Ford Falcon. Manual - part 141

303-01b-78 

Engine — 5.4L (3V) 

303-01b-78

ASSEMBLY (Continued)

17. Tighten the bolts in two stages, using the

19. Position the head gasket over the dowel pins.

sequence shown.

RH is shown; LH is similar.

Stage 1: Tighten to 43 Nm (32 lb-ft).

 CAUTION: Make sure all coolant

Stage 2: Tighten an additional 105 degrees.

residue and foreign material are cleaned

NOTE: Main bearing caps are removed for

from the block surface and cylinder bore.

clarity.

 CAUTION: The use of sealing aids

(aviation cement, copper spray, and glue)

is not permitted. The gasket must be

installed dry.

20. Rotate the crankshaft until the crankshaft keyway

points toward the 9 o’clock position.

18. Position the oil pump and install the bolts loosely.

Tighten the bolts in the sequence shown.

21. Position the cylinder head over the dowels and

head gasket and install the cylinder head bolts

loosely.

RH is shown; LH is similar.

 CAUTION: The cylinder head bolts

must be discarded and new bolts installed.

They are tighten-to-yield designed and

cannot be reused.
NOTE: NOTE: Do not turn the crankshaft until

instructed to do so.

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Engine — 5.4L (3V) 

303-01b-79

ASSEMBLY (Continued)

23. Install the oil level indicator tube.

Install a new O-ring seal on the oil level

indicator tube.
Install the oil level indicator tube.
Install the bolt and tighten to 10 Nm (89 lb-in).

24. Install the RH exhaust manifold gaskets and the

exhaust manifold. Tighten the nuts in the

sequence shown.

22. Tighten the bolts in three stages, in the sequence

shown.

RH is shown; LH is similar.

Stage 1: Tighten to 40 Nm (30 lb-ft).
Stage 2: Tighten an additional 90 degrees.
Stage 3: Tighten an additional 90 degrees.

25. Install the LH exhaust manifold and the exhaust

manifold gaskets. Tighten the nuts in the

sequence shown.

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303-01b-80 

Engine — 5.4L (3V) 

303-01b-80

ASSEMBLY (Continued)

26. Compress the tensioner plunger, using a vise.

30. Install the RH timing chain guide.

 CAUTION: Timing chain procedures must

be followed exactly or damage to valves and

pistons will result.

31. Install the LH timing chain guide.

27. Install a retaining clip on the tensioner to hold the

plunger in during installation.

32. Pre-position the camshafts.
 

1.  Rotate the LH camshaft until the timing mark

is approximately at 6 o’clock.

 

2.  Rotate the RH camshaft until the timing mark

28. Remove the tensioner from the vise.

is approximately at 12 o’clock.

29. If the copper links are not visible, mark two links

 

on one end and one link on the other end, and

use as timing marks.

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Engine — 5.4L (3V) 

303-01b-81

ASSEMBLY (Continued)

 

33. Remove the Crankshaft Holding Tool.

36. Position the timing chain on the camshaft

sprocket with the camshaft sprocket timing mark

34. Install the crankshaft sprocket, making sure the

positioned between the two copper (marked)

flange faces forward.

chain links.
NOTE: Make sure the upper half of the timing

chain is below the tensioner arm dowel.
NOTE: If necessary, use the Camshaft Alignment

Set to adjust the camshaft sprocket slightly to

obtain timing mark alignment.

35. 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.

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