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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