Ford Falcon. Manual - part 142

303-01b-82 

Engine — 5.4L (3V) 

303-01b-82

ASSEMBLY (Continued)

37. Position the LH timing chain tensioner arm on the 40. Position the RH timing chain on the camshaft

dowel pin and install the LH timing chain

sprocket. Make sure the camshaft sprocket timing

tensioner.

mark is positioned between the two copper

(marked) chain links.

NOTE: The LH timing chain tensioner arm has a

bump near the dowel hole for identification.

NOTE: The lower half of the timing chain must be

positioned above the tensioner arm dowel.
NOTE: If necessary, use the Camshaft Alignment

Set to adjust the camshaft sprocket slightly to

obtain timing mark alignment.

38. Remove the retaining clip from the LH timing

chain tensioner.

41. Position the RH timing chain tensioner arm on the

dowel pin and install the RH timing chain

tensioner.

39. 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.

42. Remove the retaining clip from the RH timing

chain tensioner.

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303-01b-83 

Engine — 5.4L (3V) 

303-01b-83

ASSEMBLY (Continued)

43. As a post-check, verify correct alignment of all

timing marks.

44. Install the camshaft roller followers.
 

1.  Compress the valve spring.

 

2.  Install the camshaft roller followers in their

original locations.

47. Install a new engine front cover gasket on the

engine front cover. Position the engine front

NOTE: Lubricate the camshaft roller followers

cover. Install the fasteners finger-tight.

using clean engine oil.
NOTE: The use of a special tool may be

required.

45. Install the crankshaft sensor ring on the

crankshaft.

48. Tighten the engine front cover fasteners in

sequence in three stages.

Stage 1: Tighten fasteners 1 through 5 to 25

Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm

46. Apply a bead of silicone gasket and sealant along

(35 lb-ft).

the cylinder head-to-cylinder block surface at the

Stage 3: Tighten fasteners 8 through 15 to 48

locations shown.

Nm (35 lb-ft).

NOTE: If the front cover is not secured within four

minutes, the sealant must be removed and the

sealing area cleaned. To clean the sealing area,

use silicone gasket remover and metal surface

prep. Follow the directions on the packaging.

Failure to follow this procedure can cause future

oil leakage.

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303-01b-84 

Engine — 5.4L (3V) 

303-01b-84

ASSEMBLY (Continued)

Item

Description

Item

Description

14

N808140 Stud and Washer, Hex Head

1

N806177 Bolt, Hex Flange Head Pilot, M8

Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27

x 1.25 x 53

15

N808140 Stud and Washer, Hex Head

2

N806177 Bolt, Hex Flange Head Pilot, M8

Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27

x 1.25 x 53

3

N806177 Bolt, Hex Flange Head Pilot, M8

49. Install the oil pump screen and pickup tube

x 1.25 x 53

spacer.

4

N806177 Bolt, Hex Flange Head Pilot, M8

x 1.25 x 53

5

N806177 Bolt, Hex Flange Head Pilot, M8

x 1.25 x 53

6

N808529 Stud, Hex Head Pilot, M10 x 1.5

x 59 — M10 x 1.5 x 30

7

N808529 Stud, Hex Head Pilot, M10 x 1.5

x 59 — M10 x 1.5 x 30

8

N808142 Screw and Washer, Hex Pilot,

M10 x 1.5 x 57.5

9

N808142 Screw and Washer, Hex Pilot,

M10 x 1.5 x 57.5

10

N808142 Screw and Washer, Hex Pilot,

M10 x 1.5 x 57.5

11

N808140 Stud and Washer, Hex Head

Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27

12

N808140 Stud and Washer, Hex Head

Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27

13

N808140 Stud and Washer, Hex Head

Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 27

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303-01b-85 

Engine — 5.4L (3V) 

303-01b-85

ASSEMBLY (Continued)

50. Position the oil pump screen and pickup tube and 53. Position the belt idler pulley and install the bolt.

install the bolts.

 CAUTION: 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 with the O-ring

with clean engine oil.

51. Position the oil filter adapter and install the four

bolts.
NOTE: NOTE: Clean and inspect the mating

surfaces, and install new gaskets.

54. Install the coolant pump.
 

1.  Lubricate the new O-ring seal using engine

coolant and install the O-ring seal onto the

coolant pump.

 

2.  Position the coolant pump into the engine

block.

 

3.  Install the bolts.

 CAUTION: Do not rotate the coolant

pump housing once the coolant pump has

been positioned in the cylinder block.

Damage to the O-ring seal will occur.

52. Position the power steering pump and install the

three bolts.

55. Lubricate the engine front cover and the front oil

seal inner lip with clean engine oil.

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