303-01C-1

Engine 5.4L (3V)

303-01C-1

ASSEMBLY
Special Tool(s)

Engine

Compressor, Piston Ring

303-D032 (D81L-6002-C) or
equivalent

Special Tool(s)
Remover/Installer, Cylinder
Head
303-572 (T97T-6000-A)

Installer, Crankshaft Rear Seal

303-518 (T95P-6701-DH)
Installer, Connecting Rod
303-442 (T93P-6136-A)

Installer, Crankshaft Oil Slinger

303-517 (T95P-6701-CH)
Compressor, Valve Spring
303-1039

Installer, Crankshaft Rear Seal

303-516 (T95P-6701-EH)
Installer, Crankshaft Vibration
Damper
303-102 (T74P-6316-B)
Holding Tool, Crankshaft
303-448 (T93P-6303-A)
Installer, Crankshaft Front Seal
303-635

Alignment Pins, Cylinder Head

303-1040 (SR-015486)
Installer, Front Cover Seal
303-335 (T88T-6701-A)

(Continued)

(Continued)

Copyright 2005, Ford Motor Company

Last updated: 5/10/2006

2006 F-150, Mark LT, 9/2005

303-01C-2

Engine 5.4L (3V)

303-01C-2

ASSEMBLY (Continued)
Special Tool(s)

Material
Modular Engine Lift Bracket
303-F047 (014-00073) or
equivalent

Locking Tool, Camshaft Phaser

Sprocket
303-1046

Material
Item
Motorcraft Metal Surface
Prep
ZC-31
Silicone Gasket Remover
ZC-30

Specification

Item
Silicone Gasket and
Sealant
TA-30
Motorcraft SAE 5W-20
Premium Synthetic Blend
Motor Oil
XO-5W20-QSP (US);
Motorcraft SAE 5W-20
Super Premium Motor Oil
CXO-5W20-LSP12
(Canada); or equivalent
Motorcraft Premium Gold
Engine Coolant
VC-7-B (US); CVC-7-A
(Canada); or equivalent
(yellow color)
Threadlock 262
TA-26 or equivalent
Hydraulic Chain Tensioner
Retaining Clip
1L3Z-6P250-AA

Specification
WSE-M4G323-A4

WSS-M2C930-A

WSS-M97B51-A1

WSK-M2G351-A6

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-3

Engine 5.4L (3V)

303-01C-3

ASSEMBLY (Continued)
Engine Upper End

2006 F-150, Mark LT, 9/2005

303-01C-4

Engine 5.4L (3V)

303-01C-4

ASSEMBLY (Continued)
Item

Part Number

Description

1
2
3
4
5
6

12B637
6A505
6750
N605892
6K873
N807834

6B280

8
9
10

6C255
6529
6518

11

6514

12
13
14

6513
6A517
6C501

15

6279

16

6C524

17
18
19
20

6B284
12405
12A366
6065

21

W707747

22

9Y431

23
24

9431
W701706

25
26
27
28

6507
6505
6083
W701520

29

6C261

30
31

6050
14B102

32

W701571

Engine wiring harness

Valve cover LH
Oil level indicator
Oil level indicator tube bolt
Oil level indicator tube
Camshaft bearing cap bolt (10
required)
Camshaft bearing cap (4
required)
Camshaft LH
Roller follower (24 required)
Valve spring retainer key (48
required)
Valve spring retainer (24
required)
Valve spring (24 required)
Valve stem seal (24 required)
Hydraulic lash adjuster (24
required)
Camshaft phaser sprocket bolt
LH
Camshaft phaser sprocket
LH
Camshaft bearing cap
Spark plug (4 required)
Ignition coil (4 required)
Cylinder head bolt (20
required)
Exhaust manifold stud (8
required)
Exhaust manifold gasket (2
required)
Exhaust manifold LH
Exhaust manifold nut (8
required)
Intake valve (16 required)
Exhaust valve (8 required)
Cylinder head gasket LH
Variable camshaft timing
(VCT) oil control solenoid
assembly bolt (2 required)
VCT oil control solenoid
assembly
Cylinder head LH
Cylinder head temperature
(CHT) sensor jumper harness
Heater outlet tube stud bolt

Item
33
34
35
36

Part Number
18663
6051
6049
9Y431

37
38

9430
W701706

39

W707747

40

6C260

41

W701520

42

6279

43

6C524

44
45

6B284
N807834

46

6B280

47
48
49
50
51
52
53
54
55

6251
12405
12A366
W706175
6582
6765
6766
6758
W503282

56

W503279

57
58
59
60
61
62

8594
N806807
8575
8C369
6N041
9A474

63

9S440

64

N811050

Description
Heater outlet tube
Cylinder head gasket RH
Cylinder head RH
Exhaust manifold gasket (2
required)
Exhaust manifold RH
Exhaust manifold nut (8
required)
Exhaust manifold stud (8
required)
VCT oil control solenoid
assembly
VCT oil control solenoid
assembly bolt (2 required)
Camshaft phaser sprocket bolt
RH
Camshaft phaser sprocket
RH
Camshaft bearing cap
Camshaft bearing cap bolt (10
required)
Camshaft bearing cap (4
required)
Camshaft RH
Spark plug (4 required)
Ignition coil (4 required)
Ignition coil bolt (8 required)
Valve cover RH
Oil fill adapter
Oil fill adapter cap
Crankcase ventilation tube
Coolant crossover tube bolt (3
required)
Thermostat housing bolt (2
required)
Thermostat housing
Thermostat O-ring seal
Thermostat
Coolant crossover tube
Intake manifold dust cover
Intake manifold vacuum
harness
Intake manifold vacuum
harness support bracket
Intake manifold vacuum
harness support bracket bolt

(Continued)

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-5

Engine 5.4L (3V)

303-01C-5

ASSEMBLY (Continued)
Item
65

Description
Intake manifold bolt (10
required)
Intake manifold assembly
Positive crankcase ventilation
(PCV) tube

Item
68

Part Number

Description

N804758

18801

3
4

6C086
W503282

6L266

N606543

7
8

6268
6M256

Radio ignition interference

capacitor nut
Radio ignition interference
capacitor
Engine front cover
Timing chain guide bolt
RH (2 required)
Timing chain tensioner
RH
Timing chain tensioner bolt
RH (2 required)
Timing chain RH
Timing chain guide RH

Item
9

66
67

Part Number
W709775
9Y451
6K817

69

Part Number
W500204
9F624

Description
PCV heater element assembly
bolt (2 required)
PCV heater element assembly

(Continued)

Engine Front end

Item

(Continued)

Part Number
N606543

10
11
12

6M269
6M274
N605892

13
14
15

6306
6B274
N606527

16
17
18

6268
6K255
12A227

Description
Timing chain tensioner bolt
LH (2 required)
Timing chain tensioner LH
Tensioner arm LH
Timing chain guide upper
bolt LH
Crankshaft sprocket
Timing chain guide LH
Timing chain guide lower
bolt LH
Timing Chain LH
Tensioner arm RH
Ignition pulse wheel

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-6

Engine 5.4L (3V)

303-01C-6

ASSEMBLY (Continued)
Item
19

Part Number
W707225

20

W706447

21

3A696

22
23

W706605
N808529

24

N806177

25

6C315

26
27

N806155
12A216

28

N808102

29

6700

Description
Power steering pump stud
bolt
Power steering pump bolt (2
required)
Power steering pump
assembly
Engine front cover bolt
Engine front cover stud bolt
(2 required)
Engine front cover bolt (9
required)
Crankshaft position (CKP)
sensor
CKP sensor bolt
Accessory drive belt idler
pulley
Accessory drive belt idler
pulley bolt
Crankshaft front seal

Item
30
31
32
33
34

Part Number
6316
N806165
W701512
8A528
N806282

35

N806177

36
37

8501
N808102

38

12A216

39

N806155

40
41

6B288
W709573

Description
Crankshaft pulley
Crankshaft pulley washer
Crankshaft pulley bolt
Coolant pump pulley
Coolant pump pulley bolt (4
required)
Coolant pump bolt (4
required)
Coolant pump
Accessory drive belt idler
pulley bolt
Accessory drive belt idler
pulley
Camshaft position (CMP)
sensor bolt (2 required)
CMP sensor (2 required)
Engine front cover stud bolt
(3 required)

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-7

Engine 5.4L (3V)

303-01C-7

ASSEMBLY (Continued)
Engine Lower end

Item

Part Number

Description

6150

6152

6159

6161

6159

Upper compression ring (8

required)
Lower compression ring (8
required)
Outer oil control ring (8
required)
Inner oil control ring (8
required)
Outer oil control ring (8
required)

Item
6

Part Number
6140

7
8
9

6135
6110
6200

10

6211

Description
Piston pin retainer (16
required)
Piston pin (8 required)
Piston (8 required)
Connecting rod assembly (8
required)
Connecting rod bearing (8
required)

(Continued)

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-8

Engine 5.4L (3V)

303-01C-8

ASSEMBLY (Continued)
Item
11

Part Number
6K318

12

N806155

13
14
15
16
17
18
19

6310
6701
6375
N806168
6714
6890
N806156

20

9278

21
22
23
24
25

6881
6A636
W701605
6675
12A648

26
27

6710
N605904

28

N806155

29

6622

30

N806180

31

6K258

32

6345

33

6A346

34

6C357

35

6325

36

6A338

37

6K302

38
39

6303
N806201

Description
Crankshaft rear seal retainer
plate
Crankshaft rear seal retainer
plate bolt (6 required)
Crankshaft rear seal
Crankshaft oil slinger
Flexplate
Flexplate bolt (8 required)
Oil filter
Oil filter threaded adapter
Oil filter adapter bolt (4
required)
Engine oil pressure (EOP)
sensor
Oil filter adapter
Oil filter adapter gasket
Oil pan bolt (16 required)
Oil pan
Engine oil temperature (EOT)
sensor
Oil pan gasket
Oil pump screen and pickup
tube bolt
Oil pump screen and pickup
tube bolt (2 required)
Oil pump screen and pickup
tube
Oil pump screen and pickup
tube spacer
Crankshaft main bearing cap
stud
Crankshaft main bearing cap
bolt (9 required)
Crankshaft main bearing
dowel (10 required)
Crankshaft main bearing cap
bolt (10 required)
Crankshaft main bearing cap
(5 required)
Crankshaft bearing Lower
(5 required)
Crankshaft thrust washer
Lower
Crankshaft
Crankshaft key

Item
40

Part Number
6A341

41
42

6333
6333

43

6210

44

6211

45
46
47
48

6621
N806183
6010
W500225

49

12A699

Description
Crankshaft thrust washer
Upper (2 required)
Crankshaft bearing Upper
Crankshaft bearing Upper
(4 required)
Connecting rod cap (8
required)
Connecting rod bearing (8
required)
Oil pump
Oil pump bolt (3 required)
Cylinder block
Knock sensor bolt (2
required)
Knock sensor (2 required)

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.

(Continued)

2006 F-150, Mark LT, 9/2005

303-01C-9

Engine 5.4L (3V)

303-01C-9

ASSEMBLY (Continued)
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 2 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 4

main bearings.

2006 F-150, Mark LT, 9/2005

303-01C-10

Engine 5.4L (3V)

303-01C-10

ASSEMBLY (Continued)
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.

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.

2006 F-150, Mark LT, 9/2005

303-01C-11

Engine 5.4L (3V)

303-01C-11

ASSEMBLY (Continued)
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 2 steps.

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.

Install the crankshaft onto the upper crankshaft

main bearings.

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.

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.

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, keeping the cap as
square as possible, alternately draw the cap
down evenly using the cap fasteners.

2006 F-150, Mark LT, 9/2005

303-01C-12

Engine 5.4L (3V)

303-01C-12

ASSEMBLY (Continued)
11. Install the dowel pins so the flat sides face the
crankshaft.

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.

2006 F-150, Mark LT, 9/2005

303-01C-13

Engine 5.4L (3V)

303-01C-13

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. Assemble the 8 pistons. For additional

information, refer to Piston in this section.
16. Make sure the ring gaps (oil spacer-A, oil
ring-B, compression ring-C) are correctly
spaced around the circumference of the piston.

14. Check the piston-to-cylinder block and piston

ring clearances. For additional information, refer
to Section 303-00.

2006 F-150, Mark LT, 9/2005

303-01C-14

Engine 5.4L (3V)

303-01C-14

ASSEMBLY (Continued)
17.

18.

CAUTION: Do not scratch the cylinder

walls or crankshaft journals with the
connecting rod.

19.

CAUTION: The rod cap installation

must keep the same orientation as marked
during disassembly.

NOTE: The following piston installation steps

are for all 8 connecting rods, rod bearings and
pistons. Only 1 connecting rod, rod bearing and
piston is shown.

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.

Use the special tools to install the connecting

rod with the upper connecting rod bearing in
place.

Position the lower bearing and connecting rod,

and install the new bolts loosely.

Lubricate the piston and ring with clean

engine oil

Lubricate the rod bearings with clean engine

oil.

20. NOTE: Main bearing caps are removed for

clarity.
Tighten the bolts in 2 stages, in the sequence
shown.

Stage 1: Tighten to 43 Nm (32 lb-ft).

Stage 2: Tighten an additional 105 degrees.

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 special tools.

2006 F-150, Mark LT, 9/2005

303-01C-15

Engine 5.4L (3V)

303-01C-15

ASSEMBLY (Continued)
21. Position the oil pump and install the bolts.

Tighten to 10 Nm (89 lb-in).

24. Position the crankshaft with the special tool,

then remove the tool.
22. Install the oil pump screen and pickup tube
spacer.

23.

Tighten to 25 Nm (18 lb-ft).

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 prior to installation.
Position the oil pump screen and pickup tube
and install the bolts.

Tighten the oil pump screen and pickup

tube-to-oil pump bolts to 10 Nm (89 lb-in).

Tighten the oil pump screen and pickup

tube-to-spacer bolt to 25 Nm (18 lb-ft).

2006 F-150, Mark LT, 9/2005

303-01C-16

Engine 5.4L (3V)

303-01C-16

ASSEMBLY (Continued)
25.

CAUTION: Make sure all coolant

residue and foreign material are cleaned
from the block surface and cylinder bore.
CAUTION: The use of sealing aids
(aviation cement, copper spray and glue) is
not permitted. The gasket must be installed
dry.

26. Tighten the bolts in 3 stages, in the sequence

shown.
RH shown, LH similar.

Stage 1: Tighten to 40 Nm (30 lb-ft).

Stage 2: Tighten an additional 90 degrees.

Stage 3: Tighten an additional 90 degrees.

CAUTION: The cylinder head bolts

must be discarded and new bolts installed.
They are tighten-to-yield designed and
cannot be reused.
NOTE: Do not turn the crankshaft until
instructed to do so.
NOTE: LH shown, RH similar.
Using the special tools, position the cylinder
head gaskets and cylinder heads over the
dowels and install the cylinder head bolts
loosely.

27. Remove the special tool from the LH cylinder

head.

2006 F-150, Mark LT, 9/2005

303-01C-17

Engine 5.4L (3V)

303-01C-17

ASSEMBLY (Continued)
28. Remove the special tool from the RH cylinder
head.

29. Install the hydraulic lash adjusters into the RH

and LH cylinder heads.

Lubricate the hydraulic lash adjusters with

clean engine oil prior to installation.

32.

CAUTION: Damage to the variable

camshaft timing (VCT) phaser sprocket
assembly will occur if mishandled or used as
a lifting or leveraging device.
NOTE: LH shown, RH similar.

30. Install the LH and RH camshafts.

Install the VCT phaser sprockets and new VCT

phaser bolts finger tight.

Lubricate the camshaft and camshaft

journals with clean engine oil prior to
installation.

31. NOTE: LH shown, RH similar.

Install the LH and RH camshaft bearing caps in
their original locations.

Lubricate the camshaft bearing caps with

clean engine oil.

Position the front camshaft bearing cap.

Position the remaining camshaft bearing

caps.

Install the bolts loosely.

Tighten to 10 Nm (89 lb-in) in the sequence

shown.
2006 F-150, Mark LT, 9/2005

303-01C-18

Engine 5.4L (3V)

303-01C-18

ASSEMBLY (Continued)
33.

CAUTION: Damage to the VCT

phaser sprocket assembly will occur if
mishandled or used as a lifting or leveraging
device.

35. Install a retaining clip on the tensioner to hold

the plunger in during installation.

CAUTION: Only use hand tools to

remove the VCT phaser sprocket assembly
or damage may occur to the camshaft or
VCT phaser sprocket.
NOTE: LH shown, RH similar.
Using the special tool, tighten the LH and RH
VCT phaser sprocket bolts in 2 stages.

Stage 1: Tighten to 40 Nm (30 lb-ft).

Stage 2: Tighten an additional 90 degrees.

36. Remove the tensioner from the vise.
37. If the copper links are not visible, mark 2 links
on one end and 1 link on the other end, and use
as timing marks.

34.

CAUTION: Timing chain procedures

must be followed exactly or damage to valves
and pistons will result.
CAUTION: Prior to installation,
inspect the tensioner-sealing bead for seal
integrity. If cracks, tears, separation from
the tensioner body or permanent
compression of the seal bead is observed,
install a new tensioner.

38. Install the crankshaft sprocket, making sure the

flange faces forward.

Compress the tensioner plunger, using a vise.

2006 F-150, Mark LT, 9/2005

303-01C-19

Engine 5.4L (3V)

303-01C-19

ASSEMBLY (Continued)
39. Install the 4 bolts and the LH and RH timing
chain guides.

Tighten to 10 Nm (89 lb-in).

40. 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.

41. 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 2 copper (marked)
chain links.

2006 F-150, Mark LT, 9/2005

303-01C-20

Engine 5.4L (3V)

303-01C-20

ASSEMBLY (Continued)
42. 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 and bolts.

Tighten to 25 Nm (18 lb-ft).

45. NOTE: The lower half of the timing chain

must be positioned above the tensioner arm
dowel.
NOTE: The camshaft phaser and sprocket will
be stamped with one of the illustrated timing
marks for the RH camshaft.
43. Remove the retaining clip from the LH timing
chain tensioner.

Position the RH timing chain on the camshaft

sprocket. Make sure the camshaft sprocket
timing mark is positioned between the 2 copper
(marked) chain links.

44. 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.

2006 F-150, Mark LT, 9/2005

303-01C-21

Engine 5.4L (3V)

303-01C-21

ASSEMBLY (Continued)
46. Position the RH timing chain tensioner arm on
the dowel pin and install the RH timing chain
tensioner and bolts.

Tighten to 25 Nm (18 lb-ft).

47. Remove the retaining clip from the RH timing

chain tensioner.

49. Install the crankshaft sensor ring on the

crankshaft.

48. As a post-check, verify correct alignment of all

timing marks.

2006 F-150, Mark LT, 9/2005

303-01C-22

Engine 5.4L (3V)

303-01C-22

ASSEMBLY (Continued)
50. Using the special tool, install all of the
camshaft roller followers.

Lubricate the camshaft roller followers with

clean engine oil prior to installation.

2006 F-150, Mark LT, 9/2005

303-01C-23

Engine 5.4L (3V)

303-01C-23

ASSEMBLY (Continued)
51.

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.
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. 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.
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 at the locations shown.

2006 F-150, Mark LT, 9/2005

303-01C-24

Engine 5.4L (3V)

303-01C-24

ASSEMBLY (Continued)
52. 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.

Item

Part
Number

N806177

Bolt, Hex Flange Head Pilot,

M8 x 1.25 x 50

10

N806177

Bolt, Hex Flange Head Pilot,

M8 x 1.25 x 50

11

N806177

Bolt, Hex Flange Head Pilot,

M8 x 1.25 x 50

12

W709573

Stud and Washer, Hex Head

Pilot, M8 x 1.25 x 1.25 x 94

13

W709573

Stud and Washer, Hex Head

Pilot, M8 x 1.25 x 1.25 x 94

14

W709573

Stud and Washer, Hex Head

Pilot, M8 x 1.25 x 1.25 x 94

15

W706605

Bolt, Hex Head Pilot, M8 x

1.25 x 56

Description

53. 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).
Item

Part
Number

N806177

Bolt, Hex Flange Head Pilot,

M8 x 1.25 x 50

N806177

Bolt, Hex Flange Head Pilot,

M8 x 1.25 x 50

N806177

Bolt, Hex Flange Head Pilot,

M8 x 1.25 x 50

N806177

Bolt, Hex Flange Head Pilot,

M8 x 1.25 x 50

N806177

Bolt, Hex Flange Head Pilot,

M8 x 1.25 x 50

N808529

Stud, Hex Head Pilot, M10 x

1.5 x 1.5 x 103

N808529

Stud, Hex Head Pilot, M10 x

1.5 x 1.5 x 103

N806177

Bolt, Hex Flange Head Pilot,

M8 x 1.25 x 50

Description

2006 F-150, Mark LT, 9/2005

303-01C-25

Engine 5.4L (3V)

303-01C-25

ASSEMBLY (Continued)
54. NOTE: Lubricate the new O-ring seal with
clean engine oil prior to installation.
Install the LH camshaft position (CMP) sensor
and the bolt.

Tighten to 10 Nm (89 lb-in).

57. Tighten the 4 coolant pump bolts.

Tighten to 25 Nm (18 lb-ft).

55. NOTE: Lubricate the new O-ring seal with

clean engine oil prior to installation.
Install the RH CMP sensor and the bolt.

Tighten to 10 Nm (89 lb-in).

58. Lubricate the engine front cover and the

crankshaft seal inner lip with clean engine oil.

56.

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.
Position the coolant pump and install the bolts
loosely.

Lubricate the new O-ring seal using clean

engine coolant and install the O-ring seal
onto the coolant pump.

2006 F-150, Mark LT, 9/2005

303-01C-26

Engine 5.4L (3V)

303-01C-26

ASSEMBLY (Continued)
59. Using the special tools, install a new crankshaft
seal into the engine front cover.

62. Tighten the new crankshaft pulley bolt in 4

stages.
60. NOTE: If 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. 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.

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.

Apply silicone gasket and sealant to the

Woodruff key slot on the crankshaft pulley.

63. Position the crankshaft position (CKP) sensor

and the bolt.

Tighten to 10 Nm (89 lb-in).

61. Use the special tool to install the crankshaft

pulley.

2006 F-150, Mark LT, 9/2005

303-01C-27

Engine 5.4L (3V)

303-01C-27

ASSEMBLY (Continued)
64. Position the accessory drive belt tensioner and
install the 3 bolts.

Tighten to 25 Nm (18 lb-ft).

65. Install the 3 accessory drive belt idler pulleys,

the coolant pump pulley and the 7 bolts.

Tighten to 25 Nm (18 lb-ft).

67. Install 8 new LH exhaust manifold-to-cylinder

head studs.

66.

Tighten to 12 Nm (9 lb-ft).

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.
NOTE: Clean and inspect the mating surfaces,
and install new gaskets.
Position the oil filter adapter and install the 4
bolts.

Tighten to 25 Nm (18 lb-ft).

2006 F-150, Mark LT, 9/2005

303-01C-28

Engine 5.4L (3V)

303-01C-28

ASSEMBLY (Continued)
68. Position a new gasket, the LH exhaust manifold
and tighten the 8 new nuts in the sequence
shown.

69.

70. Install 8 new RH exhaust manifold-to-cylinder

head studs.

Tighten to 12 Nm (9 lb-ft).

Tighten to 25 Nm (18 lb-ft).

CAUTION: Clean the engine support

insulator-to-cylinder block mating surface of
any dirt or foreign material prior to
installation.

71. Position a new gasket, the RH exhaust manifold

and tighten the 8 new nuts in the sequence
shown.

Tighten to 25 Nm (18 lb-ft).

Install the LH engine support insulator and the

3 bolts.

Apply Threadlock 262 to the bolt threads

prior to installation.

Tighten to 63 Nm (46 lb-ft).

2006 F-150, Mark LT, 9/2005

303-01C-29

Engine 5.4L (3V)

303-01C-29

ASSEMBLY (Continued)
72.

CAUTION: Clean the engine support

insulator-to-cylinder block mating surface of
any dirt or foreign material prior to
installation.
Install the RH engine support insulator and the
3 bolts.

Apply Threadlock 262 to the bolt threads

prior to installation.

Tighten to 63 Nm (46 lb-ft).

75.

CAUTION: When installing the valve

cover, make sure to avoid damaging the
VCT solenoid.
Position the RH valve cover and gasket on the
cylinder head and tighten the bolts in the
sequence shown.

73.

Tighten to 10 Nm (89 lb-in).

CAUTION: Do not use metal scrapers,

wire brushes, power abrasive discs or other
abrasive means to clean sealing surfaces.
These tools cause scratches and gouges which
make leak paths. Use a plastic scraping tool
to remove all traces of old sealant.
Clean the valve cover mating surface with
silicone gasket remover and metal surface prep.
Follow the directions on the packaging.

74. NOTE: If 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. 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 in 2 places
where the engine front cover meets the cylinder
head.

2006 F-150, Mark LT, 9/2005

303-01C-30

Engine 5.4L (3V)

303-01C-30

ASSEMBLY (Continued)
76.

CAUTION: Do not use metal scrapers,

wire brushes, power abrasive discs or other
abrasive means to clean sealing surfaces.
These tools cause scratches and gouges which
make leak paths. Use a plastic scraping tool
to remove all traces of old sealant.
Clean the valve cover mating surface with
silicone gasket remover and metal surface prep.
Follow the directions on the packaging.

77. NOTE: If 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. 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 in 2 places
where the engine front cover meets the cylinder
head.

79. Install the oil level indicator tube and the bolt.

78.

Install a new O-ring seal and lubricate the

O-ring seal with clean engine oil prior to
installation.

Tighten to 10 Nm (89 lb-in).

CAUTION: When installing the valve

cover, make sure to avoid damaging the
VCT solenoid.
Position the LH valve cover and gasket on the
cylinder head and tighten the bolts in the
sequence shown.

Tighten to 10 Nm (89 lb-in).

2006 F-150, Mark LT, 9/2005

303-01C-31

Engine 5.4L (3V)

303-01C-31

ASSEMBLY (Continued)
80. NOTE: Do not reuse the O-ring seals.
NOTE: Lubricate the O-ring seals with clean
engine coolant prior to installation.
Slide the coolant tube forward with the new
O-ring seals into the cylinder block.

81. Install the coolant tube stud bolt.

Tighten to 10 Nm (89 lb-in).

82. Install the 2 knock sensors (KS) and the bolts.

Tighten to 20 Nm (15 lb-ft).

83. Position the electrical harness on the engine

assembly and connect the engine wiring harness
retainers to the valve cover studs.
84. Connect the CKP sensor electrical connector.

85. NOTE: LH shown, RH similar.

Install the 8 ignition coils and the 8 bolts.

Tighten to 6 Nm (53 lb-in).

86. Install the LH radio ignition interference

capacitor and the stud bolt.

Tighten to 25 Nm (18 lb-ft).

2006 F-150, Mark LT, 9/2005

303-01C-32

Engine 5.4L (3V)

303-01C-32

ASSEMBLY (Continued)
87. Connect the cylinder head temperature (CHT)
sensor electrical connector.

91. Install the RH radio ignition interference

capacitor and the stud bolt.
88. Connect the 4 RH ignition coil electrical
connectors.

89. Connect the 2 engine wiring harness retainers

from the RH valve cover studs.

Tighten to 25 Nm (18 lb-ft).

92. Position the upper radiator hose support bracket

and install the nut.

Tighten to 10 Nm (89 lb-in).

90. Connect the RH VCT solenoid electrical

connector.

2006 F-150, Mark LT, 9/2005

303-01C-33

Engine 5.4L (3V)

303-01C-33

ASSEMBLY (Continued)
93. Connect the RH CMP sensor electrical
connector.

97. NOTE: If 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. 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 a 4 mm (0.16 in) bead of silicone gasket
and sealant around the crankshaft rear seal
retainer sealing surface.

94. Install the special tool.

98. Install the crankshaft rear seal retainer plate and

loosely install the 6 bolts.

95. Using a suitable floor crane, remove the engine

from the engine stand.
96.

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 crankshaft 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.

2006 F-150, Mark LT, 9/2005

303-01C-34

Engine 5.4L (3V)

303-01C-34

ASSEMBLY (Continued)
99. Tighten the bolts in the sequence shown.

Tighten to 10 Nm (89 lb-in).

102. NOTE: If 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. 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 at the engine
front cover-to-cylinder block sealing surface.

100.

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.

101. NOTE: If 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. 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 at the
crankshaft rear seal retainer plate-to-cylinder
block sealing surface.

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

2006 F-150, Mark LT, 9/2005

303-01C-35

Engine 5.4L (3V)

303-01C-35

ASSEMBLY (Continued)
104. Tighten the bolts in 3 stages, in the sequence
shown.

Stage 1: Tighten to 2 Nm (18 lb-in).

Stage 2: Tighten to 20 Nm (15 lb-ft).

Stage 3: Tighten an additional 60 degrees.

106. Using the special tools, install a new

crankshaft rear oil slinger.

107. Install the flexplate and the 8 bolts in the

sequence shown.

Tighten to 80 Nm (59 lb-ft).

105. NOTE: Lubricate the inner lip of the

crankshaft rear seal with clean engine oil.
Using the special tools, install a new
crankshaft rear seal.

2006 F-150, Mark LT, 9/2005