Ford Falcon. Manual — part 145

303-01c-1

Engine — V8 (4V)

303-01c-1

SECTION : 303-01c Engine — V8 (4V)

VEHICLE APPLICATION : 2003.0 BA Falcon
CONTENTS

PAGE

SPECIFICATIONS

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-3

DESCRIPTION AND OPERATION

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01c-6

Identification

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01c-6

Code Information . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-6

Induction System . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-6

Valve Train . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01c-6

Positive Crankcase Ventilation System . . . . . . . . . . . . . . . . . . . 303-01c-6

Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01c-6

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-7

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01c-7

Drive Belt System . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01c-7

DIAGNOSIS AND TESTING

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-17

IN-VEHICLE REPAIRS

Intake Manifold Upper . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01c-18

Intake Manifold — Lower . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-18

Valve Cover — RH . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01c-20

Valve Cover — LH . . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01c-22

Crankshaft Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01c-22

Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . ..303-01c-24

Engine Front Cover . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-24

Timing Drive Components . . . . . . . . . . . . . . . . . . . . . . . . .303-01c-28

Valve — Springs, Retainer and Valve Stem Seal . . . . . . . . . . . . . . . ..303-01c-33

Hydraulic Lash Adjusters . . . . . . . . . . . . . . . . . . . . . . . . ..303-01c-35

Roller Followers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01c-35

Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-36

Exhaust Manifold — LH . . . . . . . . . . . . . . . . . . . . . . . . . .303-01c-40

Oil Filter Adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-40

Oil Pressure Sender . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01c-41

Oil Level Indicator and Tube . . . . . . . . . . . . . . . . . . . . . . . .303-01c-42

Oil Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..303-01c-42

Oil Pump Screen and Pickup Tube . . . . . . . . . . . . . . . . . . . . ...303-01c-44

Flexplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01c-45

Crankshaft Rear Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . ..303-01c-45

Engine Mounts — RH . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01c-47

Engine Mounts — LH . . . . . . . . . . . . . . . . . . . . . . . . . . .303-01c-47

REMOVAL

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-48

303-01c-2

Engine — V8 (4V)

303-01c-2

(Continued)

DISASSEMBLY

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-52

DISASSEMBLY AND ASSEMBLY OF SUBASSEMBLIES

Piston . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303-01c-62

Cylinder Head RH and LH . . . . . . . . . . . . . . . . . . . . . . . . .303-01c-63

ASSEMBLY

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-70

INSTALLATION

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...303-01c-89

303-01c-3

Engine — V8 (4V)

303-01c-3

SPECIFICATIONS

General Specifications

Description

Specification

Description

Specification

Alignment bore-to-bore

± 0.038 mm (0.0015 in)

max. bend

Magnetic clutch

Side play (as assembled

0.300

± 0.175 mm

Air gap between pulley

0.35 mm-0.75 mm (0.014

to crank)-standard play

(0.0118

± 0.0069 in)

and hub

in 0.029 in)

Side play (as assembled

0.475 mm (0.0187 in)

Displacement

5.4L (4V)

to crank)-max. play

No. cylinders

8

Piston

Bore/stroke

90.215/105.8 mm

Cylinder bore diameter

90.200-90.210 mm

(3.552/4.165 in)

Grade 1

(3.5511-3.5515 in)

Firing order

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

Cylinder bore diameter

90.210-90.220 mm

Camshaft

Grade 2

(3.5516-3.5521 in)

Lobe lift exhaust LH

6.5958 mm (0.2597 in)

Cylinder bore diameter

90.220-90.230 mm

Lobe lift exhaust RH

6.5855 mm (0.2593 in)

Grade 3

(3.5519-3.5524 in)

Lobe lift intake

6.58077 mm (0.250847

Piston diameter (Grade

90.180

± 0.005 mm

in)

2) at right angle to pin

(3.5504

± 0.0002 in)

bore

Lobe lift – allowable lift

0

loss

Piston to bore clearance

-0.005 to +0.025 mm

(-0.0002 to 0.001 in)

Valve lift @ zero

10.00 mm (0.3937 in)

lash-intake

Pin bore diameter

22.008-22.014 mm

(piston)

(0.8665-0.8667 in)

Valve lift @ zero

10.00 mm (0.3937 in)

lash-exhaust

Pin diameter

22.0005-22.0030 mm

(0.8662-0.8663 in)

Camshaft end play

0.027-0.190 mm

(0.0011-0.0075 in)

Pin clearance (negative

0.01395-0.005 mm

or positive)

(0.001-0.0002 in)

Camshaft end play

0.025-0.190 mm

service limit

(0.0010-0.0075 in)

Pin bore diameter (rod)

22.012-22.024 mm

(0.8666-0.8671 in)

Camshaft journal to

0.076-0.025 mm

bearing clearance

(0.0030-0.0010 in)

Pin clearance (negative

0.009-0.0235 mm

or positive) (rod)

(0.0002-0.0009 in)

Clearance service

26.962-26.936 mm

limit-journal diameters

(1.0615-1.0605 in)

Ring groove width top

1.53-1.55 mm

(0.0602-0.061 in)

Clearance service

27.012-26.987 mm

limit-journal inside

(1.0635-1.0625 in)

Ring groove width

1.52-1.54 mm

diameter (cap

intermediate

(0.0598-0.0606 in)

assembled)

Ring groove width oil

3.030-3.050 mm

Clearance service

0.09 mm (0.0035 in) (4

control

(0.1193-0.1201 in)

limit-Camshaft runout:

places)

Piston ring gap top

0.13-0.28 mm

Full indicator

(0.0051-0.0111 in)

measurement on all

Piston ring gap

0.25-0.40 mm

journals when supported

intermediate

(0.0098-0.0157 in)

on front and rear

journals.

Piston ring gap oil control 0.15-0.65 mm

(0.0059-0.0256 in)

Connecting Rod

Crankshaft

Big end journal inside

53.049-53.027 mm

diameter with assembled (2.0885-2.0877 in)

Main bearing journal

67.483-67.503 mm

liners

diameter

(2.6568-2.6576 in)

Rod bearing to journal

0.064-0.026 mm

Main bearing journal

0.0075 mm (0.0003 in)

clearance

(0.0025-0.001 in)

diameter: maximum

between cross sections

out-of-round

Pin bore diameter (rod)

22.024-22.012 mm

(0.867-0.8666 in)

Main bearing journal

0.004 mm (0.0002 in)

diameter: maximum taper

Rod length (centerline

169.1 mm (6.6575 in)

(straightness)

bore-to-bore)

Runout: FIM of center

0.05 mm (0.0019 in) (3

Alignment bore-to-bore

± 0.05 mm (0.0021 in)

journals when located on places)

max. twist

front and rear journal

G89770 en

303-01c-4

Engine — V8 (4V)

303-01c-4

SPECIFICATIONS (Continued)

Description

Specification

Description

Specification

Crankshaft journal to

0.048-0.024 mm

Valve spring out of

2.5 degrees

main bearing clearance

(0.001891-0.0009 in)

square limit - intake

Connecting rod journal

53.003-52.983 mm

Valve spring out of

2.5 degrees

diameter

(2.0867-2.0859 in)

square limit - exhaust

Connecting rod journal

0.0075 mm (0.0003 in)

Valve guide inside

7.044-7.015 mm

diameter: maximum

between cross sections

diameter

(0.2773-0.2762 in)

out-of-round

Lubricants

Connecting rod journal

0.004 mm (0.0002 in)

Silicone Gasket and

WSE-M4G323-A4

diameter: maximum taper

Sealant F7AZ-19554-EA

Crankshaft end play

0.075-0.377 mm

Metal Surface Cleaner

WSE-M5B392-A

(0.003-0.0148 in)

F4AZ-19A536-RA

Cylinder Head/Valve Train

Engine Coolant

ESE-M97B44-A

Combustion chamber

53

± 1.5cc

/WSS-M97B51-A

volume

(3.2342-0.0915 ci)

10W30 GF2 Engine Oil

WSS-M2C910-A

Valve seat width - intake

2.1-1.9 mm

Pipe Sealant with

WSK-M2G350-A2 and

(0.0827-0.0748 in)

Teflon® D8AZ-19554-A

ESR-M18P7-A

Valve seat width -

2.1-1.9 mm

or equivalent

exhaust

(0.0827-0.0748 in)

Torque Specifications

Valve seat angle

45.00-44.50 degrees

Description

Nm

Valve seat runout (TIR)

0.025 mm (0.001 in)

Valve cover bolts¹

—

Valve stem guide

0.069-0.020 mm

Camshaft bearing cap bolts¹

—

clearance - intake

(0.0027-0.0008 in)

Camshaft sprocket bolts

120

Valve stem guide

0.095-0.045 mm (0.0037

Connecting rod bolts¹

—

clearance - exhaust

- 0.0018 in)

Crankshaft damper pulley bolt¹

—

Valve head diameter -

37.11-36.86 mm

intake

(1.461-1.4512 in)

Crankshaft main bearing bolts (cross

—

mounted)¹

Valve head diameter -

30.12-29.87 mm

exhaust

(1.1858-1.176 in)

Crankshaft main bearing bolts

—

(vertical)¹

Valve face runout (limit)

0.05 mm (0.0019 in)

Cylinder heads bolts¹

—

Valve face angle

45.75-45.25 degrees

Exhaust manifold nuts

23-27

Valve stem diameter -

6.995-6.975 mm

intake

(0.2754-0.2746 in)

Drive belt idler pulley bolt

25

Valve stem diameter -

6.970-6.949 mm

Flywheel bolts

73-87

exhaust

(0.2744-0.2736 in)

Engine front cover bolts¹

—

Valve spring compression 711.7 N @ 26.4

Heater return tube bolt

20-30

pressure - intake

Heater supply tube screw & washer

8-12

Valve spring compression 711.7 N @ 26.4

Ignition coil cover bolts

10

pressure - exhaust

Lower intake manifold bolts¹

—

Valve spring free length - 45.5

Upper intake manifold bolts¹

—

intake

Oil filter adapter bolt

25

Valve spring free length - 50.2 mm (1.9764 in)

exhaust

Oil level indicator tube bolt

10

Valve spring installed

289.1 N @ 36.14

Oil pan bolts¹

—

pressure - intake

Oil pan drain plug

11-16

Valve spring installed

289.1 N @ 36.14

Oil pressure switch

12-16

pressure - exhaust

Oil pump bolts

10

Valve spring installed

272.6 N @ 36.15

Oil pump screen cover and tube bolts

10

pressure service limit -

intake

Oil pump screen cover and tube

25

spacer

Valve spring installed

272.6 N @ 36.15

pressure service limit -

Power steering pump bolts

25

exhaust

G89770 en