Engine - 5.4l v8 - VIN M, Z & 3 Ford Econoline I

ENGINE IDENTIFICATION

Engine is identified by eighth character of Vehicle Identification Number (VIN). See ENGINE IDENTIFICATION CODES table. VIN is located on top of instrument panel, near lower left corner of windshield. VIN is also stamped on Vehicle Certification (VC) label mounted on left door pillar.

An engine code label is located in engine compartment, in front of radiator and on right valve cover. Label contains engine calibration number, engine build date, engine plant code and engine code.

Emission calibration number label is located on upper radiator shield. This label identifies engine calibration number, engine code number and revision level. Numbers from labels are required when ordering replacement parts.

ENGINE IDENTIFICATION CODES

VALVE CLEARANCE ADJUSTMENT

Hydraulic valve lash adjusters are used. No valve adjustment is required.

TROUBLE SHOOTING

Note. To trouble shoot engine mechanical components, see ENGINE MECHANICAL in BASIC TROUBLE SHOOTING article in GENERAL INFORMATION.

REMOVAL & INSTALLATION

Note. For reassembly reference, label all electrical connectors, vacuum hoses and fuel lines before removal. Place mating marks on engine hood and other major assemblies before removal.

FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS

1. On Compressed Natural Gas (CNG) engines, connect grounding cable to fuel injection supply manifold and to ground rod. Turn manual lockdown valve jackscrew on fuel tank solenoid valve(s). On vehicles equipped with extended range fuel tank, jackscrew can be reached through access hole in vapor retaining cover. Ensure bleed valve on fuel rail pressure kit is closed. Connect Fuel Rail Pressure Test and Venting Kit (134-00116) to fuel pressure relief valve on fuel injection supply manifold. Connect venting hose assembly to fuel rail pressure test and venting kit. Connect venting hose assembly to vent stack. Slowly open bleed valve on fuel rail pressure test and venting kit and allow lines to vent for one minute. Close bleed valve and remove fuel rail pressure test and venting kit.
2. On Liquid Natural Gas (LNG)/Liquid Propane Bi-Fuel engines, raise and support vehicle. Remove fuel tank shield. Close fuel tank valve. Set fuel selector switch to ALT and run vehicle until indicator lamp goes out.
3. On Gasoline engines, remove fuel cap to release fuel tank pressure. Connect EFI Pressure Gauge to relief valve on right rear corner of fuel rail. Release pressure using valve on pressure gauge.
4. On all models before disconnecting fuel lines, disconnect negative battery cable. To disconnect fuel lines, remove retaining clip from outside of fuel line coupling.
5. Install Spring Lock Coupling Remover (D87L-9280-A for 3/8" line; D87L-9280-B for 1/2" line; T83P-19623-C for 5/8" line) onto fuel line coupling so it enters cage opening. (Scheme 157)
6. Push spring lock coupling remover into cage opening to release female fitting from garter spring. Pull couplings apart. Remove spring lock coupling remover.
7. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) onto fuel lines. Before installing, lightly coat "O" rings with clean engine oil. Clean fittings, and replace garter spring, if necessary.
8. Install female fitting onto male fitting and push until garter spring snaps over flared end of female fitting. Ensure lines lock together and garter spring is over female fitting flared end.
9. Install retaining clip. Install Black retaining clip onto fuel supply line and Gray clip onto fuel return line. Ensure horseshoe portion of clip is over coupling. DO NOT install retaining clip over rubber fuel line.

Scheme 157

Removal (Pickup)

1. Disconnect negative battery cable. Remove hood. Remove air cleaner assembly. Remove accessory drive belt. Drain cooling system. Remove radiator. Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__fuel-pressure-release-fuel-line) .
2. Disconnect necessary harness and ground connections. Disconnect necessary water and vacuum connections. Remove A/C condenser, and plug openings. Remove EGR manifold tube, and unclip mega fuse holders from junction block bracket. Remove junction block bracket.
3. Remove upper intake manifold. See «INTAKE MANIFOLD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) . Remove bulkhead connector cover. Unbolt power steering bracket, and position reservoir and bracket assembly aside.
4. Raise and support vehicle. Remove starter. Remove A/C compressor, and plug openings. Remove transmission cooler line from block mounted clip. Remove transmission inspection cover, torque converter bolts and transmission-to engine bolts. Remove power steering retaining bolts, and position power steering pump aside.
5. Disconnect dual-converter "Y" pipe from exhaust manifolds, and position aside. Remove right and left engine mount bolts. Remove oil cooler, and position oil cooler aside. Remove oil filter adapter. Lower vehicle and support transmission. Remove engine from vehicle.

Installation (Pickup)

1. To install, reverse removal procedure. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications) .
2. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) onto fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring, if necessary.
3. Adjust all control cables and fluid levels. Refill cooling system. Evacuate and charge A/C system.

Removal (Van)

1. Disconnect negative battery cable(s). Discharge A/C system using approved refrigerant recovery/recycling equipment. Release fuel pressure and disconnect fuel lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__fuel-pressure-release-fuel-line) .
2. Disconnect necessary harness and ground connections. Remove intake manifold. See «INTAKE MANIFOLD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) . Remove air deflector, radiator grille, radiator grille opening panel and upper and lower core supports. Remove radiator, fan shroud and cooling fan.
3. Remove headlight and side marker assemblies. Remove A/C condenser, and plug openings. Remove accessory drive belt. Drain power steering fluid by disconnecting reservoir hose at power steering pump. Disconnect high pressure hose at power steering pump. Remove lower radiator hose. Disconnect suction hose at receiver-drier, and plug openings.
4. Raise and support vehicle. Disconnect dual-converter "Y" pipe at exhaust manifold. Drain engine oil and remove oil filter. Remove oil cooler. Remove starter. Remove transmission-to-engine bolts.
5. Remove and discard torque converter nuts. Remove engine mount-to-subframe nuts. Lower vehicle. Remove transmission oil filler tube. Support transmission. Remove engine from vehicle.

Installation (Van)

1. To install, reverse removal procedure. Install torque converter using NEW nuts. Tighten all bolts and nuts specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications) .
2. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) onto fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring, if necessary.
3. Adjust all control cables and fluid levels. Refill cooling system. Evacuate and charge A/C system.

Removal

1. Disconnect negative battery cable(s). On Vans, remove engine cover. On Lightning models, remove air charge cooler. See «CHARGE AIR COOLER»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3). On all models, release fuel pressure and disconnect fuel lines. See «FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__fuel-pressure-release-fuel-line).
2. Drain cooling system. Disconnect upper radiator hose from thermostat housing. Remove air cleaner and outlet tube assembly, if equipped. Disconnect control cables from throttle body. Unbolt throttle body control cable bracket and position aside.
3. Disconnect necessary vacuum and water connections. Disconnect necessary harness and ground connections. Remove brake booster vacuum hose bracket. Remove EGR manifold tube. Remove spark plug wires. Remove accessory drive belt. Remove generator.
4. Remove throttle body. Remove heater return tube. Remove thermostat. Remove intake manifold retaining bolts in reverse order of tightening sequence. (Scheme 158) Lift intake manifold assembly, disconnect manifold turning valve and remove intake manifold assembly from vehicle.

Installation

1. To install, reverse removal procedure. Use NEW gaskets and "O" rings. Tighten intake manifold bolts to specification in sequence. (Scheme 158) See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications).
2. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) onto fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring, if necessary.
3. To install remaining components, reverse removal procedure. Adjust all control cables and fluid levels. Refill cooling system. When installing spark plug wires, ensure wires are in correct position on coils.

Scheme 158

EXHAUST MANIFOLD

Raise and support vehicle. Remove front fender splash shield. Remove wheel opening molding on 4WD models. If removing left exhaust manifold, remove EGR manifold tube and brake vacuum booster hose bracket. On either side, disconnect exhaust manifold flange. Remove exhaust manifold retaining nuts in reverse order of tightening sequence. (Scheme 159) Remove exhaust manifold and gasket.

To install, reverse removal procedure. Tighten exhaust manifold nuts to specification in sequence. (Scheme 159) See TORQUE SPECIFICATIONS.

Scheme 159

1. On 1998 models, disconnect negative battery cable(s). Remove intake manifold. See «INTAKE MANIFOLD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3). On 1999 and newer models, remove the engine. See «ENGINE»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3).
2. On all models, remove exhaust manifold. See «EXHAUST MANIFOLD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__exhaust-manifold). Remove timing chains. See «TIMING CHAINS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3).
3. On 1998 models, disconnect heater hoses. On 1998 Pickups, remove heater pipe-to-engine mounting studs. Remove heater pipe and discard "O" ring. On all models, remove cylinder head bolts in reverse order of tightening sequence. (Scheme 160) Remove cylinder head and gasket.

Inspection

Check cylinder head for warpage, cracks and damage. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Repair or replace cylinder head as necessary.

1. Ensure proper gaskets are installed. Right and left cylinder head gaskets are not interchangeable. Install crankshaft holder. Install camshaft holder, one on each head.
2. Install cylinder heads and retaining bolts. Torque bolts in sequence and to specification. (Scheme 160) See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications). On 1998 Pickups, install a new "O" ring on heater pipe. Lubricate "O" ring with clean coolant and install heater pipe. To complete installation, reverse removal procedure. Tighten nuts and bolts to specification.

Scheme 160

Removal (Pickup - Left)

1. Disconnect negative battery cable(s). Remove air cleaner. Unbolt power steering reservoir bracket, and position reservoir and bracket assembly aside.
2. Disconnect PCV hose from valve cover. Disconnect control cables from throttle body. Unbolt throttle body control cable bracket, and position aside. Remove EGR manifold tube. Disconnect necessary harness connectors. Remove valve cover retaining bolts. Remove valve cover and gasket.

Removal (Pickup - Right)

1. Disconnect negative battery cable(s). Remove air cleaner. Disconnect PCV valve hose from valve cover. Remove throttle body splash shield. Remove junction block splash shield.
2. Remove junction block cables from starter relay. Unclip mega fuses from junction block bracket. Disconnect necessary harness connectors. Remove junction block bracket. Remove heater hoses. Disconnect emissions vacuum control connections. Disconnect crankshaft position sensor electrical connection. Remove valve cover and gasket. Valve cover bolts are part of valve cover and should not be removed.

Disconnect negative battery cable(s). Remove engine cover. If removing left valve cover, remove air cleaner and outlet tube. Remove EGR manifold tube. If removing right valve cover, remove oil filler tube. If removing either valve cover, remove PCV tube from valve cover. Disconnect necessary harness connectors. Remove valve cover and gasket. Valve cover bolts are part of valve cover and should not be removed.

Installation (All Models)

1. Clean sealing surfaces on valve cover and cylinder head. Using gasket adhesive, glue valve cover gasket onto valve cover. Apply a bead of silicone gasket adhesive onto seam where cylinder head and front cover meet.
2. Install valve cover, and tighten retaining bolts in sequence. (Scheme 161) To complete installation, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications).
3. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) onto fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring, if necessary.

Scheme 161

FRONT CRANKSHAFT SEAL

Disconnect negative battery cable(s). Remove crankshaft pulley. Using front cover seal remover, remove front seal.

Lubricate oil seal bore and seal lip with engine oil before installing. Using seal installer, install oil seal. Apply silicone sealant onto keyway of crankshaft damper before installing. Using crankshaft damper replacer, install crankshaft damper. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

FRONT COVER

1. Disconnect negative battery cable(s). Remove valve covers. See «VALVE COVERS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) . Remove radiator. Remove water pump. See «WATER PUMP»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) . Raise and support vehicle. Remove power steering pump retaining bolts, and position aside. Disconnect crankshaft position sensor harness connector. Drain engine oil. Remove oil pan-to-front cover bolts.
2. Lower vehicle. Remove front oil seal. See «FRONT CRANKSHAFT SEAL»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__front-crankshaft-seal) . Disconnect camshaft position sensor harness connector. Remove accessory drive belt. Remove left side accessory drive belt idler pulley. Remove front cover retaining bolts. Remove front cover and gasket.

To install, reverse removal procedure. Apply sealant onto front cover-to-oil pan, cylinder block and valve cover mating surfaces. Apply silicone sealant onto keyway of crankshaft damper before installing. Tighten bolts to specification in sequence. (Scheme 162) See TORQUE SPECIFICATIONS.

Scheme 162

1. Remove front cover. See «FRONT COVER»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__front-cover). Remove crankshaft position sensor pulse wheel from crankshaft. Using crankshaft positioner, position crankshaft as shown in illustration. (Scheme 163) Install camshaft holder, one on each cylinder head.
2. Remove right and left timing chain tensioners. Remove timing chain tensioner guides. Remove crankshaft positioner. Remove right and left timing chains and crankshaft sprockets. Remove timing chain guides.

Inspect components for damage. Inspect friction surfaces on tensioner arms and chain guides for wear. Replace components if necessary. If tensioner arms or guides are worn or damaged, remove and clean oil pan. Also, replace oil pump screen cover and tube.

Note. Be sure upper half of left timing chain is below, and lower half of right timing chain is above, timing chain tensioner guide dowels. (Scheme 166)

1. Using edge of a vise, compress tensioner plunger. Using a small screwdriver, release ratchet mechanism and retract ratchet arm. While holding ratchet arm in, install paper clip to hold ratchet assembly and plunger in place during installation. (Scheme 164)
2. If copper links are not visible, fold timing chain in half and mark 2 links on one end and one link on other end of timing chains. (Scheme 165) Install timing chain guides. Using crankshaft positioner, ensure that crankshaft is aligned properly. (Scheme 163)
3. Install right and left timing chains. Ensure timing marks and copper link are properly aligned. (Scheme 167) Install timing chain tensioner guides. Install timing chain tensioners. Remove paper clip from timing chain tensioners. Complete installation by reversing removal procedure. Tighten all nuts and bolt to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications).

Scheme 163

Scheme 164

Scheme 165

Scheme 166

Scheme 167

1. Remove valve covers. See «VALVE COVERS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) . Rotate crankshaft until piston in cylinder to be serviced is at bottom of its stroke, and camshaft lobe is at base circle.
2. Install valve spring spacer between valve spring coils to prevent valve stem oil seal damage. Using valve spring compressor, compress valve spring. Remove camshaft follower and lash adjuster.

Inspect components for damage. Specifications are unavailable from manufacturer.

1. To install, reverse removal procedure. Coat components with engine oil before installing. Before installing valve cover, apply silicone sealant at front cover-to-cylinder block areas.
2. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) onto fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).

CAMSHAFT

Remove camshaft followers and lash adjusters. See CAMSHAFT FOLLOWER & LASH ADJUSTER. Remove timing chains. See TIMING CHAINS. Remove camshaft cap bolts in reverse order of tightening sequence. (Scheme 168) Remove camshaft caps and camshaft.

Measure camshaft bore I.D. and journal O.D. to determine oil clearance. Measure lobe lift. Replace camshaft if measurements are not within specification. See CAMSHAFT table under ENGINE SPECIFICATIONS.

1. Coat components with engine oil, and install components. Install all bolts for camshaft caps, and tighten them finger tight. Tighten bolts to 72-106 INCH lbs. (8-12 N.m) in sequence. (Scheme 168)
2. Ensure camshaft end play is within specification. See «CAMSHAFT»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) table under ENGINE SPECIFICATIONS. To install remaining components, reverse removal procedure. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications).

Scheme 168

1. Disconnect negative battery cable(s). Remove transmission. See appropriate TRANSMISSION REMOVAL & INSTALLATION article in AUTOMATIC TRANSMISSIONS. Remove flywheel/flexplate.
2. Using rear crankshaft slinger remover and slide hammer, remove crankshaft oil slinger. Using rear crankshaft seal remover and slide hammer, remove rear crankshaft oil seal.

Clean and inspect all mating surfaces. Using rear crankshaft seal replacer and rear crankshaft seal adapter, install rear crankshaft seal. With rear crankshaft adapter still installed, use rear crankshaft slinger replacer and seal replacer to install seal slinger. To complete installation, reverse removal procedure. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

1. Disconnect negative battery cable. Remove air cleaner outlet tube. Disconnect throttle position sensor. Disconnect idle air control connector. Disconnect vacuum lines and vent hoses.
2. Disconnect throttle control linkages. Position accelerator cable bracket aside. Disconnect EGR valve. Disconnect all vacuum lines. Remove throttle body spacer.
3. Remove accessory drive belt. Drain Charge Air Cooling (CAC) system. Remove CAC hoses. Remove CAC water supply and return hoses. Remove EGR vacuum regulator valve.
4. Remove supercharger. (Scheme 169) Remove upper intake manifold. Remove Charge Air Cooler. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications).

Scheme 169

1. Partially drain the cooling system. Disconnect the upper radiator hose. Remove the 2 thermostat housing bolts. Remove the thermostat housing. (Scheme 170)
2. Remove the thermostat and the "O" ring seal. (Scheme 171) Discard the "O" ring seal.

1. Use a new "O" ring seal to position the thermostat in the upper intake manifold. Install the thermostat housing and the bolts. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications) . Connect the upper radiator hose. Fill and the cooling system.
2. Start the engine and allow to idle until normal operating temperature is reached. The engine coolant temperature gauge should maintain a stabilized reading in the middle of the NORMAL range and the upper radiator hose should feel hot to the touch. Shut the engine off and allow it to cool. Check the engine for coolant leaks. Check the engine coolant level and fill as necessary.

Scheme 170

Scheme 171

1. Drain cooling system. Remove cooling fan and fan shroud. Remove accessory drive belt. Remove water pump pulley. Remove water pump retaining bolts. Remove water pump and "O" ring.
2. To install, reverse removal procedure. Lubricate "O" ring with coolant before installing. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications) . Fill cooling system.

OIL PAN

Removal (Pickup - 2WD)

1. Remove the radiator air deflector screws and remove the radiator air deflector. Remove the generator. Disconnect the throttle cable, speed control actuator cable and return spring. (Scheme 172)
2. Remove the throttle cable bracket bolts and position the bracket and cables aside. Disconnect the vapor management valve hose. Remove the crankcase ventilation tube and the Idle Air Control (IAC) valve fresh air tube. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum line and the main vacuum harness.
3. Disconnect the Throttle Position (TP) sensor electrical connector and the engine vacuum regulator connector. (Scheme 173) Disconnect the fuel pressure regulator vacuum line. Disconnect the vapor management valve vacuum line. (Scheme 174) Remove the brake booster vacuum line bracket bolt and disconnect the brake booster vacuum line and bracket. (Scheme 175)
4. Disconnect the differential pressure feedback EGR sensor electrical connector. (Scheme 176) Remove the differential pressure feedback EGR sensor nut. (Scheme 177) Disconnect the IAC motor electrical connector. Disconnect the upper and lower EGR fittings and disconnect the differential pressure feedback EGR sensor hoses and position the EGR tube aside. (Scheme 178)
5. Remove the 4 bolts and remove the throttle body adapter. (Scheme 179) Remove the fan shroud bolts and position the fan shroud aside. (Scheme 180) Install the Engine Lift Bracket (303-639) on the engine using the generator mounting bolts. (Scheme 181) Install the Heavy Duty Engine Support (303-F070). (Scheme 182)
6. Raise and support the vehicle. Remove the starter solenoid terminal cover. Disconnect the starter motor electrical connectors. Remove the positive battery cable and starter solenoid wire retaining nuts. (Scheme 183) Remove the ground wire retaining nut and detach the ground wire. (Scheme 184)
7. Remove the 3 starter retaining bolts and remove the starter. Remove the oil pan drain plug and drain the engine oil and into a suitable drain pan. Remove the left and right motor mount through bolts. Lower the vehicle. Raise the engine using the heavy duty engine support. Raise the vehicle on the hoist.
8. Remove the oil pan bolts and position the oil pan aside to gain access to the oil pump screen and pickup tube retaining bolts. Remove the bolt securing the rear of the oil pump screen and pickup tube. Remove the bolts securing the front of the oil pump screen and pickup tube. Remove the oil pan and the oil pickup tube together.

Scheme 172

Scheme 173

Scheme 174

Scheme 175

Scheme 176

Scheme 177

Scheme 178

Scheme 179

Scheme 180

Scheme 181

Scheme 182

Scheme 183

Scheme 184

Installation (Pickup - 2WD)

Note. If the oil pan is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can result in future oil leakage.

1. Clean and inspect the mating surfaces. Position the oil pan gasket, the oil pan and the oil pump screen and pickup tube together to the cylinder block.
2. Install a NEW "O" ring and lubricate with clean engine oil. Position the oil pump screen and pickup tube. Install oil pump screen and pickup tube retaining bolts. Tighten oil pump screen and pickup tube retaining bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications). Apply silicone gasket and sealant at the engine front cover to cylinder block mating surface.
3. Apply silicone gasket and sealant at the rear oil seal retainer to cylinder block sealing surface. Position the oil pan gasket and install the oil pan bolts. Tighten oil pan bolts to specification, in sequence, using the following 3 stages. (Scheme 185) Stage 1: Tighten to 18 INCH lbs. (2 N.m). Stage 2: Tighten to 15 ft. lbs. (20 N.m). Stage 3: Tighten an additional 60 degrees. (Scheme 186)
4. Lower the vehicle. Lower the engine and remove the Heavy Duty Engine Support (303-F070). (Scheme 182) Raise and support vehicle on the hoist.
5. Install the right and left side motor mount through bolts. Tighten the right and left side motor mount through bolts. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications). Install and tighten the oil pan drain plug to specification.
6. Install the starter and install the 3 starter retaining bolts and tighten to specification. Connect the ground cable and install the nut. (Scheme 184) Connect the starter motor electrical connectors.
7. Position and install the starter solenoid wire and tighten nut to specification. (Scheme 183) Position and install positive battery cable to starter solenoid battery cable and tighten nut to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications).
8. Install the starter motor solenoid cover. Lower the vehicle. Remove the Engine Lift Bracket (303-639). (Scheme 181) Position the fan shroud. (Scheme 180) Tighten fan shroud bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications).
9. Install the throttle body adapter and the 4 bolts. Tighten the throttle body adapter bolts in sequence, to specification, using the following 2 stages. (Scheme 179) Stage 1: Tighten to 89 INCH lbs. (10 N.m). Stage 2: Tighten an additional 90 degrees. (Scheme 186)
10. Install the EGR tube to exhaust manifold tube and EGR valve. Hand-tighten the upper and lower fittings. (Scheme 178) Tighten the upper and lower EGR tube fittings to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications). Connect the 2 differential pressure feedback EGR sensor hoses.
11. Connect the Idle Air Control (IAC) valve. Install the differential pressure feedback EGR sensor nut and tighten to specification. (Scheme 177) See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications). Connect the brake booster vacuum line and bracket and install the brake booster vacuum line bracket bolt. (Scheme 175) Connect the differential pressure feedback EGR sensor electrical connector. (Scheme 176)
12. Connect the vapor management valve vacuum line. (Scheme 174) Connect the fuel pressure regulator vacuum line. Connect the Throttle Position (TP) sensor connector and the engine vacuum regulator electrical and vacuum connectors. (Scheme 173)
13. Connect the EGR valve the main vacuum harness vacuum connections. Install the crankcase ventilation tube and the IAC fresh air tube. Connect the vapor management hose. Install the throttle cable bracket and the bolts. (Scheme 172)
14. Connect the throttle cable, speed control actuator cable and throttle return spring. (Scheme 172) Install the generator. See appropriate article in STARTING & CHARGING SYSTEMS. Install the radiator air deflector. Fill the engine to proper level with appropriate engine oil.

Scheme 185

Scheme 186

Removal (Pickup - 4WD)

1. Turn the air suspension switch off. Air suspension switch is located behind right kick panel. Raise and support the vehicle on a hoist. On vehicles equipped with the Dual Overhead Camshaft (DOHC), remove the front axle assembly. See appropriate article in DRIVE AXLES. On all vehicles, remove oil pan drain plug and drain the engine oil into a suitable drain pan. Install oil pan drain plug and tighten to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications).
2. On vehicles equipped with a Single Overhead Camshaft (SOHC), support the front axle housing with a jack stand and remove the front axle mount bolt and axle support bolts. (Scheme 187) Remove the front axle support from vehicle. Remove the right and front axle housing mount bolts and lower the axle to allow clearance for the oil pan to be removed. (Scheme 188)
3. On all vehicles, remove the oil pan bolts and remove the oil pan. Discard the oil pan gasket. Inspect the oil pan for damage and replace as necessary. Using Metal Surface Cleaner (F4AZ-19A536-RA), clean the sealing surfaces. Allow the sealing surfaces to dry for 4 minutes or until there is no sign of wetness, whichever is longest. Failure to do so can cause future oil leaks.

Scheme 187

Scheme 188

Installation (Pickup - 4WD)

Note. If the oil pan and the oil pan gasket are not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner (F4AZ-19A536-RA). 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.

1. Using Silicone Gasket and Sealant (F7AZ-19554-EA), apply the silicone at the engine front cover-to-cylinder block and rear oil seal retainer-to-cylinder block sealing points. (Scheme 189)
2. Install the oil pan gasket and the oil pan. Loosely install all the oil pan bolts. Tighten the oil pan bolts to specification, in sequence, using the following 3 stages. (Scheme 185) Stage 1: Tighten to 18 INCH lbs. (2 N.m). Stage 2: Tighten to 15 ft. lbs. (20 N.m). Stage 3: Tighten an additional 60 degrees. (Scheme 186)
3. On vehicles equipped with the Dual Overhead Camshaft (DOHC), install the front axle assembly. See appropriate article in DRIVE AXLES. On vehicles equipped with a Single Overhead Camshaft (SOHC), position the front axle housing and loosely install the front axle housing mount bolts. (Scheme 188) Tighten front axle housing mount bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications).
4. Position the front axle housing support and install the bolts. (Scheme 187) Tighten the front axle housing support bolts. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications). Remove the jack stand.
5. Lower the vehicle. Fill the engine to proper level with appropriate engine oil. Start the engine and inspect for leaks. Turn on the air suspension switch.

Scheme 189

1. Disconnect negative battery cable(s). Remove engine cover. Remove air cleaner and outlet tube assembly. Remove cooling fan and fan shroud. Remove oil indicator tube. Remove throttle body. Raise and support vehicle.
2. Drain engine oil. Drain cooling system. Remove upper radiator hose. Remove motor mount-to-subframe nuts. Remove flywheel inspection plate. Raise engine, and position blocks between motor mounts and subframe.
3. Remove oil pan retaining bolts in reverse order of tightening sequence. (Scheme 185) Lower oil pan, and remove oil pump pickup tube. Remove oil pan with pickup tube inside oil pan.

1. To install, reverse removal procedure. Apply silicone sealant onto front cover and seal retainer-to-cylinder block areas before installing gasket and oil pan. Tighten all bolts to specification in sequence. (Scheme 185) See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications).
2. When installing fuel lines, fit NEW fuel resistant "O" rings (Brown) on fuel lines. Lightly coat "O" rings with clean engine oil before installing. Clean fittings, and replace garter spring (if necessary).

Scheme 190

Scheme 191

Scheme 192

Scheme 193

1. Raise and support the vehicle.
2. Remove the drain plug and drain the engine oil.
3. Drain the engine coolant system. Refer to ENGINE COOLING .
4. Remove the oil bypass filter (6714).
5. Remove the oil cooler insert, and remove the oil cooler.
6. Clean and inspect the oil cooler. Plug the coolant connections. Flush the oil passages with parts cleaner. If metal particles are present in the oil cooler, install a new cooler.

Scheme 194

1. Install the oil cooler insert.
2. Install the oil bypass filter.
3. Install the drain plug.
4. Lower the vehicle.
5. Fill the engine with clean engine oil.
6. Fill the engine coolant.

Scheme 195

Scheme 196

Scheme 197

Scheme 198

Scheme 199

Scheme 200

Scheme 201

1. Raise and support the vehicle.
2. Remove the drain plug and drain the engine oil.
3. Drain the engine coolant. Refer to ENGINE COOLING .
4. Disconnect the oil pressure sender electrical connector.
5. Remove the oil pressure sensor (9278).
6. Remove the oil bypass filter (6714).
7. Slide back the hose clamp and disconnect the lower radiator hose (8286) from the oil filter adapter (6881).
8. Remove the bolts, the oil filter adapter and discard the gasket.

Scheme 202

Scheme 203

Scheme 204

Scheme 205

1. Position the oil filter adapter and install the four bolts.
2. Position the lower radiator hose on the oil filter adapter and secure the hose clamp.
3. Install the oil bypass filter.
4. Install the oil pressure sensor.
5. Connect the oil pressure sender electrical connector.
6. Install the drain plug.
7. Lower the vehicle.
8. Fill the engine with clean engine oil.
9. Fill the engine coolant. Refer to ENGINE COOLING .

Scheme 206

Scheme 207

Scheme 208

Scheme 209

Scheme 210

1. Raise and support the vehicle.
2. Drain the engine coolant system. Refer to ENGINE COOLING .
3. Remove the front drive axle assembly. Refer to «AXLE ASSEMBLY--FRONT DRIVE»(ref-178223-S10235584512005061300000) .
4. Remove the drain plug and drain the engine oil.
5. Disconnect the oil pressure sender electrical connector.
6. Remove the oil pressure sensor.
7. Remove the bypass oil filter.
8. Slide back the hose clamp and disconnect the lower radiator hose from the oil filter adapter.
9. Remove the four bolts and the oil filter adapter and gasket. Discard the gasket.

Scheme 211

Scheme 212

Scheme 213

Scheme 214

Scheme 215

Scheme 216

1. Install the oil filter adapter. Clean and inspect the mating surfaces. Install a new oil filter adapter gasket. Position the oil filter adapter and install the four bolts.
2. Position the lower radiator hose on the oil filter adapter and secure hose clamp.
3. Install the bypass oil filter.
4. Instal the oil pressure sensor.
5. Connect the oil pressure sender electrical connector.
6. Install the drain plug.
7. Install the front drive axle assembly. Refer to «AXLE ASSEMBLY--FRONT DRIVE»(ref-178223-S10235584512005061300000) .
8. Lower the vehicle.
9. Refill the engine cooling system. Refer to ENGINE COOLING .
10. Fill the engine with clean engine oil.

Cylinder Head

Check cylinder head for cracks or damage. If maximum warpage exceeds .004" (.10 mm), replace cylinder head.

Valve Springs

Inspect valve spring free length, out-of-square and pressure. Replace valve spring if not as specified. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Stem Oil Seals

Use Seal Installer to install oil seals.

Valve Guides

1. Valve guides may be reamed for oversize valves if stem-to-guide oil clearance exceeds specification. See «CYLINDER HEAD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) table under ENGINE SPECIFICATIONS. Valves are available in .015" (.38 mm) and .030" (.76 mm) oversize.
2. Valve guides may also be replaced with a NEW guide if oversize valves are not available or guide is damaged. Ream valve guides until proper stem-to-guide clearance exists.

Valve Seat

Ensure valve seat angle, seat width and seat runout are within specification. See CYLINDER HEAD table under ENGINE SPECIFICATIONS. Grind valve seats when valve guide is reamed or replaced. Replacement information is not available.

Valves

Ensure head diameter, stem diameter, valve face runout and valve margin are within specification. See VALVES & VALVE SPRINGS table under ENGINE SPECIFICATIONS.

Valve Seat Correction Angles

If seat width is too wide after grinding seat, use a 75-degree stone to remove stock from bottom of valve seat (raise seat) or a 30-degree stone to remove stock from top of seat (lower seat).

Piston & Rod Assembly

Note direction of connecting rod installation on piston. Install piston and connecting rod in engine, with arrow on top of piston toward front of engine.

Fitting Pistons

1. Standard service pistons are coded 1, 2 and 3 on dome of piston. Measure piston skirt diameter at 90-degree angle to piston pin, 1.62" (42.0 mm) below piston top. Replace piston if piston diameter is not within specification. See «PISTONS, PINS & RINGS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) table under ENGINE SPECIFICATIONS.
2. Measure cylinder bore at .50" (12.7 mm) below top of piston travel and .50" (12.7 mm) above bottom of piston travel. Ensure piston clearance is within specification. See «PISTONS, PINS & RINGS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) table.
3. If piston clearance is not within specification, choose a selective fit piston to bring piston clearance within specification. See «PISTONS, PINS & RINGS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) table, for selective fit piston sizes.
4. If piston clearance cannot be corrected using a selective fit piston, bore all cylinders to nearest oversize.

Piston Rings

Ensure ring end gap and side clearance are within specification. See PISTONS, PINS & RINGS table under ENGINE SPECIFICATIONS. Position oil control ring expander with gap positioned straight forward and rails with gaps 180 degrees apart, aligned with piston pin. Install compression rings with gaps staggered, so ring gaps do not align.

Rod Bearings

1. Ensure piston and connecting rod are installed in engine with arrow on top of piston toward front of engine.
2. Check bearing clearances using Plastigage. Ensure bearing oil clearance and side play are within specification. See «CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) and «CONNECTING RODS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) tables under ENGINE SPECIFICATIONS. If oil clearance exceeds specification, grind crankshaft to fit undersize bearings. Tighten connecting rod bearing cap bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications) .

Note. When checking bearing clearances using Plastigage, side bolts and side adjusting screws do not need to be installed.

Crankshaft & Main Bearings

1. Measure main bearing clearances using Plastigage. Main bearing caps are marked for location, with No. 1 at front, and No. 5 at rear of engine. Arrow on main bearing cap must point toward front of engine. Lubricate bearing shells with assembly lube or heavy oil before installation.
2. Install main bearing inserts in cylinder block. Lay crankshaft into cylinder block. Push crankshaft rearward. Roll thrust washer into cylinder block, ensure coating on bearing is facing crankshaft thrust surface.
3. Install main bearing caps using NEW bolts, do not fully tighten. Using a pry bar, push crankshaft forward to seat thrust washer. While holding crankshaft forward, evenly pry No. 5 main bearing cap rearward. DO NOT cock bearing cap. Tighten main bearing cap bolts to specification in 2 steps using proper sequence. see scheme 66 See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3__torque-specifications).
4. Tighten side adjusting screws against cylinder block to specification in 2 steps using proper sequence. see scheme 66 Side adjusting screws have left-hand threads. Tighten side bolts.

Scheme 217

Cylinder Block

1. Using a feeler gauge and straightedge, inspect cylinder block deck for warpage. If not within specification, resurface or replace cylinder block. See «CYLINDER BLOCK»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) table under ENGINE SPECIFICATIONS. CAUTION: DO NOT machine more than .010" (.025 mm) from original cylinder block head surface.
2. Check cylinder bore diameter, out-of-round and taper. Cylinder bore is measured at .50" (12.7 mm) below top of cylinder block head surface and .50" (12.7 mm) above piston when at bottom of cylinder bore.
3. Bore cylinder block if measurements are not within specification. See «CYLINDER BLOCK»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-54l-v8-vin-m-z-3) table.

ENGINE LUBRICATION SYSTEM

Rotor-type pump is driven by crankshaft and delivers pressurized oil to main gallery.

Crankcase Capacity

Crankcase capacity with filter change is 6 qts (5.7L).

Oil Pressure

Specification is unavailable from manufacturer.

OIL PUMP

Note. Disassembly and inspection procedures are not available.

Remove oil pan and pick-up tube. See OIL PAN under REMOVAL & INSTALLATION. Remove timing chains and crankshaft sprockets. See TIMING CHAINS under REMOVAL & INSTALLATION. Remove oil pump retaining bolts. Remove oil pump.

To install, reverse removal procedure. Ensure flat areas of oil pump rotor aligns with flat areas of crankshaft. Tighten bolts to specification. See TORQUE SPECIFICATIONS .

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

CRANKSHAFT, MAIN BEARINGS & CONNECTING ROD BEARINGS SPECIFICATIONS

CRANKSHAFT, MAIN & CONNECTING ROD BEARINGS

PISTONS, PISTON PINS & PISTON RINGS SPECIFICATIONS

PISTONS, PINS & RINGS

CONNECTING RODS SPECIFICATIONS

CONNECTING RODS

CYLINDER HEAD SPECIFICATIONS

CYLINDER HEAD

BALANCE SHAFT SPECIFICATIONS

BALANCE SHAFT

CAMSHAFT SPECIFICATIONS

CAMSHAFT

CYLINDER BLOCK SPECIFICATIONS

CYLINDER BLOCK

ENGINE VALVES & VALVE SPRINGS SPECIFICATIONS

VALVES & VALVE SPRINGS

See also:
• ENGINE MECHANICAL
• ENGINE IDENTIFICATION CODES
• FUEL PRESSURE RELEASE & FUEL LINE CONNECTIONS
• TORQUE SPECIFICATIONS
• EXHAUST MANIFOLD
• FRONT CRANKSHAFT SEAL
• FRONT COVER
• OIL PAN