SECTION C Engine 5.4L (3V)

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1 303-01C-i Engine 5.4L (3V) C-i SECTION C Engine 5.4L (3V) CONTENTS PAGE IN-VEHICLE REPAIR Engine Front Cover C-2

2 303-01C-2 Engine 5.4L (3V) C-2 IN-VEHICLE REPAIR Engine Front Cover Special Tool(s) Installer, Crankshaft Front Seal (T88T-6701-A) Remover, Crankshaft Front Seal (T74P-6700-A) Installer, Crankshaft Front Seal Remover, Crankshaft Vibration Damper (T58P-6316-D) Installer, Crankshaft Vibration Damper (T74P-6316-B) Installer, Power Steering Pump Pulley (T91P-3A733-A)

3 303-01C-3 Engine 5.4L (3V) C-3 Remover, Power Steering Pump Pulley (T69L B) Installer Set, Teflon Seal 211-D207 (D90P-3517-A) or equivalent Material Item Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent Silicone Gasket and Sealant TA-30 Motorcraft Metal Surface Prep ZC-31 Silicone Gasket Remover ZC-30 Specification WSS-M2C930-A WSE-M4G323-A Accessory drive belt

4 303-01C-4 Engine 5.4L (3V) C-4 2 W Crankshaft pulley bolt 3 N Crankshaft pulley bolt washer Crankshaft pulley Crankshaft front seal 6 N Accessory drive belt idler pulley bolt 7 19A216 Accessory drive belt idler pulley 8 N Accessory drive belt idler pulley bolt 9 19A216 Accessory drive belt idler pulley 10 N Accessory drive belt idler pulley bolt 11 19A216 Accessory drive belt idler pulley 12 N Coolant pump pulley bolt (4 required) 13 8A528 Coolant pump pulley 14 N Accessory drive belt tensioner bolt (3 required)

5 303-01C-5 Engine 5.4L (3V) C B209 Accessory drive belt tensioner 16 RH camshaft position (CMP) sensor electrical connector (part of 12B637) 17 N RH CMP sensor bolt 18 6B288 RH CMP sensor 19 RH CMP sensor O-ring seal 20 N RH radio ignition interference capacitor nut RH radio ignition interference capacitor 22 N LH radio ignition interference capacitor nut LH radio ignition interference capacitor 24 LH CMP sensor electrical connector (part of 12B637) 25 N LH CMP sensor bolt 26 6B288 LH CMP sensor 27 LH CMP sensor O-ring seal 28 W Power steering pump bolt (3 required) 29 3A696 Power steering pump 30 Crankshaft position (CKP) sensor electrical connector (part of 12B637) 31 W Oil pan bolt (4 required) 32 W Engine front cover bolt 33 N Engine front cover studs (2 required) 34 N Engine front cover bolt (9 required) 35 W Engine front cover stud (3 required) 36 6C086 Engine front cover 37 6D081 Engine front cover gasket (3 required)

6 303-01C-6 Engine 5.4L (3V) C-6 38 N CKP sensor bolt 39 6C315 CKP sensor 40 CKP sensor O-ring seal Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section Drain the engine oil. 3. Remove the engine cooling fan. For additional information, refer to Section Remove the RH valve cover. For additional information, refer to Valve Cover RH in this section. 5. Remove the LH valve cover. For additional information, refer to Valve Cover LH in this section. 6. Rotate the tensioner clockwise and remove the accessory drive belt. 7. Remove the nut and position aside the transmission cooler tube support bracket. 8. Remove the nut and position aside the power steering pressure hose support bracket. 9. Using the special tool, remove the power steering pump pulley.

303-01C-7 Engine 5.4L (3V) 303-01C-7 10. Disconnect the power steering pressure tube. Drain the power steering fluid into a suitable container. 11.

7 303-01C-7 Engine 5.4L (3V) C Disconnect the power steering pressure tube. Drain the power steering fluid into a suitable container. 11. Remove the 3 bolts and position the power steering pump aside. 12. Remove the crankshaft pulley bolt and washer. Discard the crankshaft pulley bolt. 13. Using the special tool, remove the crankshaft pulley. 14. Using the special tool, remove and discard the crankshaft front seal.

8 303-01C-8 Engine 5.4L (3V) C Remove the 3 bolts and the 3 accessory drive idler pulleys. 16. Remove the 4 bolts and the coolant pump pulley. 17. Remove the 3 bolts and the accessory drive belt tensioner. 18. Disconnect the RH camshaft position (CMP) sensor electrical connector. 19. Remove the bolt and the RH CMP sensor. Discard the O-ring seal. 20. Remove the nut and the upper radiator hose support bracket. 21. Remove the nut and position the RH radio ignition interference capacitor aside. 22. Disconnect the LH CMP sensor electrical connector. 23. Remove the bolt and the LH CMP sensor. Discard the O-ring seal. 24. Remove the nut and position the LH radio ignition interference capacitor aside. 25. Disconnect the crankshaft position (CKP) sensor electrical connector. 26. Remove the 4 front oil pan bolts. 27. Remove the bolts and the studs. 28. NOTICE:

9 303-01C-9 Engine 5.4L (3V) C-9 Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. Remove the engine front cover from the front cover to cylinder block dowel. Remove the engine front cover gaskets. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces. 29. Remove the bolt and the CKP sensor. Discard the O-ring seal. Installation 1. Install the CKP sensor and the bolt. 2. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant. NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.

10 303-01C-10 Engine 5.4L (3V) C Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger tight. 4. Tighten the engine front cover fasteners in the sequence shown in 2 stages. Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). 1 N Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 2 N Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 3 N Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 4 N Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 5 N Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 6 N Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x N Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x N Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50 9 N Bolt, Hex Flange Head Pilot, M8 x 1.25 x N Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50

11 303-01C-11 Engine 5.4L (3V) C-11 (Continued) 11 N Bolt, Hex Flange Head Pilot, M8 x 1.25 x W Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x W Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x W Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x W Bolt, Hex Head Pilot, M8 x 1.25 x Loosely install the bolts, then tighten the bolts in 2 stages, in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 60 degrees. 6. Connect the CKP sensor electrical connector. 7. Position the power steering pump assembly and install the 3 bolts. Tighten to 25 Nm (18 lb-ft).

12 303-01C-12 Engine 5.4L (3V) C Using the special tool, install a new O-ring seal on the pressure line fitting. 9. Connect the power steering pressure tube. Tighten to 65 Nm (48 lb-ft). 10. Using the special tool, install the power steering pump pulley. 11. Position the power steering pressure hose support bracket and install the nut.

13 303-01C-13 Engine 5.4L (3V) C Position the transmission cooler tube support bracket and install the nut. 13. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Using a new O-ring seal, install the RH CMP sensor and the bolt. 14. Connect the RH CMP sensor electrical connector. 15. Install the LH radio ignition interference capacitor and the nut. 16. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Using a new O-ring seal, install the LH CMP sensor and the bolt. 17. Connect the LH CMP sensor electrical connector. 18. Install the RH radio ignition interference capacitor and the nut. 19. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 25 Nm (18 lb-ft). 20. Install the coolant pump pulley and the 4 bolts. Tighten to 25 Nm (18 lb-ft). 21. Install the 3 accessory drive idler pulleys and the 3 bolts. Tighten to 25 Nm (18 lb-ft). 22. Position the upper radiator hose support bracket and install the nut.

14 303-01C-14 Engine 5.4L (3V) C Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil. 24. Using the special tools, install a new crankshaft front seal into the engine front cover. 25. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. 26. Use the special tool to install the crankshaft pulley.

15 303-01C-15 Engine 5.4L (3V) C Tighten the new crankshaft pulley bolt in 4 stages. Stage 1: Tighten to 90 Nm (66 lb-ft). Stage 2: Loosen 360 degrees. Stage 3: Tighten to 50 Nm (37 lb-ft). Stage 4: Tighten an additional 90 degrees. 28. Rotate the tensioner clockwise and install the accessory drive belt. 29. Install the RH valve cover. For additional information, refer to Valve Cover RH in this section. 30. Install the LH valve cover. For additional information, refer to Valve Cover LH in this section. 31. Install the engine cooling fan. For additional information, refer to Section Fill the crankcase with clean engine oil.

Engine Front Cover. Special Tool(s) 3-Jaw Puller 303-D121 or equivalent. Installer, Front Cover Oil Seal (T88T-6701-A)

Engine Front Cover. Special Tool(s) 3-Jaw Puller 303-D121 or equivalent. Installer, Front Cover Oil Seal (T88T-6701-A) SECTION 303-01B: Engine 4.6L (3V) 2009 Mustang Workshop Manual IN-VEHICLE REPAIR Procedure revision date: 05/23/2008 Engine Front Cover Special Tool(s) 3-Jaw Puller 303-D121 or equivalent Installer, Front