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
8
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
Nm
bore)
Valve cover bolts
10
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
26
Piston ring end gap
0.25-0.40 mm
(CHT)
—intermediate
(0.0098-0.0158 in)
Camshaft position (CMP) sensor bolt
10
Piston ring end gap — oil 0.15-0.65 mm
control
(0.0059-0.0256 in)
Crankshaft position (CKP) sensor bolt
10
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
25
Piston ring-to-groove
0.030-0.050 mm
Exhaust manifold studs
12
clearance — top
(0.0012-0.0020 in)
Exhaust manifold-to-Y-pipe nuts
40
Piston ring-to-groove
0.030-0.080 mm
Drive belt idler pulley bolt
25
clearance — intermediate (0.0012-0.0031 in)
Flywheel bolts
80
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
48
(0.8662-0.8663 in)
G89770 en
303-01b-5
Engine — 5.4L (3V)
303-01b-5
SPECIFICATIONS (Continued)
Description
Nm
Torque converter-to-flexplate nuts
35
Fuel injection supply manifold bracket
10
bolts
Generator upper mounting bracket
10
bolts
Generator lower mounting bolts
25
Ignition coil
6
Intake manifold to cylinder head bolts¹
—
Knock sensor
20
Oil filter
16
Oil filter adapter bolts
25
Oil level indicator tube bolt
10
Oil pan bolts¹
—
Oil pan drain plug
14
Oil pressure switch
14
Oil pump bolts
10
Oil pump screen and pickup tube bolts
10
Oil pump screen and pickup tube
25
spacer
Oil pump screen and pickup tube
25
spacer bolt
Power steering pump bolts
25
Rear main oil seal retainer bolts Spark
10
plugs
Spark plugs
18
Thermostat housing bolts
10
Throttle body spacer-to-intake manifold
10
bolts
Timing chain guide bolts
10
Timing chain hydraulic tensioner bolts
25
Coolant pump bolts
25
Coolant pump pulley bolts
25
Motor mount-to-cylinder block bolts
63
Motor mount through bolt
200
Motor mount nut
103
Oil pressure switch
14
Power steering reservoir bracket bolts
25
Power steering reservoir bracket nut
25
Ground strap nut
10
Fuel injection supply manifold bolts
10
Generator bracket bolts
10
Intake manifold bolts¹
—
Transmission cooler line bracket nut
10
¹ Refer to the procedure in this section.
G89770 en
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