Page 1 of 11 2004 F-150 Workshop Manual 4/23/2009 http://www

Page 1 of 11 2004 F-150 Workshop Manual 4/23/2009 http://www

2004 F-150 Workshop Manual

SECTION 303-01B: Engine — 5.4L (3V)

IN-VEHICLE REPAIR

Camshaft, Valve Springs and Valve Seals — LH    

Special Tool(s)

Compressor, Valve Spring

303-1039

  Printable View (993 KB)

  

Wedge, Timing Chain

303-1175

Installer, Valve Stem Seal

303-383 (T91P- 6571-A)

Material

Item

Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil

XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil

CXO-5W20-LSP12 (Canada); or equivalent

Metal Surface Prep

ZC-31

Specification

WSS-M2C930-

A

1.

If servicing the LH camshaft, remove the cooling fan and shroud. For additional information, refer to Section 303-03 .

2.

Remove the LH valve cover. For additional information, refer to Valve Cover LH .

3.

NOTE: Camshaft removed for clarity.

Remove the parts in the order indicated in the following illustrations and tables.

To remove individual parts, only carry out the listed steps:

Part

Valve springs and valve seals

Steps

1-4

LH camshaft 5-9

LH camshaft phaser and sprocket 5-10

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2004 F-150 Workshop Manual

Procedure revision date: 03/14/2006

1

Item

6518

Part Number

2

3

6A536

6513

Description

Valve spring retainer keys (24 req'd)

Removal Note

Installation Note

Valve spring retainers (12 req'd)

Removal Note

Installation Note

Valve springs (12 req'd)

Removal Note

Installation Note http://www.fordtechservice.dealerconnection.com/pubs/content/~WS42/~MUS~LEN/19/S...

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2004 F-150 Workshop Manual

4 6571 Valve seals (12 req'd)

Installation Note

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5

6

7

8

9

10

Item

6279

Part Number

N807834

6B284

6B280

6C255

6A257

Description

Camshaft phaser and sprocket bolt

Removal Note

Installation Note

LH camshaft bearing cap bolts (10 req'd)

Removal Note

Installation Note

LH camshaft bearing cap

Removal Note

Installation Note

LH camshaft bearing cap (4 req'd)

Removal Note

Installation Note

LH camshaft

Removal Note

Installation Note

Camshaft phaser and sprocket

Removal Note

Installation Note

4.

To install, reverse the removal procedure.

Items 1-3: Valve Spring Retainer Keys, Valve Spring Retainers, and Valve Springs Removal Note

1.

Position the camshaft so that the cylinder being serviced has the intake and exhaust cam lobes away from the roller follower. Lobe must be horizontally 90 degrees higher.

2.

NOTICE: 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 roller follower. http://www.fordtechservice.dealerconnection.com/pubs/content/~WS42/~MUS~LEN/19/S...

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2004 F-150 Workshop Manual Page 3 of 11

3.

Hold the valves in the cylinder head.

Remove the spark plug of the cylinder being serviced.

Use a suitable tool to apply air pressure to the cylinder.

4.

Using the special tool, remove the valve spring retainer keys, valve spring retainer and the valve spring.

5.

Repeat the previous steps for each valve being serviced.

Items 5-9: LH Camshaft Phaser and Sprocket Bolt, Camshaft Bearing Cap Bolts, Bearing Caps, and Camshaft Removal Note

NOTICE: Engine is not freewheeling. 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.

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

Loosen and back off the LH camshaft phaser and sprocket bolt one full turn.

3.

Disconnect the LH camshaft position (CMP) sensor electrical connector.

4.

Remove the LH CMP sensor and the bolt. http://www.fordtechservice.dealerconnection.com/pubs/content/~WS42/~MUS~LEN/19/S...

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2004 F-150 Workshop Manual Page 4 of 11

5.

NOTE: If the camshaft lobes are not exactly positioned as shown, 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 two intake camshaft lobes and the exhaust lobe on the No. 5 cylinder.

6.

Remove only the three camshaft roller followers shown in the illustration.

7.

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

NOTE: The camshaft roller followers must be installed in their original locations. Record camshaft roller follower locations.

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

Using the special tool, remove only the three designated camshaft roller followers from the previous step.

8.

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

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. http://www.fordtechservice.dealerconnection.com/pubs/content/~WS42/~MUS~LEN/19/S...

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2004 F-150 Workshop Manual

9.

NOTICE: Engine is not freewheeling. Camshaft procedure must be followed exactly or damage to valves and pistons will result.

NOTICE: The Timing Chain Wedge tool must be installed square to the timing chain and the engine block.

NOTE: Engine front cover removed for clarity.

Install the special tool in the LH timing chain as shown.

Page 5 of 11

10.

NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special 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

in this section.

NOTICE: 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: RH shown, LH similar.

Scribe a location mark on the timing chain and the camshaft phaser and sprocket assembly.

11.

NOTICE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from sideloading.

NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.

Remove the bolts in the sequence shown and remove the front camshaft bearing cap and then the remaining bearing caps. http://www.fordtechservice.dealerconnection.com/pubs/content/~WS42/~MUS~LEN/19/S...

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2004 F-150 Workshop Manual Page 6 of 11

12.

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.

13.

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

NOTICE: Only use hand tools to remove the camshaft phaser and sprocket bolt or damage may occur to the camshaft or camshaft phaser and sprocket.

NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special 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

in this section.

Remove the bolt and withdraw the camshaft from the camshaft phaser and sprocket assembly, leaving the camshaft phaser and sprocket assembly in place.

Discard the bolt and washer.

14.

Clean and inspect the camshaft bearing caps.

Item 10: Camshaft Phaser and Sprocket Removal Note

1.

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

NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special 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

in this section.

Remove the camshaft phaser and sprocket from the timing chain.

2.

Inspect the front of the camshaft phaser and sprocket for missing or damaged roll pins.

If the roll pins are missing or damaged, a new camshaft phaser and sprocket must be installed.

3.

Inspect the rear of the camshaft phaser and sprocket for a deformed or damaged location pin.

If the location pin is deformed or damaged a new camshaft phaser and sprocket must be installed. http://www.fordtechservice.dealerconnection.com/pubs/content/~WS42/~MUS~LEN/19/S...

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2004 F-150 Workshop Manual Page 7 of 11

4.

Visually inspect the camshaft phaser and sprocket for squareness (A). If the trigger wheel or spring is deformed or damaged (B), install a new camshaft phaser and sprocket.

Item 10: Camshaft Phase and Sprocket Installation Note

1.

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

If installing a new camshaft phaser and sprocket, transfer the original scribe mark to the new camshaft phaser and sprocket.

2.

NOTICE: 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.

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

Align the scribe marks and position the camshaft phaser and sprocket into the timing chain.

Items 5-9: LH Camshaft Phaser and Sprocket Bolt, Camshaft Bearing Cap Bolts, Bearing Caps, and Camshaft Installation Note

1.

Lubricate the camshaft and camshaft journals with clean engine oil.

2.

NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special 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

in this section.

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

NOTICE: Do not allow the camshaft roller followers to move out of position when installing the camshaft.

Install the camshaft into the camshaft phaser and sprocket assembly and onto the head. Install a new camshaft phaser and sprocket bolt finger tight.

3.

NOTICE: Do not remove the Timing Chain Wedge tool at any time during assembly. If the special 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

in this section.

NOTICE: 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. http://www.fordtechservice.dealerconnection.com/pubs/content/~WS42/~MUS~LEN/19/S...

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2004 F-150 Workshop Manual

NOTE: RH shown, LH similar.

Verify the camshaft phaser and sprocket and timing chain scribe marks are still in alignment.

4.

NOTICE: Do not allow the camshaft roller followers to move out of position when installing the camshaft.

Install the 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 bolts loosely.

5.

Tighten the bolts in the sequence shown.

Tighten to 10 Nm (89 lb-in).

Page 8 of 11

6.

NOTE: Engine front cover removed for clarity.

Remove the special tools.

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. http://www.fordtechservice.dealerconnection.com/pubs/content/~WS42/~MUS~LEN/19/S...

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2004 F-150 Workshop Manual

8.

Verify correct camshaft position by noting the position of the No. 5 cylinder intake and exhaust camshaft lobes.

9.

Using the special tool, install the three originally removed camshaft roller followers.

Page 9 of 11

10.

Install the CMP sensor and the bolt.

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

11.

Connect the CMP electrical connector.

12.

NOTICE: Only use hand tools to install the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket.

NOTICE: 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 two stages:

Stage 1: Tighten to 40 Nm (30 lb-ft).

Stage 2: Tighten an additional 90 degrees.

Item 4: Valve Seal Installation Note

1.

NOTE: The valve stem seal must be bottomed on the valve seat. http://www.fordtechservice.dealerconnection.com/pubs/content/~WS42/~MUS~LEN/19/S...

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2004 F-150 Workshop Manual

NOTE: Make sure that the garter spring is present in the valve stem seal.

Using the special tool, install a new valve stem seal.

Items 1-3: Valve Spring Retainer Keys, Valve Spring Retainers, and Valve Springs Installation Note

1.

Position the valve spring and the valve spring retainer.

2.

Using the special tool, install the valve spring retainer keys and remove the special tool.

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3.

Using the special tool, install the roller followers.

  

  

  

  

  

  

  

  

   http://www.fordtechservice.dealerconnection.com/pubs/content/~WS42/~MUS~LEN/19/S...

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2004 F-150 Workshop Manual

 

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