Part 2 of 2

Engine-5.4L Continued





41. 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.





42. Install the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.





43. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.





44. Remove the retaining clip from the RH timing chain tensioner.





45. As a post-check, verify correct alignment of all timing marks.





46. Install the special tool between the valve spring coils to prevent valve stem seal damage.





47. 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.

48. 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 ft. lbs.).





49. Install the crankshaft sensor ring on the crankshaft.





50. 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.





51. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.








52. Tighten the engine front cover fasteners in sequence in three stages.
Stage 1: Tighten fasteners 1 through 7 to 25 Nm (18 ft. lbs.).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 ft. lbs.).
Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 ft. lbs.).





53. Position the belt idler pulley and install the bolt.





54. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.





55. Use the special tools to install the crankshaft front seal into the engine front cover.





56. 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.





57. Use the special tool to install the crankshaft pulley.





58. 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 ft. lbs.).
^ Stage 2: Loosen 360 degrees.
^ Stage 3: Tighten to 50 Nm (37 ft. lbs.).
^ Stage 4: Tighten an additional 90 degrees.





59. NOTE: The front lower hole in the power steering pump is not used. Position the power steering pump and install the bolts.





60. 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.





61. 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.





62. Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.





63. Tighten the bolts in the sequence shown.





64. 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.





65. 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.





66. Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.





67. Tighten the bolts in the sequence shown.





68. Install the crankcase ventilation tube on the LH valve cover.





69. NOTE: RH shown, LH similar.

Install the radio frequency interference capacitors.
70. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.





71. Connect the CKP sensor electrical connector.





72. Connect the oil pressure switch electrical connector.





73. Connect the KS electrical connector.





74. Connect the RH radio frequency interference capacitor electrical connector.





75. Connect the CMP sensor electrical connector.





76. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.





77. NOTE: LH shown, RH similar.

Install the cylinder block drain plugs.





78. Position a new gasket and the oil filter adapter. Install the bolts and nut.





79. Position the LH and RH engine mounts to the cylinder block and install the six bolts.





80. If equipped, install the A/C compressor and the bolts.





81. 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.





82. Position the coolant pump pulley on the coolant pump and install the bolts.

83. 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.





84. 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 a 4 mm (0.16 inch) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.





85. Install the crankshaft rear seal retainer plate and loosely install the six bolts.





86. Tighten the bolts in the sequence shown.





87. Install the oil drain plug before installing the oil pan.





88. Install the oil pump screen and pickup tube spacer.





89. 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.

90. 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.





91. 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, 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 at the rear oil seal retainer-to-cylinder block sealing surface.





92. Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.





93. Install the oil pan gasket and the oil pan and loosely install the bolts.





94. Tighten the bolts in two stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 ft. lbs.).
^ Stage 2: Tighten an additional 90 degrees.





95. Install the special tool.





96. NOTE: The oil level indicator and tube are removed for clarity.

Install the special tool.





97. Install the special tool and remove the engine from the work stand.
98. Lower the engine onto wooden blocks.





99. Install the special tool and raise the engine.





100. Install the oil level indicator tube nut and insert the oil level indicator.





101. NOTE: Lubricate the inner lip of the crankshaft rear seal with clean engine oil.

Using the special tools, install a new crankshaft rear seal.





102. Using the special tools, install the crankshaft rear oil slinger.





103. Install the flexplate and bolts. Tighten the bolts in the sequence shown.