Engine Mechanical - 5.4L (3V): Removal & Installation Ford Expedition III

Removal

Scheme 1

1. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-364096) .
2. Remove the generator. For additional information, refer to «CHARGING SYSTEM»(ref-364045) .
3. Disconnect the quick connect couplings and remove the crankcase ventilation tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) .
4. Remove the bolt, loosen the clamp and remove the air intake resonator assembly.
5. Remove the 3 bolts and the Throttle Body (TB)-to-Air Cleaner (ACL) outlet tube adapter.
6. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) .
7. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) .
8. Disconnect the electrical connector and the Evaporative Emission (EVAP) tube quick connect coupling from the EVAP canister purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) .
9. Disconnect the upper radiator hose from the thermostat housing.
10. Disconnect the heater coolant hose from the coolant crossover manifold assembly.
11. Disconnect the 8 fuel injector electrical connectors.
12. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.
13. Disconnect the 4 LH ignition coil and the LH Variable Camshaft Timing (VCT) solenoid electrical connectors and detach the 2 engine wiring harness retainers from the LH valve cover studs.
14. Disconnect the intake manifold vacuum tube from the brake booster vacuum hose.
15. NOTE: The intake manifold vacuum tube must be removed with the intake manifold as an assembly. Disconnect the intake manifold vacuum tube from the LH valve cover studbolt and the support bracket at the rear of the LH cylinder head.
16. Remove the 10 intake manifold bolts.
17. NOTE: 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. Remove the 3 bolts, the coolant crossover manifold assembly and discard the gaskets. Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
18. NOTE: The intake manifold vacuum tube must be positioned under the engine wiring harness and removed with the intake manifold as an assembly. Position the intake forward to gain access to the wiring harness retainers.
19. Disconnect the 2 engine wiring harness retainers from the rear of the intake manifold.
20. Disconnect the Cylinder Head Temperature (CHT) sensor jumper harness electrical connector retainer.
21. NOTE: 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: The intake manifold vacuum tube must be positioned under the engine wiring harness and removed with the intake manifold as an assembly. Remove the intake manifold and discard the gaskets. Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

Scheme 2

1. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. NOTE: The intake manifold vacuum tube must be positioned under the engine wiring harness during installation of the intake manifold. Using new intake manifold gaskets, position the intake manifold.
2. Position the intake manifold forward and connect the CHT sensor jumper harness electrical connector retainer.
3. Connect the 2 engine wiring harness retainers to the rear of the intake manifold and position back the intake manifold assembly.
4. Using new gaskets, position the coolant crossover manifold assembly and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
5. Install the 10 intake manifold bolts and tighten in 2 stages in the sequence shown in illustration. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 10 Nm (89 lb-in).
6. Connect the intake manifold vacuum tube to the support bracket and the valve cover stud.
7. Connect the brake booster vacuum hose to the intake manifold vacuum tube and position the clamp.
8. Connect the 4 LH ignition coil and the LH VCT solenoid electrical connectors and attach the 2 engine wiring harness retainers to the LH valve cover studs.
9. Connect the TP sensor and electronic throttle control electrical connectors.
10. Connect the 8 fuel injector electrical connectors.
11. Connect the heater coolant hose to the coolant crossover manifold assembly.
12. Connect the upper radiator hose to the thermostat housing.
13. Connect the electrical connector and the EVAP tube quick connect coupling to the EVAP canister purge valve. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) .
14. Connect the fuel supply tube quick connect coupling. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) .
15. Position the PCV tube and connect the quick connect couplings. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) .
16. Position the TB -to- ACL outlet tube adapter and install the 3 bolts. Tighten the bolt to 10 Nm (89 lb-in).
17. Position the air intake resonator assembly, install the bolt and the clamp. Tighten the bolt to 10 Nm (89 lb-in).
18. Position the crankcase ventilation tube and connect the quick connect couplings. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) .
19. Install the generator. For additional information, refer to «CHARGING SYSTEM»(ref-364045) .
20. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-364096) .

Scheme 3

PART DESCRIPTION CHART

Scheme 4

PART DESCRIPTION CHART

1. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-364085) .
2. Remove the bolt and position the oil level indicator and tube aside.
3. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) .
4. Disconnect the intake manifold vacuum tube hose from the brake booster.
5. Disconnect the intake manifold vacuum tube from the support bracket and the valve cover stud.
6. Disconnect the Variable Camshaft Timing (VCT) solenoid electrical connector.
7. Disconnect the 3 wiring harness retainers from the front of the LH valve cover and the 2 wiring harness retainers from the LH valve cover studs.
8. Remove the 4 LH ignition coils. For additional information, refer to «ENGINE IGNITION - 5.4L (3V)»(ref-364098) .
9. NOTE: 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: When removing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid. NOTE: The fasteners are part of the valve cover and should not be removed. Loosen the 10 fasteners and remove the LH valve cover and gasket. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Scheme 5

Scheme 6

1. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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 bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
2. NOTE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid. Position the LH valve cover and new gasket on the cylinder head and tighten the 10 fasteners in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
3. Position the intake manifold vacuum tube assembly onto the support bracket and the valve cover stud.
4. Connect the intake manifold vacuum tube hose to the brake booster.
5. Install the 4 LH ignition coils. For additional information, refer to «ENGINE IGNITION - 5.4L (3V)»(ref-364098) .
6. Connect the 3 wiring harness retainers to the front of the RH valve cover and the 2 wiring harness retainers to the RH valve cover studs.
7. Connect the VCT solenoid electrical connector.
8. Position the PCV tube and connect the quick connect couplings. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) .
9. Position back the oil level indicator and tube and install the bolt. Tighten to 10 Nm (89 lb-in).
10. Install the ACL outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-364085) .

Vehicles with auxiliary heat

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

1. Drain the cooling system. For additional information, refer to «ENGINE COOLING»(ref-364096) .
2. Disconnect the 2 auxiliary heat coolant hoses and position the auxiliary heat coolant hoses aside. All vehicles
3. Disconnect the quick connect couplings and remove the crankcase vent tube. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) .
4. Disconnect the PCM electrical connector and position aside.
5. Remove the nut and the ground cable and disconnect the wiring harness retainer.
6. Disconnect the PCM electrical connector.
7. Disconnect the 2 electrical connectors and the wiring harness retainer and position the wiring harness aside.
8. Disconnect the RH radio ignition interference capacitor and engine cooling fan clutch electrical connectors.
9. Remove the 4 RH ignition coils. For additional information, refer to «ENGINE IGNITION - 5.4L (3V)»(ref-364098) .
10. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
11. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs and position the wiring harness aside.
12. NOTE: 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: When removing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid. NOTE: The fasteners are part of the valve cover and should not be removed. Loosen the 9 fasteners and remove the RH valve cover and gasket. Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.

Installation

All vehicles

Scheme 13

Scheme 14

1. NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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 bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
2. NOTE: When installing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid. Position the RH valve cover and new gasket on the cylinder head and tighten the 9 fasteners in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
3. Install the 4 RH ignition coils. For additional information, refer to «ENGINE IGNITION - 5.4L (3V)»(ref-364098) .
4. Position back the engine wiring harness and connect the 2 electrical connectors and the wiring harness retainer.
5. Connect the PCM electrical connector.
6. Connect the wiring harness retainer and ground cable and install the nut. Tighten to 10 Nm (89 lb-in).
7. Connect the PCM electrical connector.
8. Connect the RH radio ignition interference capacitor and engine cooling fan clutch electrical connectors.
9. Connect the RH VCT solenoid electrical connector.
10. Connect the wiring harness retainers to the valve cover.
11. Position the crankcase vent tube and connect the quick connect couplings. For additional information, refer to «FUEL SYSTEM - GENERAL INFORMATION»(ref-364097) . Vehicles with auxiliary heat
12. Connect the 2 auxiliary heat coolant hoses.
13. Fill and bleed the coolant system. For additional information, refer to «ENGINE COOLING»(ref-364096) .

Note. The camshaft procedure must be followed exactly or damage to the valves and pistons will result.

Scheme 15

Scheme 16

Scheme 17

Scheme 18

Scheme 19

Scheme 20

Scheme 21

1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
2. Remove the LH valve cover. For additional information, refer to «VALVE COVER - LH»(ref-364032-S10292222982010062700000) .
3. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. Loosen and back off the LH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the LH Camshaft Position (CMP) sensor electrical connector.
5. Remove the bolt and the LH CMP sensor.
6. NOTE: If the camshaft lobes are not exactly positioned as shown in illustration, the crankshaft keyway will require one full additional rotation to 12 o'clock. The No. 5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 5 cylinder.
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. NOTE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the previous step.
9. NOTE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. NOTE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTE: The Timing Chain Locking Tool must be installed square to the timing chain and the engine block. NOTE: Engine front cover removed for clarity. Install the Timing Chain Locking Tool in the LH timing chain as shown in illustration.
11. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. NOTE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading. Remove the 2 bolts and the LH camshaft front bearing cap.
13. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining 8 bolts in the sequence shown in illustration and remove the 4 camshaft bearing caps.
14. Clean and inspect the LH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
15. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . Remove the bolt and the camshaft phaser and sprocket assembly from the camshaft. Discard the bolt and washer.
16. Remove the camshaft.
17. Remove and inspect the camshaft phaser and sprocket for damage. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-364043) .

Scheme 22

1. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
2. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to the new camshaft phaser and sprocket. Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in alignment.
3. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to install the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft phaser and sprocket bolt finger-tight.
4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Install the 5 camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil. Position the 2 front camshaft bearing cap. Position the remaining 8 camshaft bearing caps. Install the 10 bolts loosely.
5. Tighten the bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
6. NOTE: Engine front cover removed for clarity. Remove the Timing Chain Locking Tool.
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
8. Verify correct camshaft position by noting the position of the No. 5 cylinder intake and exhaust camshaft lobes.
9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers.
10. Install the CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in).
11. Connect the CMP electrical connector.
12. NOTE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Tighten the camshaft phaser and sprocket bolt in 2 stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
13. Install the LH valve cover. For additional information, refer to «VALVE COVER - LH»(ref-364032-S10292222982010062700000) .

Note. The camshaft procedure must be followed exactly or damage to the valves and pistons will result.

Scheme 23

Scheme 24

Scheme 25

Scheme 26

Scheme 27

1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
2. Remove the RH valve cover. For additional information, refer to «VALVE COVER - RH»(ref-364032-S08492254712010062700000) .
3. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. Loosen and backoff the RH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
5. Remove the bolt and the RH CMP sensor.
6. NOTE: If the camshaft lobes are not exactly positioned as shown in illustration, the crankshaft will require one full additional rotation to 12 o'clock. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. NOTE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the previous step.
9. NOTE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. NOTE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTE: The Timing Chain Locking Tool must be installed square to the timing chain and the engine block. NOTE: Engine front cover removed for clarity. Install the Timing Chain Locking Tool in the RH timing chain as shown in illustration.
11. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. NOTE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading. Remove the 2 bolts and the front camshaft bearing cap.
13. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage. Remove the remaining bolts in the sequence shown in illustration and remove the remaining camshaft bearing caps.
14. Clean and inspect the RH camshaft bearing caps. The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
15. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . Remove the bolt and the camshaft phaser and sprocket assembly from the camshaft. Discard the bolt and washer.
16. Remove the camshaft.
17. Remove and inspect the camshaft phaser and sprocket for damage. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-364043) .

1. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Lubricate the camshaft and camshaft journals with clean engine oil and install the camshaft.
2. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to the new camshaft phaser and sprocket. Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in alignment.
3. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to install the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft phaser and sprocket bolt finger-tight.
4. NOTE: Do not allow the camshaft roller followers to move out of position when installing the camshaft. Install the 5 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 10 bolts loosely.
5. Tighten the 10 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
6. NOTE: Engine front cover removed for clarity. Remove the Timing Chain Locking Tool.
7. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
8. Verify correct camshaft position by noting the position of the No. 1 cylinder intake and exhaust camshaft lobes.
9. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers.
10. Install the CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in).
11. Connect the CMP electrical connector.
12. NOTE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Tighten the new camshaft phaser and sprocket bolt in 2 stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
13. Install the RH valve cover. For additional information, refer to «VALVE COVER - RH»(ref-364032-S08492254712010062700000) .

Note. The camshaft procedure must be followed exactly or damage to the valves and pistons will result.

1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
2. Remove the LH valve cover. For additional information, refer to «VALVE COVER - LH»(ref-364032-S10292222982010062700000) .
3. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. Loosen and back off the LH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the LH Camshaft Position (CMP) sensor electrical connector.
5. Remove the bolt and the LH CMP sensor.
6. NOTE: If the camshaft lobes are not exactly positioned as shown in illustration, the crankshaft keyway will require one full additional rotation to 12 o'clock. The No. 5 cylinder camshaft lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 5 cylinder.
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. NOTE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the previous step.
9. NOTE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. NOTE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTE: The Timing Chain Locking Tool must be installed square to the timing chain and the engine block or damage may result. NOTE: Engine front cover removed for clarity. Install the Timing Chain Locking Tool in the LH timing chain as shown in illustration.
11. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . Remove the bolt and the camshaft phaser and sprocket assembly from the camshaft. Discard the bolt and washer.
13. Remove the camshaft phaser and sprocket assembly from the timing chain and inspect for damage. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-364043) .

1. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to the new camshaft phaser and sprocket. Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in alignment.
2. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to install the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft phaser and sprocket bolt finger-tight.
3. NOTE: Engine front cover removed for clarity. Remove the Timing Chain Locking Tool.
4. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
5. Verify correct camshaft position by noting the position of the No. 5 cylinder intake and exhaust camshaft lobes.
6. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers.
7. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Install the CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in).
8. Connect the CMP electrical connector.
9. NOTE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Tighten the camshaft phaser and sprocket bolt in 2 stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
10. Install the LH valve cover. For additional information, refer to «VALVE COVER - LH»(ref-364032-S10292222982010062700000) .

Note. This procedure must be followed exactly or damage to the valves and pistons will result.

1. Position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
2. Remove the RH valve cover. For additional information, refer to «VALVE COVER - RH»(ref-364032-S08492254712010062700000) .
3. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. Loosen and backoff the RH camshaft phaser and sprocket bolt one full turn.
4. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
5. Remove the bolt and the RH CMP sensor.
6. NOTE: If the camshaft lobes are not exactly positioned as shown in illustration, the crankshaft will require one full additional rotation to 12 o'clock. The No. 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the No. 1 cylinder.
7. Remove only the 3 camshaft roller followers shown in the illustration.
8. NOTE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, remove only the 3 designated camshaft roller followers from the previous step.
9. NOTE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur. Rotate the crankshaft clockwise, as viewed from the front, positioning the crankshaft damper spoke at the 6 o'clock position and the timing mark indentation at the 7 o'clock position.
10. NOTE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result. NOTE: The Timing Chain Locking Tool must be installed square to the timing chain and the engine block. NOTE: Engine front cover removed for clarity. Install the Timing Chain Locking Tool in the RH timing chain as shown in illustration.
11. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.
12. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . Remove the bolt and remove the camshaft phaser and sprocket assembly from camshaft. Discard the bolt and washer.
13. Remove the camshaft phaser and sprocket assembly from the timing chain and inspect for damage. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-364043) .

1. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: The timing chain must be installed in its original position onto the camshaft phaser and sprocket using the scribed marks, or damage to valves and pistons will result. NOTE: If replacement of the camshaft phaser and sprocket is necessary, transfer the scribe mark to the new camshaft phaser and sprocket. Position the camshaft phaser and sprocket into the timing chain with the timing chain scribe marks in alignment.
2. NOTE: Do not remove the Timing Chain Locking Tool at any time during assembly. If the Timing Chain Locking Tool is removed or out of placement, the engine front cover must be removed and the engine must be retimed. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. NOTE: Only use hand tools to install the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket. Install the camshaft phaser and sprocket assembly onto the camshaft and install a new camshaft phaser and sprocket bolt finger-tight.
3. NOTE: Engine front cover removed for clarity. Remove the Timing Chain Locking Tool.
4. Rotate the crankshaft a half turn counterclockwise and position the crankshaft damper spoke at the 12 o'clock position and the timing mark indentation at the 1 o'clock position.
5. Verify correct camshaft position by noting the position of the No. 1 cylinder intake and exhaust camshaft lobes.
6. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, install the 3 originally removed camshaft roller followers.
7. NOTE: Lubricate the O-ring seal with clean engine oil prior to installation. Install the CMP sensor and the bolt. Tighten to 10 Nm (89 lb-in).
8. Connect the CMP electrical connector.
9. NOTE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket. NOTE: Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device. Tighten the new camshaft phaser and sprocket bolt in 2 stages: Stage 1: Tighten to 40 Nm (30 lb-ft). Stage 2: Tighten an additional 90 degrees.
10. Install the RH valve cover. For additional information, refer to «VALVE COVER - RH»(ref-364032-S08492254712010062700000) .

All Variable Camshaft Timing (VCT) housings

Scheme 28

Scheme 29

Scheme 30

1. Remove the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) . RH VCT housing
2. Remove the 2 bolts and the RH Variable Camshaft Timing (VCT) housing. LH VCT housing
3. Remove the 2 bolts and the LH VCT housing. All VCT housings
4. Remove and discard the VCT housing gasket.
5. NOTE: 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. Clean and inspect the cylinder head sealing surfaces with metal surface prep. Follow the directions on the packaging.
6. Clean and inspect the VCT housing. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-364043) .

All VCT housing

1. Install a new gasket onto the VCT housing. RH VCT housing
2. Position the RH VCT housing and install the 2 bolts. Tighten to 10 Nm (89 lb-in). LH VCT housing
3. Position the LH VCT housing and install the 2 bolts. Tighten to 10 Nm (89 lb-in). All VCT housings
4. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) .

LH cylinder head camshaft roller followers

1. Remove the LH valve cover. For additional information, refer to «VALVE COVER - LH»(ref-364032-S10292222982010062700000) . RH cylinder head camshaft roller followers
2. Remove the RH valve cover. For additional information, refer to «VALVE COVER - RH»(ref-364032-S08492254712010062700000) . All camshaft roller followers
3. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed.
4. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller follower.
5. Repeat the previous 2 steps for each camshaft roller follower being serviced.
6. Inspect the camshaft roller follower. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-364043) .

All camshaft roller followers

1. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation. Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller follower.
2. Repeat the previous step for each camshaft roller follower being serviced. LH cylinder head camshaft roller followers
3. Install the LH valve cover. For additional information, refer to «VALVE COVER - LH»(ref-364032-S10292222982010062700000) . RH cylinder head camshaft roller followers
4. Install the RH valve cover. For additional information, refer to «VALVE COVER - RH»(ref-364032-S08492254712010062700000) .

RH cylinder head valve springs

Scheme 31

1. Remove the RH valve cover. For additional information, refer to «VALVE COVER - RH»(ref-364032-S08492254712010062700000) . LH cylinder head valve springs
2. Remove the LH valve cover. For additional information, refer to «VALVE COVER - LH»(ref-364032-S10292222982010062700000) . All valve springs
3. Remove the spark plug for the cylinder being serviced. For additional information, refer to «ENGINE IGNITION - 5.4L (3V)»(ref-364098) .
4. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed.
5. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller follower.
6. Use compressed air in the cylinder being serviced to hold both valves in position. Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
7. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. If a valve drops into the cylinder, remove the cylinder head. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer keys.
8. Remove the valve spring retainer and the valve spring.
9. Inspect the valve spring. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-364043) .

All valve springs

1. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow these instructions may result in engine damage. Using the Valve Spring Compressor, install the valve spring, the valve spring retainer and the valve spring retainer keys.
2. Relieve the air pressure from the cylinder.
3. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow this instruction may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation. Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller follower.
4. Install the spark plug. For additional information, refer to «ENGINE IGNITION - 5.4L (3V)»(ref-364098) . LH cylinder head valve springs
5. Install the LH valve cover. For additional information, refer to «VALVE COVER - LH»(ref-364032-S10292222982010062700000) . RH cylinder head valve springs
6. Install the RH valve cover. For additional information, refer to «VALVE COVER - RH»(ref-364032-S08492254712010062700000) .

RH cylinder head valve seals

1. Remove the RH valve cover. For additional information, refer to «VALVE COVER - RH»(ref-364032-S08492254712010062700000) . LH cylinder head valve seals
2. Remove the LH valve cover. For additional information, refer to «VALVE COVER - LH»(ref-364032-S10292222982010062700000) . All valve seals
3. Remove the spark plug for the cylinder being serviced. For additional information, refer to «ENGINE IGNITION - 5.4L (3V)»(ref-364098) .
4. Rotate the crankshaft until the piston for the valve being serviced is at the top of its stroke with the intake valve and the exhaust valves closed.
5. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. Using the Valve Spring Compressor, compress the valve spring and remove the camshaft roller follower.
6. Use compressed air in the cylinder being serviced to hold the valves in position. Apply a minimum of 965 kPa (140 psi) of compressed air into the cylinder.
7. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. NOTE: If air pressure has forced the piston to the bottom of the cylinder, any loss of air pressure will allow the valve to fall into the cylinder. If air pressure must be removed, support the valve prior to removal. If a valve drops into the cylinder, remove the cylinder head. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . Using the Valve Spring Compressor, compress the valve spring and remove the valve spring retainer keys.
8. Remove the valve spring retainer, the valve spring and the valve seal. Discard the valve seal.
9. Inspect the components. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-364043) .

All valve seals

Scheme 32

1. NOTE: Lubricate the valve seal and valve stem with clean engine oil prior to installation. Position a new valve seal onto the valve stem.
2. Using the Valve Stem Oil Seal Installer, install the new valve seal.
3. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow this instruction may result in engine damage. Using the Valve Spring Compressor, install the valve spring, the valve spring retainer and the valve spring retainer keys.
4. Relieve the air pressure from the cylinder.
5. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Failure to follow this instruction may result in engine damage. NOTE: Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to «CYLINDER HEAD»(ref-364032-S10970677412010062700000) . NOTE: It may be necessary to push the valve down while compressing the spring. NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation. Using the Valve Spring Compressor, compress the valve spring and install the camshaft roller follower.
6. Install the spark plug. For additional information, refer to «ENGINE IGNITION - 5.4L (3V)»(ref-364098) . LH cylinder head valve seals
7. Install the LH valve cover. For additional information, refer to «VALVE COVER - LH»(ref-364032-S10292222982010062700000) . RH cylinder head valve seals
8. Install the RH valve cover. For additional information, refer to «VALVE COVER - RH»(ref-364032-S08492254712010062700000) .

Removal and Installation

RH cylinder head hydraulic lash adjusters

1. Remove the RH camshaft. For additional information, refer to «CAMSHAFT - RH»(ref-364032-S37466629782010062700000) . LH cylinder head hydraulic lash adjusters
2. Remove the LH camshaft. For additional information, refer to «CAMSHAFT - LH»(ref-364032-S00358193142010062700000) . All hydraulic lash adjusters
3. Remove the camshaft roller follower from the hydraulic lash adjuster being serviced.
4. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage. Remove the hydraulic lash adjuster that is being serviced.
5. Inspect the hydraulic lash adjuster. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-364043) .
6. NOTE: Lubricate the hydraulic lash adjuster with clean engine oil prior to installation. To install, reverse the removal procedure.

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-364035) .
2. Remove the RH inner fenderwell. For additional information, refer to «FRONT END BODY PANELS»(ref-364066) .
3. Remove the RH engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(ref-364032-S21733356132010062700000) .
4. Remove the 2 bolts and the exhaust manifold heat shield.
5. Remove the 8 exhaust manifold nuts, the 8 studs and the exhaust manifold. Discard the exhaust manifold nuts and studs.
6. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Remove and discard the 2 exhaust manifold gaskets. Clean the sealing surfaces with metal surface prep.
7. Inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-364043) .

Scheme 33

1. Using 2 new exhaust manifold gaskets and 8 new studs, position the 2 gaskets and exhaust manifold and install the 8 studs. Tighten to 12 Nm (106 lb-in).
2. Using 8 new exhaust manifold nuts, install the 8 nuts. Tighten to 25 Nm (18 lb-ft) in the sequence shown in illustration.
3. Position the exhaust manifold heat shield and install the 2 bolts. Tighten to 10 Nm (89 lb-in).
4. Install the RH engine support insulator. For additional information, refer to «ENGINE SUPPORT INSULATORS»(ref-364032-S21733356132010062700000) .
5. Install the RH inner fenderwell. For additional information, refer to «FRONT END BODY PANELS»(ref-364066) .

All vehicles

Scheme 34

Scheme 35

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-364035) .
2. Remove the Air Cleaner (ACL) outlet pipe. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-364085) .
3. Remove the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-364096) .
4. NOTE: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-364075) . Remove the bolt and disconnect the steering shaft and position aside.
5. Remove the 4 (2 LH and 2 RH) exhaust manifold-to-catalytic converter nuts. Four-Wheel Drive (4WD) vehicles
6. Remove the front driveshaft. For additional information, refer to «DRIVESHAFT»(ref-364071) . All vehicles
7. Remove the 8 exhaust manifold nuts, the 8 studs and the exhaust manifold. Discard the exhaust manifold nuts and studs.
8. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. NOTE: Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Remove and discard the 2 exhaust manifold gaskets. Clean the sealing surfaces with metal surface prep.
9. Inspect the exhaust manifold. For additional information, refer to «ENGINE SYSTEM - GENERAL INFORMATION»(ref-364043) .

All vehicles

Scheme 36

1. Using 2 new exhaust manifold gaskets and 8 new studs, position the 2 gaskets and exhaust manifold and install the 8 studs. Tighten to 12 Nm (106 lb-in).
2. Using new exhaust manifold nuts, install the 8 nuts. Tighten to 25 Nm (18 lb-ft) in the sequence shown in illustration. 4WD vehicles
3. Install the front driveshaft. For additional information, refer to «DRIVESHAFT»(ref-364071) . All vehicles
4. NOTE: Do not allow the steering column shaft to rotate while the intermediate shaft is disconnected or damage to the clockspring can result. If there is evidence that the shaft has rotated, the clockspring must be removed and recentered. For additional information, refer to «SUPPLEMENTAL RESTRAINT SYSTEM»(ref-364075) . Connect the steering shaft and install the bolt. To install, tighten to 30 Nm (22 lb-ft).
5. Install the 4 exhaust manifold-to-catalytic converter nuts.
6. Install the degas bottle. For additional information, refer to «ENGINE COOLING»(ref-364096) .
7. Install the ACL outlet tube. For additional information, refer to «INTAKE AIR DISTRIBUTION & FILTERING»(ref-364085) .

Scheme 37

PART DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

All vehicles

Scheme 38

Scheme 39

Scheme 40

Scheme 41

Scheme 42

Scheme 43

Scheme 44

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-364035) . Four-Wheel Drive (4WD) vehicles
2. If equipped, remove the 10 bolts and the 2 skid plates. All vehicles
3. Remove the oil drain plug and drain the engine oil. Install the drain plug when finished. Tighten to 23 Nm (17 lb-ft).
4. Remove the 4 nuts, the 4 bolts and the crossmember. 4WD vehicles
5. Position a suitable hydraulic jack under the front axle. Securely strap the jack to the axle.
6. NOTE: Rotate the steering column so the pinch bolt for the steering column coupling allows clearance for the isolator bolt. Remove the upper front axle carrier mounting bushing bolt.
7. Remove the axle shaft housing carrier bushing bolt.
8. Remove the lower front axle carrier mounting bushing bolt.
9. NOTE: Use care when lowering the front axle housing, or the vacuum lines to the axle solenoid may become disconnected or damaged. Lower the axle to allow clearance for the oil pan to be removed. All vehicles
10. Remove the starter wiring harness rear support bracket bolt.
11. Remove the nut and position the starter wiring harness and the transmission fluid cooler tubes aside.
12. Detach the oil pressure switch wiring harness from the oil pan bolt.
13. Remove the 16 bolts, the oil pan and the gasket. Discard the gasket.
14. NOTE: 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 gasket mating surfaces of the oil pan and engine block with silicone gasket remover and metal surface prep. Follow the directions on the packaging.

All vehicles

Scheme 45

Scheme 46

Scheme 47

Scheme 48

1. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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.
2. NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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.
3. Position a new gasket and the oil pan and install the 16 bolts. Tighten the bolts in the sequence shown in illustration in 3 stages. Stage 1: Tighten to 2 Nm (18 lb-in). Stage 2: Tighten to 20 Nm (177 lb-in). Stage 3: Tighten an additional 60 degrees.
4. Attach the oil pressure switch wiring harness to the oil pan bolt.
5. Position the transmission fluid cooler tube support bracket, the starter wiring harness support bracket and install the nut. Tighten to 10 Nm (89 lb-in).
6. Position the starter wiring harness and install the starter wiring harness rear support bracket bolt. Tighten to 10 Nm (89 lb-in).
7. Install the transmission fluid cooling tubes rear support bracket bolt. Tighten to 48 Nm (35 lb-ft). 4WD vehicles
8. NOTE: Use care when positioning the front axle housing, or the vacuum lines to the axle solenoid may become disconnected or damaged. Raise the front axle carrier into position.
9. Install the lower front axle carrier mounting bushing bolt. Tighten to 115 Nm (85 lb-ft).
10. Install the axle shaft housing carrier bushing bolt. Tighten to 115 Nm (85 lb-ft).
11. Install the upper front axle carrier mounting bushing bolt. Tighten to 115 Nm (85 lb-ft). All vehicles
12. Position the crossmember and install the 4 bolts and the 4 nuts. Tighten to 90 Nm (66 lb-ft). 4WD vehicles
13. If equipped, install the 2 skid plates and the 10 bolts. Tighten to 48 Nm (35 lb-ft). All vehicles
14. Fill the engine with clean engine oil.

1. NOTE: 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. Clean the sealing surfaces with metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.
2. Position the oil pump and install the 3 bolts. Tighten to 10 Nm (89 lb-in).
3. NOTE: 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 3 bolts. Tighten the 2 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).
4. Install the oil pan. For additional information, refer to «OIL PAN»(ref-364032-S39140089172010062700000) .
5. Install the timing drive components. For additional information, refer to «TIMING DRIVE COMPONENTS»(ref-364032-S41795278812010062700000) .

1. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-364032-S39140089172010062700000) .
2. Remove the 3 bolts and the oil pump screen and pickup tube.

1. NOTE: 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 3 bolts. Tighten the 2 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).
2. Install the oil pan. For additional information, refer to «OIL PAN»(ref-364032-S39140089172010062700000) .

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-364035) .
2. Drain the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-364096) .
3. Drain the engine oil. Install the drain plug and tighten to 23 Nm (17 lb-ft).
4. Disconnect the engine oil pressure switch electrical connector.
5. Disconnect the lower radiator hose and position it aside.
6. Remove and discard the engine oil filter. To install, lubricate the oil filter gasket with clean engine oil and tighten until the seal makes contact. Using an oil filter strap wrench, tighten the filter an additional 270 degrees.
7. Remove the 4 bolts and the oil filter adapter. To install, tighten to 25 Nm (18 lb-ft).
8. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Remove and discard the oil filter adapter gasket. Clean the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Inspect the mating surfaces.
9. To install, reverse the removal procedure. Fill the engine with clean engine oil.
10. Fill and bleed the engine cooling system. For additional information, refer to «ENGINE COOLING»(ref-364096) .

Scheme 49

PART DESCRIPTION CHART

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-364035) .
2. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
3. Remove the EOP switch. To install, tighten to 18 Nm (159 lb-in).
4. To install, reverse the removal procedure.

1. Remove the LH exhaust manifold. For additional information, refer to «EXHAUST MANIFOLD - LH»(ref-364032-S22697537402010062700000) .
2. Remove the oil level indicator and tube bolt. To install, tighten to 10 Nm (89 lb-in).
3. Remove the oil level indicator and tube from the cylinder block. Discard the O-ring seal.
4. NOTE: Lubricate the new oil level indicator tube O-ring seal with clean engine oil prior to installation. To install, reverse the removal procedure. Install a new O-ring seal.

Scheme 50

PART DESCRIPTION CHART

1. For additional information, refer to the appropriate procedure(s).

Scheme 51

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6R80»(ref-364034) .
2. Remove the 8 bolts and the flexplate. To install, tighten to 80 Nm (59 lb-ft) in the sequence shown in illustration.
3. To install, reverse the removal procedure.

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6R80»(ref-364034) .
2. Remove the oil pan. For additional information, refer to «OIL PAN»(ref-364032-S39140089172010062700000) .
3. Remove the rear engine cover.
4. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger.
5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.
6. Remove the 6 bolts and the crankshaft rear seal retainer plate.

Scheme 52

Scheme 53

1. NOTE: 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 the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Clean and inspect the mating surface.
2. NOTE: If the rear crankshaft seal retaining plate is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with 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 may cause future oil leaks. NOTE: The silicone must be applied on the groove along the retainer plate. Apply a 4.06 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer plate sealing surface.
3. Install the crankshaft rear seal retainer plate and the 6 bolts in the sequence shown in illustration. Tighten to 10 Nm (89 lb-in).
4. NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation. Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.
5. NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation. Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install a new crankshaft oil slinger.
6. Install the rear engine cover.
7. Install the flexplate and tighten the 8 bolts in the sequence shown in illustration. Tighten to 80 Nm (59 lb-ft).
8. Install the oil pan. For additional information, refer to «OIL PAN»(ref-364032-S39140089172010062700000) .
9. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION - 6R80»(ref-364034) .

All engine support insulators

Scheme 54

Scheme 55

Scheme 56

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-364035) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-364088) .
3. Remove the Throttle Body (TB). For additional information, refer to «FUEL CHARGING & CONTROLS - 5.4L (3V)»(ref-364099) .
4. Remove the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-364096) .
5. Remove the generator. For additional information, refer to «CHARGING SYSTEM»(ref-364045) .
6. Remove the starter. For additional information, refer to «STARTING SYSTEM»(ref-364100) .
7. If servicing the engine support insulators on a Four-Wheel Drive (4WD) vehicle, remove the front driveshaft. For additional information, refer to «DRIVESHAFT»(ref-364071) .
8. Install the Engine Support Bar, Support Hook and Engine Support Bracket.
9. Remove the 4 (2 RH and 2 LH) Y-pipe flange nuts.
10. NOTE: Only use hand tools when removing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur. Loosen the 2 transmission mount-to-crossmember nuts. RH engine support insulator
11. NOTE: Only use hand tools when loosening the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Loosen the LH engine support insulator through bolt.
12. NOTE: Only use hand tools when removing the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Remove the RH engine support insulator through bolt.
13. NOTE: Only use hand tools when removing the engine support insulator nuts or damage to the engine support insulator can occur. NOTE: If during nut removal the stud bolt is extracted from the engine support insulator, separate the nut from the stud bolt prior to stud bolt installation. Remove the 2 RH engine support insulator nuts.
14. NOTE: Only use hand tools when removing the engine support insulator stud bolts or damage to the engine support insulator can occur. Remove the 2 RH engine support insulator stud bolts.
15. Using the Engine Support Bar, Support Hook and Engine Support Bracket, raise the engine.
16. Remove the 3 bolts and the RH engine support insulator-to-cylinder block bracket.
17. Remove the RH engine support insulator. LH engine support insulator
18. NOTE: Only use hand tools when loosening the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Loosen the RH engine support insulator through bolt.
19. NOTE: Only use hand tools when removing the engine support insulator through bolts or damage to the engine support insulator-to-cylinder block bracket can occur. Remove the LH engine support insulator through bolt.
20. Using the Engine Support Bar, Support Hook and Engine Support Bracket, raise the engine.
21. NOTE: Only use hand tools when removing the engine support insulator-to-frame bolts or damage to the engine support insulator-to-frame nut plate can occur. Remove the 3 engine support insulator-to-frame bolts. Discard the 3 bolts.
22. Remove the 3 bolts and the LH engine support insulator-to-cylinder block bracket.
23. Remove the LH engine support insulator.
24. Inspect the engine support insulator-to-frame nut plate for thread damage. If the nut plate is damaged, bend 2 tabs back and remove the nut plate. Replace the nut plate with service part No. 56190 and bend the 2 tabs back to the original position.

RH engine support insulator

1. Clean the engine support insulator-to-cylinder block and engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation.
2. NOTE: Only use hand tools when installing the engine support insulator stud bolts or damage to the engine support insulator can occur. Position the RH engine support insulator into the vehicle and install the 2 stud bolts. Tighten to 15 Nm (133 lb-in).
3. Position the RH engine support insulator-to-cylinder block bracket and install the 3 bolts. Tighten to 63 Nm (46 lb-ft).
4. NOTE: Only use hand tools when installing the RH engine support insulator nuts or damage to the engine support insulator can occur. Install the 2 RH engine support insulator nuts. Tighten to 175 Nm (129 lb-ft). LH engine support insulator
5. Clean the engine support insulator-to-cylinder block and engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation.
6. Position the LH engine support insulator and hand start the 3 new engine support insulator-to-frame bolts. Tighten to 175 Nm (129 lb-ft).
7. Position the LH engine support insulator-to-cylinder block bracket and install the 3 bolts. Tighten to 63 Nm (46 lb-ft). All engine support insulator
8. Using the Engine Support Bar, Support Hook and Engine Support Bracket, lower the engine into position.
9. NOTE: Only use hand tools when installing the engine support insulator through bolt or damage to the engine support insulator-to-cylinder block bracket can occur. Install the LH and RH engine support insulator bolts. Apply threadlock to the bolt threads prior to installation. Tighten to 350 Nm (258 lb-ft).
10. NOTE: Only use hand tools when installing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur. Install the transmission mount-to-crossmember nuts. Tighten to 103 Nm (76 lb-ft).
11. Position the Y-pipe and install the 4 (2 RH and 2 LH) nuts. Tighten to 40 Nm (30 lb-ft).
12. Remove the Engine Support Bar, Support Hook and Engine Support Bracket.
13. Install the starter. For additional information, refer to «STARTING SYSTEM»(ref-364100) .
14. If servicing the engine support insulator on a 4WD vehicle, install the front driveshaft. For additional information, refer to «DRIVESHAFT»(ref-364071) .
15. Install the generator. For additional information, refer to «CHARGING SYSTEM»(ref-364045) .
16. Install the cooling fan. For additional information, refer to «ENGINE COOLING»(ref-364096) .
17. Install the TB . For additional information, refer to «FUEL CHARGING & CONTROLS - 5.4L (3V)»(ref-364099) .
18. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-364088) .