Ford Falcon. Manual - part 122

303-01b-2

Engine — 5.4L (3V)

303-01b-2

(Continued)

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Cylinder Head ....................................................................................................................303-01b-67

ASSEMBLY

Engine ................................................................................................................................303-01b-71

303-01b-3

Engine — 5.4L (3V)

303-01b-3

SPECIFICATIONS

General Specifications

Description

Specification

Description

Specification

Valve face angle

45.5 deg

Lubricants and Sealants

Valve seat width intake

1.2-1.4mm

SAE 5W-20 Premium

WSS-M2C153-H

Valve seat width exhaust 1.4-1.6mm

Synthetic Blend Motor Oil

Valve seat runout

TBD

XO-5W20-QSP or

Valve seat angle cyl head 44.5-45.0 deg

equivalent

Valve spring free length

Does not apply

Motorcraft Premium Gold WSS-M97B51-A1 (yellow

Valve spring squareness TBD

Engine Coolant VC-7-A

color)

(in Oregon VC-7-B) or

Valve spring compression 350N +/- 17.5N at

equivalent¹

pressure at specified

42.04mm +13N for creep

height (lbs)

when stored 760N +/-

Metal Surface Prep

ZC-31

39N at 31.04mm

Silicone Gasket and

WSE-M4G323-A4

Valve spring installed

42.04 mm

Sealant F7AZ-19554-EA

height

or equivalent

Valve spring installe

350N +/- 17.5N at

Instant Adhesive

WSK-M2G402-A4

pressure

42.04mm +13N for creep

E8AZ-19554-A or

when stored

equivalent

Roller follower ratio

TBD

Silicone Gasket Remover ZC-30

Hydraulic Lash Adjuster

Engine

Diameter

TBD

Displacement

5.4L (330 CID)

Clearance-to-bore

TBD

Number of cylinders

Service limit

TBD

Bore

90.2 mm (3.55 in)

Hydraulic leakdown rate

TBD

Stroke

105.8 mm (4.17 in)

Collapsed lash adjuster

TBD

Firing order

1-3-7-2-6-5-4-8

gap

Oil pressure minimum at

275.8-413.7 kPa (40-60

Camshaft

2,000 rpm (engine at

psi)

normal operating

Theoretical valve lift @

intake 11.1 mm exhaust

temperature)

lash

11.0 mm

Oil capacity

7.0 liters with filter

Lobe lift

0.584 mm

Compression ratio

9. 8:1

Allowable lobe lift loss

0.127 mm

Cylinder Head and Valve Train

Journal diameter

28.607-28.633 mm

Combustion chamber

42.45-45.45 cc (2.59-2.77

Camshaft journal bore

28.657-28.682 mm

volume

cu in)

inside diameter

Valve arrangement (front I-E-I-I-E-I-I-E-I-I-E-I

Camshaft

0.04-0.095 mm

to rear) — LH

journal-to-bearing

clearance

Valve arrangement (front I-E-I-I-E-I-I-E-I-I-E-I

to rear) — RH

Runout

0.05 mm

Valve guide bore

6.015-6.044

End play

0.075-0.185 mm

diameter

Cylinder Block

Valve stem diameter

5.975-5.995

Cylinder bore diameter

90.200-90.210 mm

intake

—grade 1

(3.5512-3.5516 in)

Valve stem diameter

5.95-5.97

Cylinder bore diameter

90.210-90.220 mm

exhaust

—grade 2

(3.5516-3.5520 in)

Valve stem-to-guide

0.020-0.045

Cylinder bore diameter

90.220-90.230 mm

clearance — intake

—grade 3

(3.5520-3.5524 in)

Valve stem-to-guid

0.069-0.094

Cylinder bore maximum

0.006 mm (0.0002 in)

clearance — exhaust

taper

Valve head diameter

33.62-33.98

Cylinder bore maximum

0.020 mm (0.0008 in)

intake

out-of-round

Valve head diameter

37.32-37.68

Main bearing bore inside 72.401-72.422 mm

exhaust

diameter

(2.850-2.851 in)

Valve face runout

0.05

G89770 en

303-01b-4

Engine — 5.4L (3V)

303-01b-4

SPECIFICATIONS (Continued)

Description

Specification

Description

Specification

Crankshaft

Piston pin length

61.8 mm (2.433 in)

Main bearing journal

67.483-67.503 mm

Piston pin-to-piston fit

0.005-0.0135 mm

diameter

(2.6568-2.6576 in)

(clearance)

(0.0002-0.0005 in)

Main bearing journal

0.004 mm (0.0002 in)

Connecting rod-to-pin

0.009-0.0235 mm

maximum taper

clearance

(0.0004-0.0093 in)

(straightness)

Connecting rod pin bore

22.012-22.024 mm

Main bearing journal

0.0075 mm (0.0003 in)

diameter

(0.8666-0.8671 in)

maximum out-of-round

between cross sections

Connecting rod length

169.1 mm (6.6575 in)

Main bearing

0.048-0.024 mm

(centerline bore-to-bore)

journal-to-cylinder block

(0.0019-0.0009 in)

Connecting rod maximum

± 0.038 mm (0.0015 in)

clearance

allowed bend

Connecting rod journal

53.003-52.983 mm

Connecting rod maximum

± 0.05 mm (0.0020 in)

diameter

(2.0867-2.0859 in)

allowed twist

Connecting rod journal

0.004 mm (0.0002 in)

Connecting rod bearing

53.049-53.027 mm

maximum taper

bore diameter (with

(2.0885-2.0877 in)

Connecting rod journal

0.0075 mm (0.0003 in)

assembled liners)

maximum out-of-round

between cross sections

Connecting rod

0.064-0.026 mm

Crankshaft maximum end 0.075-0.377 mm

bearing-to-crankshaft

(0.0025-0.0010 in)

play

(0.0030-0.0148 in)

clearance

Piston and Connecting Rod

Connecting rod side

0.475-0.125 mm

clearance

(0.0187-0.0049 in)

Piston diameter — grade 90.175-90.165 mm

1 (at right angle to pin

(3.5502-3.5498 in)

Accessory Drive Belt

bore)

Drive belt

6 ribs

Piston diameter — grade 90.185-90.175 mm

¹ The addition of Motorcraft Cooling System Stop

2 (at right angle to pin

(3.5506-3.5502 in)

Leak Pellets, VC-6, darkens Motorcraft Premium Gold

bore)

Engine Coolant from yellow to golden tan.

Piston diameter — grade 90.195-90.185 mm

Torque Specifications

3 (at right angle to pin

(3.5510-3.5506 in)

Description

bore)

Valve cover bolts

Piston-to-cylinder bore

0.025-0.045 mm

Camshaft bearing cap bolts¹

—

clearance (at grade size) (0.0010-0.0018 in)

Variable camshaft timing (VCT)

—

Piston ring end gap —

0.13-0.28 mm

sprocket assembly bolts¹

top

(0.0051-0.0110 in)

Cylinder head temperature sensor

Piston ring end gap

0.25-0.40 mm

(CHT)

—intermediate

(0.0098-0.0158 in)

Camshaft position (CMP) sensor bolt

Piston ring end gap — oil 0.15-0.65 mm

control

(0.0059-0.0256 in)

Crankshaft position (CKP) sensor bolt

Piston ring groove width

1.53-1.55 mm

Connecting rod bolts¹

—

— top

(0.0602-0.0610 in)

Crankshaft damper pulley bolt¹

—

Piston ring groove width

1.52-1.54 mm

Crankshaft main bearing bolts

—

— intermediate

(0.0598-0.0606 in)

(cross-mounted)¹

Piston ring groove width

3.030-3.050 mm

Crankshaft main bearing bolts

—

— oil control

(0.1193-0.1201 in)

(vertical)¹

Piston ring width

1.49-1.46 mm

Cylinder heads bolts¹

—

(0.0587-0.0575 in)

Exhaust manifold nuts

Piston ring-to-groove

0.030-0.050 mm

Exhaust manifold studs

clearance — top

(0.0012-0.0020 in)

Exhaust manifold-to-Y-pipe nuts

Piston ring-to-groove

0.030-0.080 mm

Drive belt idler pulley bolt

clearance — intermediate (0.0012-0.0031 in)

Flywheel bolts

Piston pin bore diameter

22.008-22.014 mm

(0.8665-0.8667 in)

Engine front cover bolts¹

—

Piston pin diameter

22.0005-22.0030 mm

Transmission-to-engine bolts

(0.8662-0.8663 in)

G89770 en

303-01b-5

Engine — 5.4L (3V)

303-01b-5

SPECIFICATIONS (Continued)

Description

Torque converter-to-flexplate nuts

Fuel injection supply manifold bracket

bolts
Generator upper mounting bracket

bolts
Generator lower mounting bolts

Ignition coil

Intake manifold to cylinder head bolts¹

—

Knock sensor

Oil filter

Oil filter adapter bolts

Oil level indicator tube bolt

Oil pan bolts¹

—

Oil pan drain plug

Oil pressure switch

Oil pump bolts

Oil pump screen and pickup tube bolts

Oil pump screen and pickup tube

spacer
Oil pump screen and pickup tube

spacer bolt
Power steering pump bolts

Rear main oil seal retainer bolts Spark

plugs
Spark plugs

Thermostat housing bolts

Throttle body spacer-to-intake manifold

bolts
Timing chain guide bolts

Timing chain hydraulic tensioner bolts

Coolant pump bolts

Coolant pump pulley bolts

Motor mount-to-cylinder block bolts

Motor mount through bolt

200

Motor mount nut

103

Oil pressure switch

Power steering reservoir bracket bolts

Power steering reservoir bracket nut

Ground strap nut

Fuel injection supply manifold bolts

Generator bracket bolts

Intake manifold bolts¹

—

Transmission cooler line bracket nut

¹ Refer to the procedure in this section.

G89770 en

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