How To replace 5.4L Engine on Ford Truck?

The procedure is similar for both ford and Lincoln car models:-----

The procedure is for Ford Model F series Trucks.

And Lincoln Mark LT model vehicles.

F150 1/2 ton P/U 2WD/ 4WD

F250 Super Duty P/U 2WD/4WD

F350 Super Duty P/U 2WD/4WD

F450 Super Duty P/U 2WD/4WD

F550 Super Duty P/U 2WD/4WD

The procedure to replace 5.4 L engine is as follows:----

Removal & Installation

5.4L Engine

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

All vehicles

1. Raise and safely support the vehicle.
2. Remove the hood.
3. Remove the intake manifold. See -Intake Manifold- in this section.
4. Remove the accessory drive belt.
5. Recover the A/C system.
6. Remove the radiator.
7. Remove the powertrain control module (PCM) and the support bracket.
8. Remove the cowl panel grille.
9. Detach the wiring harness and the windshield washer hose retainers from the cowl panel extension.
10. Remove the bolts and the cowl extension panel.
11. Disconnect the electrical connector and remove the bolt and the ground strap.
12. Disconnect the heater hose.
13. Remove the nut, disconnect the A/C manifold and tube assembly and position aside.
14. Remove the nut and the A/C manifold and tube assembly and support bracket.
15. Disconnect the coolant hose.
16. Remove the bolt and position the power steering reservoir assembly aside.
17. Disconnect the alternator wiring harness retainer from the right cylinder head.
18. Disconnect the A/C compressor and the A/C high pressure cut-off switch electrical connectors.
19. Disconnect the alternator wiring harness retainer from the right cylinder head and position the harness aside.
20. Disconnect the crankshaft position (CKP) sensor wiring harness retainer from the starter motor wiring harness.
21. Remove the nut and position aside the power steering pressure hose support bracket.
22. Using a puller, remove the power steering pump pulley.
23. Disconnect the power steering pressure tube. Drain the power steering fluid into a suitable container.
24. Remove the 3 bolts and position the power steering pump aside.

Manual transmission vehicles

1. Remove the clutch.

Automatic transmission vehicles

1. Remove the nut and position aside the transmission cooler tube support bracket.
2. Remove the starter.
3. Remove the 2 bolts and the flexplate inspection cover.
4. Remove the cylinder block opening cover.
5. Remove the 4 torque converter-to-flexplate nuts. Discard the nuts.
6. Disconnect the shift cable and remove the shift cable bracket.
   
   NOTE

   The upper 2 transmission-to-engine bolts will be removed later.
7. Remove the lower 5 transmission-to-engine bolts.
8. Remove the bolt and position the transmission fluid filler tube aside.

All vehicles

1. Remove the drain plug and drain the engine oil.
2. Disconnect the right heated oxygen sensor (HO ₂ S) electrical connector and detach the wiring harness retainer.
3. Disconnect the left heated exhaust gas oxygen sensor electrical connector and detach the electrical connector retainer.
4. Remove the oil filter.
5. Disconnect the oil temperature sensor electrical connector.
6. Remove the bolts and position the A/C compressor aside.
7. If equipped, disconnect the block heater electrical connector.
8. Detach the starter electrical harness support from the cylinder block.
9. Remove the 4 exhaust manifold flange nuts.
10. Remove the right engine support insulator nuts and washer.
11. Remove the left engine support insulator bolt.

Automatic transmission vehicles

1. Support the transmission.
   
   NOTE

   On 4WD vehicles, it may be necessary to reposition the transfer case vent hose to access the bolts.
2. Remove the upper 2 transmission-to-engine bolts.

All vehicles

1. Install the lifting bracket.
2. Using a suitable floor crane, remove the engine assembly from the vehicle.

To install:

All vehicles

1. Using a suitable floor crane, position the engine assembly into the vehicle.
   
   WARNING

   Only use hand tools when installing the left engine mount bolt or damage to the engine mount can occur.
   
   
   
   NOTE

   Early build vehicles are equipped with an M14 through bolt. Late build vehicles are equipped with an M18 through bolt.
2. Apply high strength threadlocker to the bolt threads and install the left engine support insulator bolt.
   1. If the M14 through bolt engine support insulator nut is missing or damaged, install a new nut using service part number W709375.
   2. If the M14 through bolt engine support insulator nut cage is damaged or missing, install a new nut using service part number W520516-S301.
   3. Early build vehicles, tighten to 220 Nm (162 ft. lbs.); Late build vehicles, tighten to 350 Nm (258 ft. lbs.).
      
      WARNING

      Only use hand tools when installing the right engine mount nuts or damage to the engine mount can occur.
3. Apply high strength threadlocker to the stud threads and install the right engine support insulator washer and nuts. Tighten to 250 Nm (184 ft. lbs.).
4. Remove the lifting bracket.

Manual transmission vehicles

1. Install the clutch.

Automatic transmission vehicles

NOTE

The upper 2 transmission-to-engine bolts will be installed later.

1. Install the lower 5 transmission-to-engine bolts. Tighten to 60 Nm (44 ft. lbs.).
2. Position the shift cable bracket and install the bolts and connect the shift cable. Tighten to 25 Nm (18 ft. lbs.).
3. Install 4 new torque converter-to-flexplate nuts. Tighten to 36 Nm (27 ft. lbs.).
4. Install the cylinder block opening cover.
5. Install the flexplate inspection cover and the 2 bolts. Tighten to 34 Nm (25 ft. lbs.).
6. Install the starter.
7. Position the transmission cooler tube support bracket and install the bolt. Tighten to 10 Nm (89 inch lbs.).

All vehicles

1. If equipped, connect the block heater electrical connector.
2. Connect the left and right heated exhaust gas oxygen sensor (HO ₂ S) electrical connector and attach the electrical connector retainer.
3. Attach the starter electrical harness support bracket.
4. Connect the oil temperature sensor electrical connector.
5. Position the A/C compressor and install the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
6. Install the 4 exhaust manifold flange nuts. Tighten to 40 Nm (30 ft. lbs.).

Automatic transmission vehicles

1. Install the upper 2 transmission-to-engine bolts. Tighten to 60 Nm (44 ft. lbs.).
2. Position the transmission filler tube and install the bolt. Tighten to 20 Nm (15 ft. lbs.).

All vehicles

1. Connect the crankshaft position (CKP) sensor wiring harness retainer to the starter motor wiring harness.
2. Connect the alternator wiring harness retainer to the right cylinder head.
3. Connect the A/C compressor and the A/C high pressure cut-off switch electrical connectors.
4. Connect the alternator wiring harness retainer to the right cylinder head.
5. Position the power steering pump assembly and install the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
6. Install a new O-ring seal on the pressure line fitting.
7. Connect the power steering pressure tube. Tighten to 65 Nm (48 ft. lbs.).
8. Install the power steering pump pulley.
9. Position the power steering pressure hose support bracket and install the nut. Tighten to 10 Nm (89 inch lbs.).
10. Position the power steering reservoir assembly and install the bolt. Tighten to 23 Nm (17 ft. lbs.).
11. Using a new O-ring seal, connect the A/C manifold and tube assembly and install the nut. Tighten to 25 Nm (18 ft. lbs.).
12. Position the A/C manifold and tube assembly support bracket and install the nut. Tighten to 25 Nm (18 ft. lbs.).
13. Connect the heater hose.
14. Disconnect the coolant hose.
15. Connect the electrical connector and position the ground strap and install the bolt. Tighten to 10 Nm (89 inch lbs.).
16. Position the cowl extension panel and install the bolts.
17. Attach the wiring harness and the windshield washer hose retainers to the cowl panel extension.
18. Install the intake manifold.
19. Install the radiator.
20. Install the powertrain control module (PCM).
21. Install the cowl.
22. Install the hood.
23. Fill the crankcase with clean engine oil.
24. Evacuate and charge the A/C system.
25. Fill and bleed the power steering system.

All vehicles

1. Raise and safely support the vehicle.
2. Remove the hood.
3. Remove the cowl vent grille.
4. Remove the radiator.
5. Remove the degas bottle (coolant reservoir).
6. Remove the intake manifold. See -Intake Manifold- in this section.
7. Remove the powertrain control module (PCM).
8. Remove the accessory drive belt.
9. Drain the engine oil.
10. Disconnect the degas bottle (coolant reservoir) coolant hose.
11. Disconnect the 2 electrical connectors on the left fender splash shield.
12. Remove the 3 bolts and position the power steering pump assembly aside.
13. Disconnect the alternator wiring harness retainer from the right cylinder head.
14. Disconnect the A/C compressor and the A/C high pressure cut-off switch electrical connectors.
15. Disconnect the alternator wiring harness retainer from the right cylinder head and position the harness aside.
16. Disconnect the crankshaft position (CKP) sensor wiring harness retainer from the starter motor wiring harness.
17. Disconnect the engine wiring harness retainer from the evaporative emissions (EVAP) canister purge valve bracket.
18. Disconnect the vacuum hose and engine wiring harness retainers.
19. Disconnect the EVAP tube quick connect couplings and the electrical connector from EVAP canister purge valve.
20. Remove the 3 nuts and remove the EVAP canister purge valve and bracket assembly.
21. Disconnect the body wiring harness retainer from the degas bottle (coolant reservoir) support bracket.
22. Remove the 3 nuts and the degas bottle (coolant reservoir) support bracket.
23. Remove the 2 nuts and the air cleaner outlet tube support bracket.
24. Disconnect the heater hose.

Manual transmission vehicles

1. Remove the clutch and pressure plate.

Automatic transmission vehicles

1. Remove the starter.
2. Remove the nut and position the transmission oil cooler lines and bracket aside.
3. Remove the 2 bolts and the flexplate inspection cover.
4. Remove the cylinder block opening cover.
5. Remove the 4 torque converter-to-flexplate nuts. Discard the nuts.
   
   NOTE

   The upper 2 transmission-to-engine bolts will be removed later.
6. Remove the 5 transmission-to-engine bolts.
7. Remove the nut, the ground cable and position the transmission fluid filler tube aside.

All vehicles

1. If equipped, disconnect the block heater electrical connector.
2. Remove the stud bolt and position the ground strap aside.
3. Disconnect the oil temperature sensor electrical connector.
4. Remove the 3 bolts and position the A/C compressor aside.
5. Disconnect the 2 heated exhaust gas oxygen sensor (HO ₂ S) electrical connectors.
6. Remove the 4 exhaust manifold flange nuts.
7. Remove the 6 right and left motor mount nuts.

Automatic transmission vehicles

1. Remove the upper 2 transmission-to-engine bolts.

All vehicles

1. Install the lifting bracket.
2. Using a suitable floor crane, remove the engine assembly from the vehicle.

To install:

All vehicles

1. Using a suitable floor crane, position the engine assembly into the vehicle.
   
   WARNING

   Only use hand tools when installing the right engine mount nut or damage to the engine mount can occur.
   
   
   
   NOTE

   Align the engine-to-transmission dowels before installing the engine mount bolt.
2. Install the 6 engine mount nuts. Tighten to 175 Nm (129 ft. lbs.).
3. Remove the lifting bracket.

Manual transmission vehicles

1. Install the clutch.

Automatic transmission vehicles

NOTE

The upper 2 transmission-to-engine bolts will be installed later.

1. Install the lower 5 transmission-to-engine bolts. Tighten to 35 Nm (26 ft. lbs.).
2. Install 4 new torque converter-to-flexplate nuts. Tighten to 35 Nm (26 ft. lbs.).
3. Install the cylinder block opening cover.
4. Install the flexplate inspection cover and the 2 bolts. Tighten to 34 Nm (25 ft. lbs.).
5. Install the transmission fluid filler tube, the ground strap and the nut. Tighten to 12 Nm (9 ft. lbs.).
6. Install the starter.

All vehicles

1. If equipped, connect the block heater electrical connector.
2. Position the starter electrical harness support bracket and install the bolt. Tighten to 10 Nm (89 inch lbs.).
3. Position the ground strap and install the stud bolt. Tighten to 10 Nm (89 inch lbs.).
4. Connect the oil temperature sensor electrical connector.
5. Position the A/C compressor and install the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
6. Install the 4 exhaust manifold flange nuts. Tighten to 40 Nm (30 ft. lbs.).
7. Connect the 2 heated exhaust gas oxygen sensor (HO ₂ S) electrical connectors.

Automatic transmission vehicles

1. Install the transmission cooler tube support bracket and the nut. Tighten to 10 Nm (89 inch lbs.).
2. Install the upper 2 transmission-to-engine bolts. Tighten to 48 Nm (35 ft. lbs.).

All vehicles

1. Position the degas bottle (coolant reservoir) support bracket and install the 3 nuts. Tighten to 10 Nm (89 inch lbs.).
2. Connect the body wiring harness retainer to the degas bottle (coolant reservoir) support bracket.
3. Position the evaporative emissions (EVAP) canister purge valve and bracket assembly, and install the 3 nuts. Tighten to 10 Nm (89 inch lbs.).
4. Connect the electrical connector and the EVAP tube quick connect couplings to the EVAP canister purge valve.
5. Connect the engine wiring harness retainer to the EVAP canister purge valve bracket.
6. Connect the crankshaft position (CKP) sensor wiring harness retainer to the starter motor wiring harness.
7. Connect the alternator wiring harness retainer to the right cylinder head.
8. Connect the A/C compressor and the A/C high pressure cut-off switch electrical connectors.
9. Connect the alternator wiring harness retainer to the right cylinder head.
10. Position the power steering pump and install the 3 bolts. Tighten to 25 Nm (18 ft. lbs.).
11. Position the air cleaner outlet tube support bracket and install the 2 nuts. Tighten to 25 Nm (18 ft. lbs.).
12. Connect the 2 electrical connectors on the left fender splash shield.
13. Connect the degas bottle (coolant reservoir) coolant hose.
14. Install the intake manifold.
15. Install the radiator.
16. Install the degas bottle (coolant reservoir).
17. Install the powertrain control module (PCM).
18. Install the cowl vent grille.
19. Install the hood.
20. Fill the crankcase with clean engine oil.
21. Evacuate and charge the A/C system.
22. Fill and bleed the power steering system.

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html