2004 F-150 5.4L Engine, 2005 F-150, 250, 350 5.4L Engine

2004 Ford F-150 : Engine Mechanical > Engine Mechanical Components > Timing Chain Cover, Chain & Sprockets > Removal &

Installation > 2004 F-150 5.4L Engine, 2005 F-150, 250, 350 5.4L Engine; 2006 Mark LT 5.4L Engine

2004 F-150 5.4L Engine, 2005 F-150, 250, 350 5.4L Engine; 2006 Mark LT 5.4L Engine

1. Before servicing the vehicle, refer to the Precautions Section.

2. Raise and safely support the vehicle.

3. Drain the engine oil.

4. Remove the engine cooling fan.

5. Remove the right valve cover.

6. Remove the left valve cover.

7. Rotate the tensioner clockwise and remove the accessory drive belt.

8. Remove the nut and position aside the transmission cooler tube

support bracket.

9. Remove the nut and position aside the power steering pressure hose

support bracket.

10. Using the special tool, remove the power steering pump pulley.

11. Disconnect the power steering pressure tube. Drain the power

steering fluid into a suitable container.

12. Remove the 3 bolts and position the power steering pump aside.

13. Remove the crankshaft pulley bolt and washer. Discard the crankshaft

pulley bolt.

14. Using the special tool, remove the crankshaft pulley.

15. Using the special tool, remove the crankshaft front seal.

16. Remove the 3 bolts and the 3 accessory drive idler pulleys.

17. Remove the 4 bolts and the coolant pump pulley.

18. Remove the 3 bolts and the accessory drive belt tensioner.

19. Disconnect the right camshaft position (CMP) sensor electrical

connector.

20. Remove the bolt and the right CMP sensor. Discard the O-ring seal.

21. Remove the nut and the upper radiator hose support bracket.

22. Remove the nut and position the right radio ignition interference

capacitor aside.

23. Disconnect the left CMP sensor electrical connector.

24. Remove the bolt and the left CMP sensor. Discard the O-ring seal.

25. Remove the nut and position the left radio ignition interference

capacitor aside.

26. Disconnect the crankshaft position (CKP) sensor electrical connector.

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27. Remove the 4 front oil pan bolts.

28. Remove the bolts and the studs.

WARNINGDo 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.

29. Remove the engine front cover from the front cover to cylinder block

dowel.

30. Remove the engine front cover gaskets.

31. Clean the mating surfaces with silicone gasket remover and metal

surface prep. Follow the directions on the packaging.

32. Inspect the mating surfaces.

33. Remove the bolt and the CKP sensor. Discard the O-ring seal.

34. Remove the crankshaft sensor ring from the crankshaft.

Position the crankshaft keyway at the 12 o'clock position—2004 F-150 5.4L Engine, Exc.

Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

35. Position the crankshaft keyway at the 12 o'clock position.

NOTEIf the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.



The number 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

number 1 cylinder—2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350

5.4L Engine, 2006 Mark LT 5.4L Engine

36. The number 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 number 1 cylinder.

WARNINGIf the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.



Remove only these 3 roller followers from the right cylinder head—2004 F-150 5.4L Engine,

Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

37. Remove only the 3 roller followers shown in the illustration from the

right cylinder head.

WARNINGDo not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.

NOTEIt may be necessary to push the valve down while compressing the spring.



Using special tool 303-1039—2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150,

250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

38. Using special tool 303-1039, remove the 3 designated roller followers

in the previous step from the right cylinder head.

WARNINGIf the components are to be reinstalled, they must be installed in the same positions.

39. Mark the components for installation into their original locations.





Remove only these 3 roller followers from the left cylinder head—2004 F-150 5.4L Engine,

Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

40. Remove only the 3 roller followers shown in the illustration from the

left cylinder head.

WARNING

Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.

NOTE

It may be necessary to push the valve down while compressing the spring.

Using the special tool, remove the 3 designated roller followers from the left cylinder head—

2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark

LT 5.4L Engine



41. Using the special tool, remove the 3 designated roller followers in the

previous step from the left cylinder head.

WARNING

The crankshaft cannot be moved past the 6 o'clock position once set.

42. Rotate the crankshaft clockwise and position the crankshaft keyway at

the 6 o'clock position.

Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock

position—2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine,

2006 Mark LT 5.4L Engine

WARNING

If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.



Remove the bolts, the left timing chain tensioner and tensioner arm—2004 F-150 5.4L

Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

43. Remove the bolts, the left timing chain tensioner and tensioner arm.

WARNING

If one or both of the tensioner mounting bolts are loosened or removed, the tensioner-sealing bead must be inspected for seal integrity. If cracks, tears or separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

44. Remove the bolts, the right timing chain tensioner and tensioner arm.

Remove the right timing chain tensioner and tensioner arm—2004 F-150 5.4L Engine, Exc.


45. Remove the right timing chain from the camshaft sprocket.

46. Remove the right timing chain from the crankshaft sprocket.

47. Remove the left timing chain from the camshaft sprocket.

48. Remove the left timing chain and crankshaft sprocket.



Remove the right and left timing chains—2004 F-150 5.4L Engine, Exc. Heritage Edition;

2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

49. Remove the bolts. Remove both timing chain guides.

Remove both timing chain guides, right shown; left similar—2004 F-150 5.4L Engine, Exc.


WARNING

Damage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

WARNING

Only use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.

Page 10 of 242004 Ford F-150 - Engine Mechanical > Engine Mechanical Components > Timing Chain Cover...


50. Using the special tool, remove the bolt and the right camshaft phaser

sprocket assembly. Discard the camshaft phaser sprocket bolt.

Using the special tool, remove the bolt and the right camshaft phaser sprocket assembly—


LT 5.4L Engine

Click to Enlarge

WARNINGDamage to the camshaft phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.

WARNINGOnly use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.

51. Using the special tool, remove the bolt and the left camshaft phaser

sprocket assembly. Discard the camshaft phaser sprocket bolt.



Using the special tool, remove the bolt and the left camshaft phaser sprocket assembly—


LT 5.4L Engine

Click to Enlarge

WARNINGRemove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.

NOTEThe camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.

52. Remove the bolts in the sequence shown and remove the right

cylinder head front camshaft bearing cap and then the remaining

bearing caps.



Camshaft bearing cap removal/installation sequence—2004 F-150 5.4L Engine, Exc. Heritage

Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

53. Clean and inspect the right camshaft bearing caps. The camshaft front

thrust bearing cap contains an oil metering groove. Make sure the

groove is free of foreign material.



The camshaft front thrust bearing cap contains an oil metering groove—2004 F-150 5.4L


54. Remove the right camshaft.

WARNINGRemove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.

NOTEThe camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.

55. Remove the bolts in the sequence shown and remove the left cylinder

head front camshaft bearing cap and then the remaining bearing caps.

56. Clean and inspect the left camshaft bearing caps. The camshaft front

thrust bearing cap contains an oil metering groove. Make sure the

groove is free of foreign material.

57. Remove the left camshaft.

WARNINGIf the components are to be reinstalled, they must be installed in the same positions.

58. Mark the components for installation into their original locations.

59. Remove all of the remaining roller followers from the cylinder heads.

To install:

1. Install the left and right camshafts. Lubricate the camshaft and

camshaft journals with clean engine oil prior to installation.

2. Lubricate the camshaft bearing caps with clean engine oil.

3. Position the front camshaft bearing cap.



4. Position the remaining camshaft bearing caps.

5. Install the bolts loosely.

6. Tighten to 10 Nm (89 inch lbs.) in the sequence shown.


7. Install the camshaft phaser sprockets and new camshaft phaser bolts

finger tight.


WARNINGOnly use hand tools to remove the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.

8. Using the special tool, tighten the left and right camshaft phaser

sprocket bolts in 2 stages.

■ Stage 1: Tighten to 40 Nm (30 ft. lbs.).

■ Stage 2: Tighten an additional 90 degrees.

Position the crankshaft with the special tool—2004 F-150 5.4L Engine, Exc. Heritage Edition;


9. Position the crankshaft with the special tool, then remove the tool.

WARNINGTiming chain procedures must be followed exactly or damage to valves and pistons will result.



WARNING

Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.

10. Compress the tensioner plunger, using a vise.

11. Install a retaining clip on the tensioner to hold the plunger in during

installation.

12. Remove the tensioner from the vise.

13. If the copper links are not visible, mark 2 links on one end and 1 link

on the other end, and use as timing marks.

14. Install the crankshaft sprocket, making sure the flange faces forward.

Right and left timing chain guides installed—2004 F-150 5.4L Engine, Exc. Heritage Edition;


15. Install the 4 bolts and the left and right timing chain guides. Tighten to

10 Nm (89 inch lbs.).

Position the lower end of the left (inner) timing chain on the crankshaft sprocket, aligning

the timing mark on the outer flange of the crankshaft sprocket with the single copper



(marked) link on the chain—2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250,

350 5.4L Engine, 2006 Mark LT 5.4L Engine

16. Position the lower end of the left (inner) timing chain on the crankshaft

sprocket, aligning the timing mark on the outer flange of the

crankshaft sprocket with the single copper (marked) link on the chain.

NOTE

Make sure the upper half of the timing chain is below the tensioner arm dowel.

Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark

positioned between the 2 copper (marked) chain links—2004 F-150 5.4L Engine, Exc.


17. Position the timing chain on the camshaft sprocket with the camshaft

sprocket timing mark positioned between the 2 copper (marked) chain

links.

NOTE

The left timing chain tensioner arm has a bump near the dowel hole for identification.

18. Position the left timing chain tensioner arm on the dowel pin and

install the left timing chain tensioner and bolts. Tighten to 25 Nm (18

ft. lbs.).

19. Remove the retaining clip from the left timing chain tensioner.



Position the lower end of the right (outer) timing chain on the crankshaft sprocket, aligning

the timing mark on the sprocket with the single copper (marked) chain link—2004 F-150

5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L

Engine

20. Position the lower end of the right (outer) timing chain on the

crankshaft sprocket, aligning the timing mark on the sprocket with the

single copper (marked) chain link.

NOTE

The lower half of the timing chain must be positioned above the tensioner arm dowel.

Position the right timing chain on the camshaft sprocket. Make sure the camshaft sprocket

timing mark is positioned between the 2 copper (marked) chain links—2004 F-150 5.4L


21. Position the right timing chain on the camshaft sprocket. Make sure

the camshaft sprocket timing mark is positioned between the 2 copper

(marked) chain links.

22. Position the right timing chain tensioner arm on the dowel pin and

install the right timing chain tensioner and bolts. Tighten to 25 Nm (18

ft. lbs.).



23. Remove the retaining clip from the right timing chain tensioner.

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

As a post-check, verify correct alignment of all timing marks—2004 F-150 5.4L Engine, Exc.


25. Install the crankshaft sensor ring on the crankshaft.

WARNING

If the components are to be reinstalled, they must be installed into their original locations.

26. Using the special tool, install all of the camshaft roller followers.

Lubricate the roller followers with clean engine oil prior to installation.

27. Install the crankshaft position (CKP) sensor and the bolt. Tighten to 10

Nm (89 inch lbs.).

WARNING

Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE

If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging.



Failure to follow this procedure can cause future oil leakage.

NOTE

Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface

and the oil pan-to-cylinder block surface—2004 F-150 5.4L Engine, Exc. Heritage Edition;




Front cover fastener identification—2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-

150, 250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

28. Apply a bead of silicone gasket and sealant along the cylinder head-to

-cylinder block surface and the oil pan-to-cylinder block surface, at the

locations shown.



29. Install a new engine front cover gasket on the engine front cover.

Position the engine front cover onto the dowels. Install the fasteners

finger tight.

30. Tighten the engine front cover fasteners in sequence in 2 stages.

■ Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 ft. lbs.).

■ Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 ft. lbs.).

31. Loosely install the oil pan-to-front cover bolts, then tighten the bolts in

2 stages, in the sequence shown.



32. Connect the CKP sensor electrical connector.

33. Position the power steering pump assembly and install the 3 bolts.

Tighten to 25 Nm (18 ft. lbs.).

34. Using the special tool, install a new O-ring seal on the pressure line

fitting.

35. Connect the power steering pressure tube. Tighten to 65 Nm (48 ft.

lbs.).

36. Using an installer, install the power steering pump pulley.

37. Position the power steering pressure hose support bracket and install

the nut. Tighten to 10 Nm (89 inch lbs.).

38. Position the transmission cooler tube support bracket and install the

nut. Tighten to 10 Nm (89 inch lbs.).

NOTE

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

39. Using a new O-ring seal, install the right camshaft position (CMP)

sensor and the bolt. Tighten to 10 Nm (89 inch lbs.).

40. Connect the right CMP sensor electrical connector.

41. Install the left radio ignition interference capacitor and the nut. Tighten

to 10 Nm (89 inch lbs.).

NOTE

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

42. Using a new O-ring seal, install the left CMP sensor and the bolt.

Tighten to 10 Nm (89 inch lbs.).

43. Connect the left CMP sensor electrical connector.

44. Install the right radio ignition interference capacitor and the nut.


45. Install the accessory drive belt tensioner and the 3 bolts. Tighten to 25

Nm (18 ft. lbs.).



46. Install the coolant pump pulley and the 4 bolts. Tighten to 25 Nm (18

ft. lbs.).

47. Install the 3 accessory drive idler pulleys and the 3 bolts. Tighten to 25

Nm (18 ft. lbs.).

48. Position the upper radiator hose support bracket and install the nut.


49. Lubricate the engine front cover and the crankshaft seal inner lip with

clean engine oil.

Front seal installation—2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150, 250, 350

5.4L Engine, 2006 Mark LT 5.4L Engine

50. Using the special tools, install the crankshaft seal into the engine front

cover.

NOTE

If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with metal surface prep and silicone gasket remover. 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.

51. Apply silicone gasket and sealant to the Woodruff key slot on the

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



Crankshaft pulley installation—2004 F-150 5.4L Engine, Exc. Heritage Edition; 2005 F-150,

250, 350 5.4L Engine, 2006 Mark LT 5.4L Engine

52. Tighten the new crankshaft pulley bolt in 4 stages.


■ Stage 2: Loosen 360 degrees.



53. Rotate the tensioner clockwise and install the accessory drive belt.

54. Install the right valve cover.

55. Install the left valve cover.

56. Install the engine cooling fan.

57. Fill the crankcase with clean engine oil.



Documents

2004 F-150 5.4L Engine, 2005 F-150, 250, 350 5.4L Engine