Page 1 of 41 SECTION 303-01B: Engine 4.6L and 5.4L 2000 F-150 Workshop Manual ASSEMBLY Procedure revision date: 01/27/2004 Engine 4.6L Special Tool(s) Compressor, Valve Spring 303-567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) Installer, Connecting Rod 303-442 (T93P-6136-A) Installer, Crankshaft Vibration Damper 303-102 (T74P-6316-B) Installer, Crankshaft Front Oil Seal 303-635 Installer, Front Cover Oil Seal 303-335 (T88T-6701-A) Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent
Page 2 of 41 Holding Tool, Crankshaft 303-448 (T93P-6303-A) Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Oil Slinger 303-517 (T95P-6701-CH) Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A) Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent Strap Wrench 303-D055 (D85L-6000-A) Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
Page 3 of 41 Material Item Motorcraft Silicone Gasket Remover ZC-30 Motorcraft Metal Surface Prep ZC-31 Silicone Gasket and Sealant F7AZ-19554-EA or equivalent Instant Adhesive E8AZ-19554-A SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP or equivalent Motorcraft Premium Engine Coolant VC-4-A (in Canada CXC-10; in Oregon VC-5) or equivalent. Do not mix coolant types. Motorcraft Premium Gold Engine Coolant VC-7-A (in Oregon VC-7-B) or equivalent. Do not mix coolant types. Hydraulic Chain Tensioner Retaining Clip Specification WSE-M4G323-A4 WSK-M2G402-A4 WSS-M2C153-H ESE-M97B44-A (green in color) WSS-M97B51-A1 (yellow in color) 1L3Z-6P250-AA Assembly All engines 1. Record the main bearing code found on the front of the engine block.
Page 4 of 41 2. Record the main bearing code found on the back of the crankshaft. Bearing select fit chart, standard bearings 3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings Chart determine the required bearing grade for each main bearing. Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code. Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the two intersect. This is the required bearing grade for the number one crankshaft main bearing. As an example, if the engine block code letter is "F" and the crankshaft code letter is "D," the correct bearing grade for this main bearing is "2." Repeat this process for the remaining four main bearings. Bearing select fit chart, oversize bearings 4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit
Page 5 of 41 Chart, Oversize Bearing Chart to determine the required grade for each main bearing. 5. 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. Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil. 6. Install the crankshaft onto the upper crankshaft main bearings.
Page 6 of 41 7. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft thrust surface). Push the crankshaft rearward and install the crankshaft upper thrust washer at the back of the No. 5 upper main bearing. 8. NOTE: Rotate the jack screws into the bearing caps enough to provide clearance to the cylinder block prior to installing the bearing caps. Install the rear main bearing cap.
Page 7 of 41 9. Install the crankshaft lower main bearings into the main bearing caps and lubricate them with clean engine oil. Locate the main bearing caps on the cylinder block and tap into place using a plastic or dead-blow hammer. 10. Install the vertical main bearing cap fasteners and tighten in the sequence shown in two stages. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
Page 8 of 41 11. Tighten the jack screws against the cylinder block in the sequence shown in two stages. Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in). 12. Install the side bolts and tighten them in the sequence shown.
Page 9 of 41 13. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. NOTE: The next three steps are for all eight connecting rods, rod caps and pistons. Only one connecting rod, rod cap and piston is shown. NOTE: Make sure the identification marks on the piston and connecting rod face toward the front of the engine. Use the special tools to install the piston and connecting rod with the upper connecting rod bearing in place. 14. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer. 15. CAUTION: The rod cap installation must keep the same orientation as marked during disassembly. NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly. Position the lower bearing and connecting rod, and install the new bolts loosely. 16. NOTE: Main bearing caps are removed for clarity. Tighten the bolts in two stages, using the sequence shown.
Page 10 of 41 Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees. 17. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown. 18. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Heads 4.6L in the Removal portion of this section. CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry. CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket. NOTE: RH head gasket shown; LH head gasket similar.
Page 11 of 41 Install the head gasket over the dowel pins. 19. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Heads 4.6L in the Removal portion of this section. CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry. CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation. NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation. NOTE: RH cylinder head shown; LH cylinder head similar. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts. LH cylinder head 20. NOTE: Make sure to tighten the bolts in sequence in three stages.
Page 12 of 41 Tighten the LH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees. RH cylinder head 21. NOTE: Make sure to tighten the bolts in the following three stages. Tighten the RH bolts in the sequence shown. Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees.
Page 13 of 41 All cylinder heads 22. Remove the special tools on both ends of the cylinder head. 23. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil. Install the hydraulic lash adjusters in their original locations.
Page 14 of 41 RH cylinder head 24. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown. LH cylinder head 25. NOTE: Lubricate the O-ring seal with clean engine oil. Install the oil level indicator tube. Install a new O-ring seal on the oil level indicator tube. Install the oil level indictor tube. Install the bolt. 26. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown.
Page 15 of 41 All cylinder heads 27. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result. CAUTION: Do not compress the ratchet assembly. This will damage the ratchet assembly. Compress the tensioner plunger, using an edge of a vise. 28. Using a small screwdriver or pick, push back and hold the ratchet mechanism. 29. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing.
Page 16 of 41 30. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation. 31. Remove the tensioner from the vise. 32. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks. 33. Install the timing chain guides. 1. Position the LH timing chain guide. 2. Install and tighten the LH bolts. 3. Position the RH timing chain guide. 4. Install and tighten the RH bolts.
Page 17 of 41 34. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position. 35. CAUTION: When instructed to do so, rotate the crankshaft counterclockwise only. Do not rotate past the position shown or severe piston and valve damage can occur. NOTE: The No. 1 cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool. Using the special tool, position the crankshaft so the No. 1 cylinder is at TDC.
Page 18 of 41 36. Remove the Crankshaft Holding Tool. 37. NOTE: Crankshaft sprockets are identical. They may only be installed one way. Refer to the following illustration for correct crankshaft sprocket installation. If removed, install the LH and RH crankshaft sprockets. 1. Timing marks aligned. 2. Keyways aligned. 38. Position the LH (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
Page 19 of 41 39. NOTE: Make sure the upper half of the timing chain is below the tensioner guide dowel. NOTE: If necessary, adjust the camshaft sprocket slightly to obtain timing mark alignment. Install the LH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket. 40. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner. 41. Remove the retaining clip from the LH timing chain tensioner.
Page 20 of 41 42. Position the RH (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket. 43. Install the RH timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket. 44. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
Page 21 of 41 45. Position the retaining clip from the RH timing chain tensioner. 46. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket. 47. Install the special tool between the valve spring coils to prevent valve stem seal damage. 48. NOTE: Lubricate the camshaft roller followers using clean engine oil. NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower. Install the camshaft roller followers. 1. Install the special tool. 2. Compress the valve spring. 3. Install the camshaft roller followers in their original locations.
Page 22 of 41 49. Remove the special tool. 50. CAUTION: When installing the spark plugs, use care not to exceed the recommended torque. Install the eight spark plugs. Tighten the spark plugs to 18 Nm (13 lb-ft). 51. Install the crankshaft sensor ring on the crankshaft. 52. NOTE: If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. 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.
Page 23 of 41 53. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight. 54. Tighten the front cover fasteners in the sequence shown to 25 Nm (18 lb-ft).
Page 24 of 41 Item Part Number Description 1 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 2 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 3 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 4 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 5 N806177 Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 6 N808586 M8 x 1.25 x M6 x 1.0 x 86.35 6 N808529 5.4L, M10 x 1.5 x 1.5 x 103.1 7 N808586 4.6L M8 x 1.25 x M6 x 1.0 x 86.35 7 N808529 5.4L, M10 x 1.5 x 1.5 x 103.1 8 N808142 Windsor Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 8 N808586 Romeo, M8 x 1.25 x M6 x 1.0 x 86.35 9 N808142 Windsor, Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 9 N806177 Romeo, Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 10 N808142 Windsor, Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 10 N806177 Romeo, Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53 11 N808140 Windsor, Stud and Washer, Hex-Head Pilot, M10 x 1.5 x M8 x 1.25 x 109.6 11 N806300 Romeo, Stud Pilot, M8 x 1.25 x 1.25 x 91.1 12 N808140 Windsor, Stud and Washer, Hex-Head Pilot, M10 x 1.5
Page 25 of 41 x M8 x 1.25 x 109.6 12 N806300 Romeo, Stud Pilot, M8 x 1.25 x 1.25 x 91.1 13 N808140 Windsor, Stud and Washer, Hex-Head Pilot, M10 x 1.5 x M8 x 1.25 x 109.6 13 N806300 Romeo, Stud Pilot, M8 x 1.25 x 1.25 x 91.1 14 N808140 Windsor, Stud and Washer, Hex-Head Pilot, M10 x 1.5 x M8 x 1.25 x 109.6 14 N806300 Romeo, Stud Pilot, M8 x 1.25 x 1.25 x 91.1 15 N808140 Windsor, Stud and Washer, Hex-Head Pilot, M10 x 1.5 x M8 x 1.25 x 109.6 15 N806300 Romeo, Stud Pilot, M8 x 1.25 x 1.25 x 91.1 55. Position the belt idler pulley and install the bolt. 56. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil. 57. Using the special tools, install the crankshaft front seal into the engine front cover.
Page 26 of 41 58. NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with solvent. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. Apply silicone to the Woodruff key slot on the crankshaft pulley. 59. Use the special tool to install the crankshaft pulley. 60. NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt. Tighten the crankshaft pulley bolt in four 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.
Page 27 of 41 61. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket. 62. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head. 63. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.
Page 28 of 41 64. Tighten the bolts in the sequence shown. 65. If a new gasket is being installed, apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket. 66. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions
Page 29 of 41 on the packaging. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head. 67. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely. 68. Tighten the bolts in the sequence shown.
Page 30 of 41 69. Install the crankshaft ventilation tube on the LH valve cover. 70. NOTE: RH shown, LH similar. Install the radio frequency interference capacitors and the hose support. 71. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs. 72. Connect the knock sensor electrical connector. 73. Connect the RH radio frequency interference capacitor electrical connector. 74. Connect the camshaft position (CMP) sensor electrical connector.
Page 31 of 41 75. Connect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors. 76. NOTE: LH shown, RH similar. Install the cylinder block drain plugs. 77. NOTE: Clean and inspect the mating surfaces, and install new gaskets. Position the oil filter adapter and install the four bolts.
Page 32 of 41 78. Position the LH engine mount to the cylinder block and install the bolts. 79. Position the RH engine mount to the cylinder block and install the bolts. 80. CAUTION: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.
Page 33 of 41 Install the coolant pump. 1. Lubricate the new O-ring seal using engine coolant and install the O-ring seal onto the coolant pump. 2. Position the coolant pump into the engine block. 3. Install the bolts. 81. Position the coolant pump pulley on the coolant pump and install the bolts. 82. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of oil sealant. Inspect the rear seal retainer plate. Clean the mating surface for the rear seal retainer plate and silicone gasket remover and metal surface prep. Follow the directions on the packaging. 83. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage.
Page 34 of 41 Apply a 4-mm (0.16-in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface. 84. Install the rear oil seal retainer plate and loosely install the six bolts. 85. Tighten the bolts in the sequence shown. 86. Install the oil drain plug.
Page 35 of 41 87. Install the oil pump screen and pickup tube spacer. 88. CAUTION: Make sure the O-ring is in place and not damaged. A missing or damaged O- ring can cause foam in the lubrication system, low oil pressure and severe engine damage. NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil. Position the oil pump screen and pickup tube and install the bolts. 89. CAUTION: 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. Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
Page 36 of 41 90. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealant areas cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant at the rear oil seal retainer-to-cylinder block sealing surface. 91. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealant areas cleaned. To clean the sealing area, follow the directions provided on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure can cause future oil leakage. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface. 92. Install the oil pan gasket and the oil pan and loosely install the bolts.
Page 37 of 41 93. Tighten the bolts in two stages, in the sequence shown. Stage 1: Tighten to 20 Nm (15 lb-ft). Stage 2: Tighten an additional 90 degrees. 94. Install the special tool.
Page 38 of 41 95. Install the special tool. 96. Install the special tool and remove the engine from the work stand. 97. Lower the engine onto wooden blocks. 98. Remove the special tool. 99. Remove the special tool.
Page 39 of 41 100. Install the special tool and raise the engine. 101. Install the power steering reservoir lower mounting bracket. 102. NOTE: Lubricate the inner lip of the crankshaft rear oil seal with clean engine oil. Using the special tools, install a new crankshaft rear oil seal.
Page 40 of 41 103. Using the special tools, install the crankshaft rear oil slinger. 104. Install the flexplate or the flywheel and bolts. Tighten the bolts in the sequence shown. 105. Install the engine. For additional information, refer to Engine in this section.
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