Engine - 5.4L

SPECIAL TOOL(S) 

Fig 1: Identifying Special Tool(s)

Courtesy of FORD MOTOR CO.

MATERIAL 

CAUTION: Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. Failure to do so can result in engine damage.
1. Remove the engine. For additional information, refer to ENGINE - 5.4L .
2. Remove the bolts and the flexplate.
   Fig 2: Removing Bolts And Flexplate

   Courtesy of FORD MOTOR CO.
3. Using the special tools, remove the crankshaft rear slinger.
   Fig 3: Removing Crankshaft Rear Slinger Using Special Tool

   Courtesy of FORD MOTOR CO.
4. Using the special tools, remove the crankshaft rear seal.
   Fig 4: Removing Crankshaft Rear Seal Using Special Tool

   Courtesy of FORD MOTOR CO.
5. Remove the bolts and the crankshaft rear seal retainer plate.
   Fig 5: Removing Bolts And Crankshaft Rear Seal Retainer Plate

   Courtesy of FORD MOTOR CO.
CAUTION: To prevent damage to the oil pan, use care when lowering the engine.
6. Lower the engine onto wooden blocks.
7. Remove the special tool.
   Fig 6: Removing Special Tool

   Courtesy of FORD MOTOR CO.
8. Install the special tool.
   Fig 7: Installing Special Tool

   Courtesy of FORD MOTOR CO.
9. Install the special tool.
   Fig 8: Installing Special Tool

   Courtesy of FORD MOTOR CO.
10. Mount the engine on a suitable work stand.
NOTE: RH shown; LH similar.
Fig 9: Removing RH And LH Engine Mounts
Courtesy of FORD MOTOR CO.
11. Remove the RH and LH engine mounts.
NOTE: LH shown; RH similar.
Fig 10: Removing Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
12. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
13. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 11: Disconnecting LH Radio Frequency Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors

    Courtesy of FORD MOTOR CO.
14. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 12: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
15. Disconnect the RH radio frequency interference capacitor electrical connector.
    Fig 13: Disconnecting RH Radio Frequency Interference Capacitor Electrical Connector

    Courtesy of FORD MOTOR CO.
16. Disconnect the knock sensor electrical connector.
    Fig 14: Disconnecting Knock Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
17. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 15: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
18. Disconnect the oil pressure switch electrical connector.
    Fig 16: Disconnecting Oil Pressure Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
NOTE: RH shown; LH similar.
Fig 17: Removing Nuts And Radio Interference Capacitors
Courtesy of FORD MOTOR CO.
20. Remove the nuts and the two radio interference capacitors.
21. Remove the crankcase ventilation tube from the LH valve cover.
    Fig 18: Removing Crankcase Ventilation Tube From LH Valve Cover

    Courtesy of FORD MOTOR CO.
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 bolts are part of the valve cover and should not be removed.
Fig 19: Removing LH Valve Cover
Courtesy of FORD MOTOR CO.
22. Remove the LH valve cover.
    • Fully loosen the bolts and remove the valve cover.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
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 bolts are part of the valve cover and should not be removed.
Fig 20: Removing RH Valve Cover
Courtesy of FORD MOTOR CO.
23. Remove the RH valve cover.
    • Fully loosen the bolts and remove the valve cover.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Inspect the valve cover gasket. If the gasket is damaged, remove and discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
24. Remove the bolt and the belt idler pulley.
    Fig 21: Removing Bolt And Belt Idler Pulley

    Courtesy of FORD MOTOR CO.
25. Remove the coolant pump pulley.
    1. Remove the bolts.
    2. Remove the coolant pump pulley.
    Fig 22: Removing Coolant Pump Pulley

    Courtesy of FORD MOTOR CO.
26. Remove and discard the crankshaft pulley bolt.

    Use the special tool to remove the crankshaft pulley.

    Fig 23: Removing Crankshaft Pulley Bolt

    Courtesy of FORD MOTOR CO.
27. Use the special tool to remove the crankshaft front seal.
    Fig 24: Removing Crankshaft Front Seal Using Special Tool

    Courtesy of FORD MOTOR CO.
28. Remove the power steering pump.
    Fig 25: Removing Power Steering Pump

    Courtesy of FORD MOTOR CO.
29. Remove the four oil pan bolts.
    Fig 26: Removing Oil Pan Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
Fig 27: Removing Fasteners
Courtesy of FORD MOTOR CO.
30. Remove the fasteners.
31. Remove the engine front cover from the cylinder block.
    Fig 28: Removing Engine Front Cover From Cylinder Block

    Courtesy of FORD MOTOR CO.
32. Remove the crankshaft sensor ring from the crankshaft.
    Fig 29: Removing Crankshaft Sensor Ring From Crankshaft

    Courtesy of FORD MOTOR CO.
CAUTION: Use care when removing the spark plugs.
NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
33. Remove the eight spark plugs.
34. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 30: Installing Special Tool Between Valve Spring Coils

    Courtesy of FORD MOTOR CO.
NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.
NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.
Fig 31: Removing Camshaft Roller Followers Using Special Tool
Courtesy of FORD MOTOR CO.
35. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
36. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 32: Identifying Crankshaft Keyway Position

    Courtesy of FORD MOTOR CO.
CAUTION: 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, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner.
Fig 33: Removing Timing Chain Tensioner Arms
Courtesy of FORD MOTOR CO.
37. Remove the timing chain tensioning system from both timing chains.
    1. Remove the bolts.
    2. Remove the timing chain tensioners.
    3. Remove the timing chain tensioner arms.
38. Remove the RH and LH timing chains and the crankshaft sprocket(s).
    • Remove the RH timing chain from the camshaft sprocket.
    • Remove the RH timing chain from the crankshaft sprocket.
    • Remove the LH timing chain from the camshaft sprocket.
    • Remove the LH timing chain and crankshaft sprocket(s).
    Fig 34: Removing RH And LH Timing Chains And Crankshaft Sprocket

    Courtesy of FORD MOTOR CO.
39. Remove both timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
    Fig 35: Removing Both Timing Chain Guides

    Courtesy of FORD MOTOR CO.
40. Remove the nuts, the RH exhaust manifold and gasket.
    • Discard the gasket.
    Fig 36: Removing Nuts, RH Exhaust Manifold And Gasket

    Courtesy of FORD MOTOR CO.
41. Remove the nuts, the LH exhaust manifold and gasket.
    • Discard the gasket.
    Fig 37: Removing Nuts, LH Exhaust Manifold And Gasket

    Courtesy of FORD MOTOR CO.
42. Remove the bolt and the oil level indicator tube.
    Fig 38: Removing Bolt And Oil Level Indicator Tube

    Courtesy of FORD MOTOR CO.
43. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
44. Install the special tools on both ends of the cylinder head.
    Fig 39: Installing Special Tools On Both Ends Of Cylinder Head

    Courtesy of FORD MOTOR CO.
NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
Fig 40: Removing Hydraulic Lash Adjusters
Courtesy of FORD MOTOR CO.
45. Remove the hydraulic lash adjusters.
CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
Fig 41: Removing Bolts And RH Cylinder Head
Courtesy of FORD MOTOR CO.
46. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
CAUTION: The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
CAUTION: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
Fig 42: Removing Bolts And LH Cylinder Head
Courtesy of FORD MOTOR CO.
47. Remove the bolts and the LH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
CAUTION: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep.
NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
48. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
    1. Remove any large deposits of silicone or gasket material with a plastic scraper.
    2. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    3. Remove the silicone gasket remover with a plastic scraper. A second application of silicone gasket remover may be required if residual traces of silicone or gasket material remain.
    4. Apply metal surface prep, following package directions, to remove any remaining traces of oil or coolant, and to prepare the surfaces to bond with the new gasket. Do not attempt to make the metal shiny. Some staining of the metal surfaces is normal.
NOTE: Make sure all cylinder head surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head surface must be clean and dry before running a flatness check.
NOTE: Use a straightedge that is calibrated by the manufacturer to be flat with 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machine edge must be flat with 0.010 mm (0.0004 in) from end to end.
NOTE: LH is shown; RH is similar.
Fig 43: Identifying Cylinder Head Gasket Position
Courtesy of FORD MOTOR CO.
49. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the deck face with a straightedge, paying particular attention to the oil pressure feed area. The cylinder head must not have depressions deeper than 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area or scratches more than 0.0254 mm (0.001 in).
50. If required, remove the mounting hardware, the oil filter adapter and the oil filter adapter gasket.
    Fig 44: Removing Mounting Hardware, Oil Filter Adapter And Oil Filter Adapter Gasket

    Courtesy of FORD MOTOR CO.
51. Clean the oil filter adapter gasket surface at the cylinder block.
    Fig 45: Cleaning Oil Filter Adapter Gasket Surface At Cylinder Block

    Courtesy of FORD MOTOR CO.
52. Remove the bolts.
    Fig 46: Removing Bolts

    Courtesy of FORD MOTOR CO.
53. Remove the coolant pump from the cylinder block.
    Fig 47: Removing Coolant Pump From Cylinder Block

    Courtesy of FORD MOTOR CO.
54. Remove the bolts and the A/C compressor.
    Fig 48: Removing Bolts And A/C Compressor

    Courtesy of FORD MOTOR CO.
55. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent following the manufacturer's instructions.
56. Remove the bolts, the oil pan and the oil pan gasket.
    • Clean and inspect the sealing surfaces.
    Fig 49: Removing Bolts, Oil Pan And Oil Pan Gasket

    Courtesy of FORD MOTOR CO.
57. Remove the bolts and the oil pump screen and pickup tube.
    Fig 50: Removing Bolts And Oil Pump Screen And Pickup Tube

    Courtesy of FORD MOTOR CO.
58. Remove the oil pump screen and pickup tube spacer.
    Fig 51: Removing Oil Pump Screen And Pickup Tube Spacer

    Courtesy of FORD MOTOR CO.
59. Remove the oil pump.
    1. Remove the bolts.
    2. Remove the oil pump.
    Fig 52: Removing Oil Pump

    Courtesy of FORD MOTOR CO.
CAUTION: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation.
Fig 53: Removing Bolts And Connecting Rod Cap
Courtesy of FORD MOTOR CO.
60. Remove the bolts and the connecting rod cap. Discard the bolts.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 54: Pushing Piston Through Top Of Cylinder Block Using Special Tool
Courtesy of FORD MOTOR CO.
61. Use the special tool to push the piston through the top of the cylinder block.
CAUTION: Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. Failure to do so can result in engine damage.
Fig 55: Removing Fasteners
Courtesy of FORD MOTOR CO.
62. Remove the fasteners.
    1. Remove and discard the cross-mounted main cap bolts.
    2. Remove the dowels.
    3. Remove and discard the main bearing cap bolts.
63. Remove the five main bearing caps and the lower crankshaft main bearings.
    Fig 56: Removing Main Bearing Caps And Lower Crankshaft Main Bearings

    Courtesy of FORD MOTOR CO.
64. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.
    Fig 57: Removing Crankshaft And Upper Crankshaft Main Bearings From Cylinder Block

    Courtesy of FORD MOTOR CO.