Ford Falcon. Manual — part 140

303-01b-74

Engine — 5.4L (3V)

303-01b-74

ASSEMBLY (Continued)

Bearing Select Fit Chart, Oversize Bearings

5. Install the crankshaft upper main bearings into the

cylinder block and lubricate them with clean

engine oil.
NOTE: Before assembling the cylinder block, all

sealing surfaces must be free of chips, dirt, paint

and foreign material. Also, make sure the coolant

and oil passages are clear.

6. Install the crankshaft onto the upper crankshaft

main bearings.
NOTE: The upper thrust washers are shown for

location purposes only. Do not install the upper

thrust washers until the crankshaft is installed.

Refer to the following two steps.

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303-01b-75

Engine — 5.4L (3V)

303-01b-75

ASSEMBLY (Continued)

7. Push the crankshaft rearward and install the rear

crankshaft upper thrust washer at the back of the

No. 5 main boss.
NOTE: The oil groove on the thrust washer must

face toward the front of the engine (against the

crankshaft thrust surface).

10. Install the crankshaft lower main bearings into the

main bearing caps and lubricate them with clean

engine oil. Locate the main bearing cap on the

cylinder block and tap into place using a plastic or

dead-blow hammer.

8. Push the crankshaft forward and install the front

crankshaft upper thrust washer at the front of the

No. 5 main boss.
NOTE: The oil groove on the thrust washer must

face toward the front of the engine (against the

crankshaft surface).

9. Install the lower crankshaft thrust washer to the

back side of the No. 5 main bearing cap, with oil

grooves facing the crankshaft surface.
NOTE: To aid in assembly, apply petroleum jelly

to the back of the crankshaft thrust washer.
NOTE: The oil groove on the thrust washer must

face toward the rear of the engine (crankshaft

surface).

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303-01b-76

Engine — 5.4L (3V)

303-01b-76

ASSEMBLY (Continued)

11. Install the dowel pins so the flat sides face the

12. Install the vertical main bearing cap fasteners and

crankshaft.

tighten in the sequence shown.

Tighten to 40 Nm (30 lb-ft).
Tighten an additional 90 degrees.

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303-01b-77

Engine — 5.4L (3V)

303-01b-77

ASSEMBLY (Continued)

13. Install the side bolts and tighten them in the

sequence shown.

Tighten to 30 Nm (22 lb-ft).
Tighten an additional 90 degrees.

15. Once the connecting rod is seated on the

crankshaft journal, remove the Connecting Rod

Installer.

CAUTION: Do not scratch the cylinder

walls or crankshaft journals with the

connecting rod.

14. Use the special tools to install the piston and

16. Position the lower bearing and connecting rod,

connecting rod with the upper connecting rod

and install the new bolts loosely.

bearing in place.

CAUTION: The rod cap installation must

CAUTION: Do not scratch the cylinder

keep the same orientation as marked during

walls or crankshaft journals with the

disassembly.

connecting rod.

NOTE: The connecting rod caps are of the

NOTE: The next three steps are for all eight

‘‘cracked’’ design and must mate with the

connecting rods, rod caps and pistons. Only one

connecting rod ends. Excessive bearing clearance

connecting rod, rod cap and piston is shown.

will result if not mated correctly.

NOTE: Make sure the identification marks on the

piston and connecting rod face toward the front of

the engine.

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