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Discussion Starter #1 (Edited)
Torque Specifications
Description lb-ft lb-in

Valve cover bolts — 89in


Camshaft bearing cap bolts — 89in
Cylinder head temperature sensor (CHT) 19ft —
Camshaft position sensor bolt — 89in
Crankshaft position sensor bolt — 89in
EGR valve to intake manifold bolts 15ft
EGR to Exhaust Manifold Tube Nuts 44ft
Exhaust manifold nuts 18ft —


Exhaust manifold studs 9ft —
Exhaust manifold-to-mid-pipe nuts 30ft —
Exhaust clamps 35ft
Exhaust Heat Shields 11ft
Drive belt idler pulley bolt 18ft —
Flywheel bolts 59ft —

Transmission-to-engine bolts 35ft —
Torque converter-to-flexplate nuts 26ft —
Fuel Rail supply manifold bracket bolts — 89in
Alternator upper mounting bracket bolts — 89in
Alternator lower mounting bolts 18ft —
Heater return tube studs 30ft —
Ignition coil bolt— 53in
Oil filter 12ft —
Oil filter adapter bolts 18ft —
Oil level indicator tube bolt — 89in
Oil line connector adapter assembly bolt 18ft —
Oil pan bolts 15ft

Oil pan drain plug 10ft —
Oil pressure switch 10ft —
Oil pump bolts — 89in
Oil pump screen and pickup tube bolts — 89in
Oil pump screen and pickup tube spacer 18ft —
Oil pump screen and pickup tube spacer bolt 18ft —
Power steering pump bolts 18ft —
Rear main oil seal retainer bolts — 89in
Spark plugs 13ft —
Thermostat housing bolts — 19ft
Idle air control valve screws 89in
Throttle body-to-Upper intake Plenum bolts 89in
Front Timing Chain COver
Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).
Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).

Timing chain guide bolts — 89in
Timing chain tensioner arm 18ft
Timing chain hydraulic tensioner bolts 18 —
Water pump bolts 18ft —
Water pump pulley bolts 18ft —
Power steering reservoir upper bracket-to-thermostat housing bolt 8ft —
Power steering reservoir upper bracket-to-middle bracket bolts 13ft —
Power steering reservoir middle bracket-to-lower bracket bolts 17 ft—
Power steering reservoir lower bracket-to-engine cylinder head bolts 59ft —
38-pin bulkhead connector bolt — 44in
42-pin bulkhead connector bolt — 44in
Bulkhead connector bracket cover bolts 9ft —
Bulkhead connector bracket-to-cowl bolts 9ft —
Starter relay nuts — 71in
Accelerator control splash shield bolts — 62in
Accelerator cable bracket bolts — 89in
Motor mount to cylinder block bolts 44ft —
Motor mount through bolts 66ft —
Oil pressure switch 10ft —
Fan shroud bolts — 80in
Differential pressure feedback EGR sensor nuts (5.4L) — 89in
Differential pressure feedback EGR sensor bracket nut (5.4L) — 89in
Differential pressure feedback EGR sensor bracket bolt (5.4L) — 89in
RFI Capacitors 89in
Accessory Drive Idler Pullies18ft
Accessory Drive Tensioner Arm 89in
Starter 15ft
Starter Electrical Connections 65in
Accessory Belt Drive Routing


Torque Specifications Supercharged Engines Only
Description Nm lb-ft lb-in

Power steering bracket lower bolts 30ft —
Power steering bracket upper bolt — 89in
Ground strap nut — 89in
Fuel injection supply manifold bolts — 89in
Ignition coil bolts — 44in
Alternator bracket bolts — 89in
Intake manifold bolts 19ft -

Super CHarger SNout Bolts 13ft
Inner Cooler to Midplate Bolts 53in
Super CHarger to Lower intake manifold bolts 33ft

Inner COoler Fluid Supply tube bracket 89in
Accelerator Cable Bracket 89in
Crankshaft damper pulley bolt
Stage 1: Tighten to 90 Nm (66 lb-ft).
Stage 2: Loosen the bolt.
Stage 3: Tighten to 50 Nm (37 lb-ft).
Stage 4: Tighten an additional 85-90 degrees

Auxiliary crankshaft pulley 74ft —
Auxiliary crankshaft pulley brace nuts 35ft —
Transmission cooler line bracket nut 11ft —
Transmission Pan bolt 11ft
FLex Plate Inspection Cover bolts 25ft
Transmission Fluid Level Indicator Tube 88-115in
Transmission SUpport Brace 66ft
Super Charger Tensioner Arm 89in
Power steering shield nut 11ft —
Super charger pulley adapter bolts 35ft —
Upper Plenum to Super CHarger bolts 89in
Super CHarger Belt Routing


Suspension
Front
Lower A Arm 121-148ft
Upper A Arm 84-112
Lower Ball Joint 83-112ft
Upper Ball Joint 57-76ft
Front Sway Bar ENd Link 15-21ft
Front Sway Bar Frame Mount 19-26ft
Upper Shock 35-46ft
Lower shock 22-29ft
Brake Line Keeper 13-17ft
Bump Stops 15-21ft

Rear
Rear Sway Bar End Link 76ft
Rear Sway Bar Axle Mount 35ft
Front Hanger Spring Eye 157-212ft
Rear Spring t SHackle 73-97
LEaf Pack to Axle Ubolts 73-97
Rear SHackle to Rear Hanger 73-97ft
Axle Bump Stops 15-21ft
Upper SHock 35-46ft
Lower SHock 35ft

Driveshaft
Center Carrier Bearing mount 46ft
DS to Rear Axle Flange 83ft

General SpecificationsSupercharged Engines Only
Item Specification

Displacement 5.4L
No. cylinder 8
Bore/stroke 90.215/105.8 mm
Fire order 1-3-7-2-6-5-4-8



Refill Capacities
Super Charger 6oz GM #12345982 supercharger oil

Brake fluid Motorcraft High Performance DOT 3 Motor Vehicle Brake Fluid
Fill to line on reservoir

Engine coolant Motorcraft Premium Engine Coolant (green-colored) or Motorcraft Premium Gold Engine Coolant (yellow-colored)
5.4L V8 engine with 1 row radiator 22.6L (23.9 quarts)
5.4L V8 engine with 2 row radiator 24.1L (25.5 quarts)

Intercooler coolant Motorcraft Premium Engine Coolant (green-colored) or Motorcraft Premium Gold Engine Coolant (yellow-colored)
5.4L Supercharged V8 engine 4.0L (4.2 quarts)

Engine oil (includes filter change)
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
All 5.4L (6.0 quarts)

Fuel tank 4x2 Regular Cab, SuperCab and SuperCrew with short wheelbase
94.6L (25.0 gallons)

Power steering fluid
Motorcraft MERCON III ATF
Fill to line on reservoir

Transmission fluid Motorcraft MERCON III ATF
Automatic- 4R100 (4x2) 16.1L (17.0 quarts)
Motorcraft MERCON V ATF
Automatic- 4R70W 13.2L (13.9 quarts)

Rear axle Motorcraft SAE 75W-140
Synthetic Rear Axle Lubricant
9.75 inch axle 2.6L (5.5 pints)
Add 118 ml (4 oz.) of Additive Friction Modifier

Windshield washer fluid Ultra-Clear Windshield Washer Concentrate
All 4.0L (4.25 quarts)

Engine Data

Cubic inches 330
Required fuel 91 octane
Firing order 1-3-7-2-6-5-4-8
Spark plug gap (0.042-0.046inch)
Ignition system DIS Coil on plug
Compression ratio 9.0:1

Vehicle Dimensions
(1) Overall length 5 738 (225.9in)
(2) Overall width 2 009 (79.1in) including mirrors (90.3in
(3) Overall height 1 878 (72.9in)
(4) Wheel base 3 518 (138.5in)
(5)Track front/rear 1 661 (65.4in)

DRIVETRAIN

Transmission Identification
On the Vehicle Cert Label (drivers side Door frame)
Look for the Code below "TR"
U= 4 speed automatic (AODE, W/4R70W)
E= 4 speed automatice (4R100)
7= 4 speed automatice (4R100), Lightning

Rear axle 9.75 in limited-slip differential with 3.73:1 final drive ratio
Driveshaft 2pc Steel with hardened yoke
Transmission Modified 4R100 4-speed automatic with OD lockout
Gear ratios
1st 2.71
2nd 1.53
3rd 1.00
4th (OD) 0.71
Reverse 2.176


OBDII Bank and o2 Sensor Reference

Bank 1 Passenger side
Bank 2 Driver's side
Sensor 1 forward 02
Sensor 2 rear 02

OBDII Code and location

02s11 Bank 1 Upstream
02s12 Bank 1 Downstream
02s22 Bank 2 Downstream
02a21 Bank 2 Upstream


Misc
CX = Factory color code for Dark Shadow Grey (see DSG)
EK01 = Factory computer code for most '02 H-D's
EK02 = Factory computer code for '03 H-D's and some late model '02 H-D's


03+ NVH BLock Identification

The NVH iron blocks have a taller ribbing. It's not a drastic deference, but you can definitely see a visual difference. It's a lot easier to tell the difference on the 4.6L aluminum blocks. On the aluminum NVH blocks the ribbing's are drastically different in height and thickness and they added a lot more ribs. On the 5.4 iron blocks the easiest place to see the difference in the ribbing is just above the oil pan rail by the starter and on the driver's side at the front of the motor above the oil pan rail. The ribs will be in an X shape in these locations. You can also look at the freeze/frost plug holes in the blocks. The NVH blocks have a beefier flange around the hole, and the metal has a more gradual slope as it fades into the side of the block, on the older blocks there is not as much of a rise were the freeze plug sets in the block and it just kind of rounds into the side of the block

Oh and it weighs like 50 more lbs than earlier castings like 205 compared to 177
 

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Discussion Starter #2
More SPecs

Cylinder Head/Valve Train
Combustion chamber volume 43.95 ± 1.5 cc
Valve seat width — intake 1.3-1.5 mm (0.0512-0.0590 inch)
Valve seat width — exhaust 2.1-1.9 mm (0.0827-0.0748 inch)
Valve seat angle 45.00-44.50 degrees
Valve seat runout (T.I.R.) 0.025 mm (0.00098 inch)

Valve Arrangement (Front to Rear)
Valve stem guide clearance
Intake 0.069-0.020 mm (0.00272-0.00079inch)
Exhaust 0.095-0.045 mm (0.0037-0.0018inch)

Valve head diameter
Intake 44.63-44.37 mm (1.757-1.747 inch)
Exhaust 34.12-33.88 mm (1.343-1.373 inch)
Valve face runout (limit) 0.05 mm (0.00197 inch)
Valve face angle 45.75-45.25 degrees

Valve stem diameter
Intake 6.995-6.975 mm (0.2754-0.2746inch)
Exhaust 6.970-6.949 mm (0.2744-0.2736inch)

Valve spring compression pressure
Intake (N @ spec.length)720-800 N @ 28.02 mm (1.1031inch)
Exhaust (N @ spec.length)720-800 N @ 28.02 mm (1.1031inch)

Valve spring free length
Intake 53.37 mm (2.101 inch)
Exhaust 53.37 mm (2.101 inch)

Valve spring installed pressure N @ spec. length
Intake 287.19-321.19 N @ 42.56 mm(1.676 inch)
Exhaust 287.19-321.19 N @ 42.56 mm(1.676 inch)

Valve springs installed pressure N @ spec. length — service limit
Intake 5% pressure loss @ 28.80 mm(1.134 inch)
Exhaust 5% pressure loss @ 28.80 mm(1.134 inch)

Valve springs — out of square limit
Intake 2.0 degrees
Exhaust 2.0 degrees
Valve guide inside diameter 7.044-7.015 mm (0.2773-0.2762inch)

Hydraulic Lash Adjuster

Diameter 16.000-15.988 mm (0.66-0.629 in)
Clearance-to-bore 0.018-0.069 mm (0.00071-0.00272in)
Service limit 0.016 mm (0.00063 in)
Hydraulic leakdown rate a 5-25 seconds
Collapsed lash adjuster gap — desired 0.085-0.45 mm (0.0033-0.0177 in)

Camshaft

Lobe lift
Exhaust 7.49744 mm (0.29517 inch)
Intake 7.11038 mm (0.27994 inch)

Lobe lift — allowable lift loss 0
Valve lift @ zero lash
Intake 13.01 mm (0.5122 inch)

Exhaust 13.75 mm (0.5413 inch)
Camshaft end play 0.027-0.190 mm (0.00106-0.00748inch)
End play service limit 0.025-0.190 mm (0.00098-0.00748inch)
Journal to bearing clearance 0.076-0.025 mm (0.002992-0.00098inch)

Clearance service limit
Journal diameters 26.962-26.936 mm (1.0615-1.0605inch)
Journal inside diameter (cap assembled) 27.012-26.987 mm (1.0635-1.0625inch)
Camshaft runout: full indicator measurement on all journals when supported on front and rear journals. (4 places)0.03 mm (0.0018 inch)

Cylinder bore diameter
Grade 1 90.200-90.210 mm (3.5512-3.5516inch)
Grade 2 90.210-90.220 mm (3.5516-3.5518inch)
Grade 3 90.220-90.230 mm (3.5518-3.5524inch)

Piston
Piston diameter (Grade 2) at right angle to pin bore 90.180 ± 0.005
Piston to bore clearance (-0.005) to +0.025 mm ([-0.0002] to+0.0010 inch)
Pin bore diameter (piston) 22.008-22.014 mm (0.8664-0.8667inch)
Pin diameter 22.0005-22.0030 mm (0.8662-0.8663 inch)
Clearance 0.01395-0.005 mm (0.00055-0.00020 inch)
Pin bore diameter (rod) 22.012-22.024 mm (0.8666-0.8670inch)
Clearance 0.009-0.0235 mm (0.00035-0.00092inch)

Ring groove width
Top 1.53-1.55 mm (0.0602-0.0610 inch)
Intermediate 1.52-1.54 mm (0.0598-0.0606 inch)
Oil control 3.030-3.050 mm (0.1192-0.1201inch)

Piston ring gap
Top 0.13-0.28 mm (0.0051-0.110 inch)
Intermediate 0.25-0.40 mm (0.0098-0.0157 inch)
Oil control 0.15-0.65 mm (0.0059-0.0256 inch)

Crankshaft
Main bearing journal diameter 67.483-67.503 mm (2.657-2.658inch)
Maximum out-of-round 0.0075 mm (0.00030 inch) between cross sections
Maximum taper 0.004 mm (0.00016 inch)
Runout: FIM of center journals when located on front and rear journal 0.05 mm (0.0020 inch) (3 places)
Clearance — crankshaft journal to main bearing clearance 0.048-0.024 mm (0.0019-0.0009inch)
Connecting rod journal diameter 53.003-52.983 mm (2.087-2.085inch)
Maximum out-of-round 0.0075 mm (0.00030 inch) between cross sections
Maximum taper 0.004 mm (0.00016 inch)
Crankshaft end play 0.075-0.377 mm (0.0029-0.0148inch)

Connecting Rod
Big end journal inside diameter with assembled liners 53.049-53.027 mm (2.0885-2.0877inch)
Rod bearing to journal clearance 0.064-0.026 mm (0.00252-0.00102inch)
Pin bore diameter (rod) 22.024-22.012 mm (0.8671-0.8666inch)
Rod length (centerline bore-to-bore) 169.1 mm (6.66 inch)

Alignment
Bore-to-bore Max. twist ± 0.05 mm (0.0020 inch)
Bore-to-bore Max. bend ± 0.038 mm (0.0015 inch)

Side play (as assembled to crank)
Standard play 0.300 ± 0.175 mm (0.0118 ± 0.0069

Maintenance and Service
 

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Giggity Giggity Giggity!!!
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96 Posts
why no cylinder head torque spec?
 

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375 Posts
Sucks that all the diagrams are gone. Hope someone fixes this soon. These were very helpful
 
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