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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303-01b-79
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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303-01b-81
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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