.
• Stage 1: Tighten to 30 Nm (22 lb-ft).
• Stage 2: Tighten an additional minimum of 60 degrees.

72. Position a new gasket, the RH exhaust manifold and tighten the 8 new nuts in the sequence shown.
• Tighten to 25 Nm (18 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-37 Engine — 5.4L (3V) 303-01A-37
(Continued)

73. Position the RH exhaust manifold heat shield and install the 2 bolts.

74. NOTICE:
The engine support insulator bracket bolts must be discarded and new bolts installed, or damage to the vehicle may occur. They are a
tighten-to-yield design and cannot be reused.

NOTICE:
Clean the engine support insulator bracket mounting surfaces of any dirt or foreign material prior to installation. Failure to follow these
instructions may result in engine support insulator damage.

NOTE:
The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.

NOTE:
Place a visible mark on the engine support insulator bracket and the bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

Position the RH engine support insulator bracket, position the engine support insulator bracket and install 3 new bolts in 2 stages.
• Stage 1: Tighten to 30 Nm (22 lb-ft).
• Stage 2: Tighten an additional minimum of 60 degrees.

75. NOTICE:
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. Use a plastic scraping tool to remove all traces of old sealant.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-38 Engine — 5.4L (3V) 303-01A-38
(Continued)

Clean the valve cover mating surface with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions on the packaging.
76. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.

Apply Silicone Gasket and Sealant in 2 places where the engine front cover meets the cylinder head.

77. NOTICE:
When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

Position the RH valve cover and gasket on the cylinder head and tighten the fasteners in the sequence shown.
• Tighten to 10 Nm (89 lb-in).

78. NOTICE:
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. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions on the packaging.
79. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-39 Engine — 5.4L (3V) 303-01A-39
(Continued)

Apply Silicone Gasket and Sealant in 2 places where the engine front cover meets the cylinder head.

80. NOTICE:
When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.

Position the LH valve cover and gasket on the cylinder head and tighten the fasteners in the sequence shown.
• Tighten to 10 Nm (89 lb-in).

81. NOTE:
Do not reuse the O-ring seals.

NOTE:
Lubricate new O-ring seals with clean engine coolant prior to installation.

Slide the coolant tube forward with the new O-ring seals into the cylinder block.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-40 Engine — 5.4L (3V) 303-01A-40
(Continued)

82. Install the coolant tube stud bolt.

• Tighten to 10 Nm (89 lb-in).

83. Install the 2 knock sensors (KS) and the bolts.

• Tighten to 20 Nm (15 lb-ft).

84. Install the oil level indicator tube and the front bolt.
• Tighten to 25 Nm (18 lb-ft).
• Install a new O-ring seal and lubricate with clean engine oil prior to installation.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-41 Engine — 5.4L (3V) 303-01A-41
(Continued)

85. Install the rear oil level indicator tube bolt.

• Tighten to 10 Nm (89 lb-in).

86. Connect the intake manifold vacuum tube to the valve cover stud and the support bracket.

87. Position the intake manifold vacuum tube support bracket and install the bolt.
• Tighten to 10 Nm (89 lb-in).

88. NOTE:
Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-42 Engine — 5.4L (3V) 303-01A-42
(Continued)

NOTE:
LH shown, RH similar.

Install the 8 ignition coils and the 8 bolts.

• Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.
• Tighten to 6 Nm (53 lb-in).

89. Position the engine wiring harness onto the engine assembly.
90. Connect the 2 engine wiring harness retainers to the LH valve cover studs.

91. Connect the engine wiring harness position retainers to the front of the LH valve cover and the LH CMP sensor electrical connector.

92. Connect the engine oil pressure (EOP) switch electrical connector.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-43 Engine — 5.4L (3V) 303-01A-43
(Continued)

93. Install the LH radio ignition interference capacitor and the nut.
• Tighten to 10 Nm (89 lb-in).

94. Connect the 2 engine wiring harness retainers from the RH valve cover studs.

95. Connect the RH VCT solenoid electrical connector.

96. Install the RH radio ignition interference capacitor and the nut.
• Tighten to 10 Nm (89 lb-in).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-44 Engine — 5.4L (3V) 303-01A-44
(Continued)

97. Connect the RH CMP sensor electrical connector.

98. Connect the engine wiring harness position retainers to the front of the RH valve cover.

99. NOTE:
LH shown, RH similar.

Connect the 8 ignition coil electrical connectors.

100. NOTE:
The large clutch assembly nut has a RH thread and must be rotated clockwise to remove it.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-45 Engine — 5.4L (3V) 303-01A-45
(Continued)

Using the special tool, install the engine cooling fan onto the coolant pump pulley.
• Tighten to 55 Nm (41 lb-ft).

101. Install the special tool.

102. Using a suitable floor crane, remove the engine from the engine stand.
103. NOTICE:
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. Failure to follow this
procedure can cause future oil leakage.

Inspect the crankshaft rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with Silicone Gasket Remover and Motorcraft
Metal Surface Prep. Follow the directions on the packaging.
104. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.

Apply a 4 mm (0.16 in) bead of Silicone Gasket and Sealant around the crankshaft rear seal retainer sealing surface.

105. Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-46 Engine — 5.4L (3V) 303-01A-46
(Continued)

106. Tighten the bolts in the sequence shown.

• Tighten to 10 Nm (89 lb-in).

107. NOTICE:
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.

Inspect the oil pan. Clean the mating surface for the oil pan with Silicone Gasket Remover and Motorcraft Metal Surface Prep. Follow the directions
on the packaging.
108. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.

Apply Silicone Gasket and Sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.

109. NOTE:
If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use Silicone Gasket Remover and
Motorcraft 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 may cause future oil leakage.

Apply Silicone Gasket and Sealant at the engine front cover-to-cylinder block sealing surface.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-47 Engine — 5.4L (3V) 303-01A-47
(Continued)

110. Install the oil pan gasket and the oil pan and loosely install the bolts.

111. Tighten the bolts in 3 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.

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-48 Engine — 5.4L (3V) 303-01A-48
(Continued)

112. NOTE:
Lubricate the inner lip of the crankshaft rear seal with clean engine oil.

Using the special tools, install a new crankshaft rear seal.

113. Using the special tools, install a new crankshaft rear oil slinger.

114. Install the flexplate or flywheel and the 8 bolts in the sequence shown.
• Tighten to 80 Nm (59 lb-ft).

2008 F-250, 350, 450, 550 Super Duty, 7/2007

303-01A-49 Engine — 5.4L (3V) 303-01A-49
(Continued)

2008 F-250, 350, 450, 550 Super Duty, 7/2007