service manual: engine - 5.4l (3v) - f-150 & mark lt in ......2016/04/15 · courtesy of ford...

IN-VEHICLE SERVICING > VALVE COVER - RH

Material

Item Specification

Motorcraft Metal Surface Prep

ZC-31

-

PAG Refrigerant Compressor Oil R-134a

Systems

YN-12-D

WSH-M1C231-B

Silicone Gasket Remover

ZC-30

-

Silicone Gasket and Sealant

TA-30

WSE-M4G323-A4

Service Manual: ENGINE - 5.4L (3V) - F-150 & MARK LT

2008 Ford Pickup 5.4L Eng F150

of 20Printer Friendly View

4/15/2016http://www2.prodemand.com/Print/Index?content=tabs&module=true&tab=true&terms=tr...

Fig 1: Exploded View Of Tube & Wiring Harness Retainer Connections With Torque Specifications

Courtesy of FORD MOTOR CO.

Item Part Number Description

1 N804758 A/C compressor manifold tube assembly nut

2 19836 A/C compressor manifold tube assembly

3 - A/C compressor manifold tube O-ring seal

4 - Suction accumulator-to-A/C compressor manifold tube

stud

5 6758 Crankcase vent tube assembly quick-connect fitting



6 - Engine wiring harness retainers (part of 12B637)

7 - Variable camshaft timing (VCT) solenoid electrical

connector (part of 12B637)

Fig 2: Exploded View Of RH Valve Cover & Gasket



8 6582 RH valve cover

9 6584 RH valve cover gasket

IN-VEHICLE SERVICING > VALVE COVER - RH > REMOVAL

1. Recover the refrigerant. For additional information, refer to CLIMATE CONTROL

SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.

2. Remove the PCM and bracket. For additional information, refer to ELECTRONIC

ENGINE CONTROLS article.

3. Remove the RH ignition coils. For additional information, refer to ENGINE IGNITION -

5.4L (3V) article.



4. Remove the nut and disconnect the A/C compressor manifold tube.

1. Discard the O-ring seals.

5. Remove the suction accumulator-to-A/C compressor manifold tube stud.

6. Disconnect the evaporator inlet tube fitting.

1. Discard the O-ring seals.

Fig 1: Locating Evaporator Inlet Tube Fitting


7. Disconnect the quick connect couplings and remove the crankcase ventilation tube. For

additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.

8. If equipped, disconnect the vacuum tube.



Fig 2: Vacuum Tube


9. Disconnect the variable camshaft timing (VCT) solenoid electrical connector.

10. Detach the engine harness retainer and position the harness aside.



Fig 3: Positioning Engine Harness And Attaching Retainer


11. Remove the battery cover.

12. Remove the transmission fluid level indicator tube retaining bolt and position the fluid

indicator tube aside.



Fig 4: Identifying Transmission Filler Tube Retaining Bolt


CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs

or other abrasive means to clean the sealing surfaces. These tools cause

scratches and gouges which make leak paths. Use a plastic scraping tool to

remove all traces of old sealant.

NOTE: The fasteners are part of the valve cover and should not be

removed.

13. Loosen the fasteners and remove the RH valve cover and gasket.

1. Clean the valve cover mating surface of the cylinder head with silicone gasket

remover and metal surface prep. Follow the directions on the packaging.

2. Discard the valve cover gasket. Clean the valve cover gasket groove with soap

and water or a suitable solvent.

IN-VEHICLE SERVICING > VALVE COVER - RH > INSTALLATION



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.

1. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover

meets the cylinder head.

Fig 1: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front

Cover Meets Cylinder Head


CAUTION: When installing the valve cover, make sure to avoid damaging

the variable camshaft timing (VCT) solenoid.

2. Position the RH valve cover and new gasket on the cylinder head and tighten the

fasteners in the sequence shown.

1. Tighten to 10 Nm (89 lb-in).



Fig 2: Tightening RH Valve Cover In Sequence


3. Position the transmission fluid level indicator tube and install the bolt.

1. Tighten to 20 Nm (15 lb-ft).



Fig 3: Identifying Transmission Filler Tube Retaining Bolt


4. Install the battery cover.

5. Position the engine harness and attach the retainer.



Fig 4: Positioning Engine Harness And Attaching Retainer


6. Connect the VCT solenoid electrical connector.

7. If equipped, connect the vacuum tube.



Fig 5: Vacuum Tube


8. Position the crankcase ventilation tube and connect the quick connect couplings. For

additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.

9. Using new O-rings, connect the evaporator inlet tube fitting.



Fig 6: Locating Evaporator Inlet Tube Fitting


10. Install the suction accumulator-to-A/C compressor manifold tube stud.


11. Lubricate the new A/C compressor manifold tube O-ring seals with refrigerant

compressor oil. Position the A/C compressor manifold tube and install the nut.

1. Tighten to 25 Nm (18 lb-ft).

12. Install the RH ignition coils. For additional information, refer to ENGINE IGNITION - 5.4L

(3V) article.

13. Install the PCM bracket and the PCM. For additional information, refer to ELECTRONIC

ENGINE CONTROLS article.

14. Evacuate, leak test and charge the refrigerant system. For additional information, refer

to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS

article.

IN-VEHICLE SERVICING > VALVE COVER - LH

Material

Item Specification



Motorcraft Metal Surface Prep

ZC-31

-

Silicone Gasket and Sealant

TA-30

WSE-M4G323-A4

Silicone Gasket Remover

ZC-30

-

Fig 1: Exploded View Of Power Steering Pump Reservoir With Torque Specifications



1 180101 Power steering reservoir support bracket nut

2 N806155 Power steering reservoir support bracket bolt

3 9A758 Power steering reservoir support bracket and

reservoir assembly



Fig 2: Exploded View Of Tube & Electrical Connections



4 6K817 PCV tube

5 - Intake manifold vacuum tube-to-brake booster hose clamp

6 - Intake manifold vacuum tube-to-brake booster hose

7 9D446 Intake manifold vacuum tube

8 - Engine wiring harness retainers (part of 12B637)

9 -



LH variable camshaft timing (VCT) solenoid electrical

connector (part of 12B637)

10 - LH radio ignition interference capacitor electrical connector

(part of 12B637)

Fig 3: Exploded View Of LH Valve Cover & Gasket



11 6A505 LH valve cover

12 6A559 LH valve cover gasket

IN-VEHICLE SERVICING > VALVE COVER - LH > REMOVAL

1. Remove the air cleaner intake pipe. For additional information, refer to INTAKE AIR

DISTRIBUTION AND FILTERING article.

2. Remove the LH ignition coils. For additional information, refer to ENGINE IGNITION -

5.4L (3V) article.

3. Remove the oil level indicator and tube. For additional information, refer to Oil Level

Indicator and Tube .



4. Remove the bolt and the nut and position the power steering reservoir and bracket

assembly aside.

5. Disconnect the quick connect couplings and remove the PCV tube. For additional

information, refer to FUEL SYSTEM - GENERAL INFORMATION article.

6. Disconnect the intake manifold vacuum tube hose from the brake booster.

7. Disconnect the intake manifold vacuum tube from the support bracket and the valve

cover stud.

8. Disconnect the radio ignition interference capacitor electrical connector.

9. Disconnect the variable camshaft timing (VCT) solenoid electrical connector and the

wiring harness retainers.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs

or other abrasive means to clean the sealing surfaces. These tools cause

scratches and gouges which make leak paths. Use a plastic scraping tool to

remove all traces of old sealant.

NOTE: The fasteners are part of the valve cover and should not be

removed.

10. Loosen the fasteners and remove the LH valve cover and gasket.

1. Clean the valve cover mating surface of the cylinder head with silicone gasket

remover and metal surface prep. Follow the directions on the packaging.

2. Discard the valve cover gasket. Clean the valve cover gasket groove with soap

and water or a suitable solvent.

IN-VEHICLE SERVICING > VALVE COVER - LH > INSTALLATION

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.

1. Apply a bead of silicone gasket and sealant in 2 places where the engine front cover

meets the cylinder head.



Fig 1: Applying Bead Of Silicone Gasket And Sealant In 2 Places Where Engine Front

Cover Meets Cylinder Head


CAUTION: When installing the valve cover, make sure to avoid damaging

the variable camshaft timing (VCT) solenoid.

2. Position the LH valve cover and new gasket on the cylinder head and tighten the

fasteners in the sequence shown.




Fig 2: Tightening LH Valve Cover In Sequence


3. Position the intake manifold vacuum tube assembly onto the support bracket and the

valve cover stud.

4. Connect the VCT solenoid electrical connector and the wiring harness retainers.



5. Connect the radio ignition interference capacitor electrical connector.

6. Position the PCV tube and connect the quick connect couplings. For additional

information, refer to FUEL SYSTEM - GENERAL INFORMATION article.

7. Connect the intake manifold vacuum tube hose to the brake booster.

8. Position the power steering reservoir and bracket assembly and install the bolt.

1. Tighten to 25 N.m (18 lb-ft).

9. Install the power steering reservoir and bracket assembly nut.

1. Tighten to 10 N.m (89 lb-in).

10. Install the oil level indicator and tube. For additional information, refer to Oil Level

Indicator and Tube .

11. Install the LH ignition coils. For additional information, refer to ENGINE IGNITION - 5.4L

(3V) article.

12. Install the air cleaner intake pipe. For additional information, refer to INTAKE AIR

DISTRIBUTION AND FILTERING article.



service manual: engine - 5.4l (3v) - f-150 & mark lt in ......2016/04/15 · courtesy of ford...

Documents