Page 1 of 41 SECTION 303-01A: Engine 5.4L (2V) 2000 F-Super Duty 250-550/Excursion/F-53 Motorhome Chassis Workshop Manual ASSEMBLY Procedure revision date: 04/04/2003 Engine Special Tool(s) Compressor, Valve Spring 303-567 (T97P-6565-AH) Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH) 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) Holding Tool, Crankshaft 303-448 (T93P-6303-A) Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
Page 2 of 41 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) Installer, Connecting Rod 303-442 (T93P-6136-A) Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent Installer, Crankshaft Rear Oil Seal 303-518 (T95P-6701-DH) Installer, Crankshaft Rear Oil Seal 303-516 (T95P-6701-BH) Installer, Crankshaft Rear Oil
Page 3 of 41 Slinger 303-517 (T95P-6701-CH) 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 Engine 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 1. Record the main bearing code found on the front of the engine block. 2. Record the main bearing code found on the back of the crankshaft.
Page 4 of 41 3. Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, 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 a "2". Repeat this process for the remaining four main bearings. 4. If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.
Page 5 of 41 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. 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. 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 rear crankshaft upper thrust washer at the back of the No. 5 main boss. 8. NOTE: The oil groove on the thrust washer must face toward the front of the engine (against the crankshaft surface). Push the crankshaft forward and install the front crankshaft upper thrust washer at the front of the No. 5 main boss.
Page 7 of 41 9. 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). Install the lower crankshaft thrust washer to the back side of the No. 5 main bearing cap, with oil grooves facing the crankshaft 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. 11. Install the dowel pins so the flat sides face the crankshaft.
Page 8 of 41 12. Install the vertical main bearing cap fasteners and tighten in the sequence shown. Tighten to 40 Nm (30 lb-ft). Tighten an additional 90 degrees. 13. Install the side bolts and tighten them in the sequence shown. Tighten to 30 Nm (22 lb-ft). Tighten an additional 90 degrees.
Page 9 of 41 14. 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. 15. 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.
Page 10 of 41 16. 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. 17. NOTE: Main bearing caps are removed for clarity. NOTE: Rotate the crankshaft after each connecting rod is installed and tightened to check for assembly binding. Tighten the bolts in two stages, using the sequence shown. Stage 1: Tighten to 43 Nm (32 lb-ft). Stage 2: Tighten an additional 105 degrees. 18. Position the oil pump and install the bolts loosely. Tighten the bolts in the sequence shown.
Page 11 of 41 19. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to Cylinder Heads 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: The RH head gasket is shown; the LH head gasket is similar. Install the head gasket over the dowel pins. 20. 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 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
Page 12 of 41 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: The RH cylinder head is shown; the LH cylinder head is similar. Install the cylinder head on the dowels and the head gasket. Loosely install new bolts. 21. NOTE: Make sure to tighten the bolts in sequence in three stages. 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. 22. 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).
Page 13 of 41 Stage 2: Tighten an additional 90 degrees. Stage 3: Tighten an additional 90 degrees. 23. Remove the special tools from both ends of the cylinder head. 24. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil. Install the hydraulic lash adjusters in their original locations.
Page 14 of 41 25. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown. 26. 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 indicator tube. Install the bolt. 27. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown. 28. 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.
Page 15 of 41 Compress the tensioner plunger, using an edge of a vise. 29. Using a small screwdriver or pick, push back and hold the ratchet mechanism. 30. While holding the ratchet mechanism, push the ratchet arm back into the tensioner housing. 31. Install a paper clip into the hole in the tensioner housing to hold the ratchet assembly and plunger in during installation.
Page 16 of 41 32. Remove the tensioner from the vise. 33. 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. 34. Install the timing chain guides. 35. Pre-position the camshafts. 1. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock. 2. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
Page 17 of 41 36. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and valve damage can occur. NOTE: The number one piston is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool. Position the crankshaft so the number one cylinder is at TDC with the special tool. 37. Remove the Crankshaft Holding Tool. 38. NOTE: The crankshaft sprockets are identical. They may only be installed one way. Refer to the following illustration for the correct crankshaft sprocket installation. If removed, install the LH and the RH crankshaft sprockets. 1. Timing marks aligned. 2. Keyways aligned.
Page 18 of 41 39. 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. 40. NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.
Page 19 of 41 41. 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. 42. Remove the retaining clip from the LH timing chain tensioner. 43. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
Page 20 of 41 44. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel. Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links. 45. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner. 46. Remove the retaining clip from the RH timing chain tensioner.
Page 21 of 41 47. As a post-check, verify correct alignment of all timing marks. 48. Install the special tool between the valve spring coils to prevent valve stem seal damage. 49. 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. 50. Remove the special tool.
Page 22 of 41 51. 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). 52. Install the crankshaft sensor ring on the crankshaft. 53. 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 54. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight. 55. Tighten the engine front cover fasteners in sequence in three stages. Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft). Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft). Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 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 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 M10 x 1.5 x 30 7 N808529 Stud, Hex Head Pilot, M10 x 1.5 x 59 M10 x 1.5 x 30 8 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 9 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 10 N808142 Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5 11 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 M8 x 1.25 x 27 12 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 M8 x 1.25 x 27 13 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 M8 x 1.25 x 27 14 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 M8 x 1.25 x 27 15 N808140 Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 M8 x 1.25 x 27
Page 25 of 41 56. Position the belt idler pulley and install the bolt. 57. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil. 58. Use the special tools to install the crankshaft front oil seal into the engine front cover. 59. 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 to the Woodruff key slot on the crankshaft pulley.
Page 26 of 41 60. Use the special tool to install the crankshaft pulley. 61. NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt. Tighten the new 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. 62. 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.
Page 27 of 41 63. 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. 64. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely. 65. Tighten the bolts in the sequence shown.
Page 28 of 41 66. 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. 67. 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. 68. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.
Page 29 of 41 69. Tighten the bolts in the sequence shown. 70. Install the positive crankcase ventilation (PCV) valve and hose in the RH valve cover. 71. Install the crankcase ventilation tube on the LH valve cover.
Page 30 of 41 72. NOTE: RH shown, LH similar. Install the radio frequency interference capacitors. 73. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs. 74. Install the bracket. 75. Connect the CKP sensor electrical connector.
Page 31 of 41 76. Connect the oil pressure switch electrical connector. 77. Connect the knock sensor electrical connector. 78. Connect the RH radio frequency interference capacitor electrical connector. 79. Connect the CMP sensor electrical connector. 80. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
Page 32 of 41 81. NOTE: LH shown, RH similar. Install the cylinder block drain plugs. 82. NOTE: Clean and inspect the mating surfaces, and install new gaskets. Position the oil filter adapter and install the four bolts. 83. Install the rear nut.
Page 33 of 41 84. Position the engine mounts to the cylinder block and install the six bolts. 85. 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. 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. 86. Position the coolant pump pulley on the coolant pump and install the bolts.
Page 34 of 41 87. 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 old sealant. Inspect the rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and metal surface prep. Follow the directions on the packaging. 88. 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. Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the rear oil seal retainer sealing surface. 89. Install the rear oil seal retainer plate and loosely install the six bolts.
Page 35 of 41 90. Tighten the bolts in the sequence shown. 91. Install the oil drain plug. 92. Install the oil pump screen and pickup tube spacer. 93. 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.
Page 36 of 41 NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate with the O-ring with clean engine oil. Position the oil pump screen and pickup tube and install the bolts. 94. 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. 95. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing 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. 96. NOTE: If the oil pan is not secured within four minutes, the sealant must be removed and the sealing 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.
Page 37 of 41 97. Install the oil pan gasket and the oil pan and loosely install the bolts. 98. 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.
Page 38 of 41 99. Remove the special tool. 100. Install the special tool. 101. Install the special tool and remove the engine from the work stand.
Page 39 of 41 102. Lower the engine onto wooden blocks. 103. Remove the special tool. 104. Remove the special tool. 105. Install the special tool and raise the engine. 106. NOTE: Lubricate the inner lip of the crankshaft rear oil seal with clean engine oil.
Page 40 of 41 Using the special tools, install a new crankshaft rear oil seal. 107. Using the special tools, install the crankshaft rear oil slinger. 108. Install the flexplate and bolts. Tighten the bolts in the sequence shown. 109. Install the engine. For additional information, refer to Engine in this section.
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