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Engine - 5.4L: Material

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MATERIAL SPECIFICATION

Item Specification
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
    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 - 4.6L  and ENGINE - 5.4L .
  2. Remove the bolts and the flexplate.
    Fig 1: Identifying Flexplate/Flywheel Retainer Bolts
    G03885481Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the crankshaft rear slinger.
    Fig 2: Removing Crankshaft Rear Oil Slinger
    G03885490Courtesy of FORD MOTOR CO.
  4. Using the special tools, remove the crankshaft rear seal.
    Fig 3: Removing Crankshaft Rear Seal Using Special Tool
    G03885491Courtesy of FORD MOTOR CO.
  5. Remove the bolts and the crankshaft rear seal retainer plate.
    Fig 4: Identifying Bolts And Crankshaft Rear Seal Retainer Plate
    G03885716Courtesy of FORD MOTOR CO.
    6. 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 5: Identifying Special Tool
    G03885604Courtesy of FORD MOTOR CO.
  8. Install the special tool.
    Fig 6: Identifying Special Tool
    G03905704Courtesy of FORD MOTOR CO.
  9. Install the special tool.
    Fig 7: Identifying Special Tool
    G03905705Courtesy of FORD MOTOR CO.
  10. Mount the engine on a suitable work stand.
    11. NOTE: RH shown; LH similar.
    Fig 8: Removing/Installing RH Engine Mount
    G03885618Courtesy of FORD MOTOR CO.
  11. Remove the RH and LH engine mounts.
    12. NOTE: LH shown; RH similar.
    Fig 9: Locating Cylinder Block Drain Plugs
    G03885619Courtesy 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 10: Locating Radio Frequency Interference Capacitor And Cylinder Head Temperature Sensor Electrical Connectors
    G03962635Courtesy of FORD MOTOR CO.
  14. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 11: Identifying Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  15. Disconnect the RH radio frequency interference capacitor electrical connector.
    Fig 12: Locating Radio Frequency Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  16. Disconnect the knock sensor electrical connector.
    Fig 13: Locating KS Electrical Connector
    G03886734Courtesy of FORD MOTOR CO.
  17. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 14: Locating CKP Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
  18. Disconnect the oil pressure switch electrical connector.
    Fig 15: Locating Oil Pressure Switch Electrical Connector
    G03886309Courtesy of FORD MOTOR CO.
  19. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
    20. NOTE: RH shown; LH similar.
    Fig 16: Identifying Radio Frequency Interference Capacitors
    G03906363Courtesy 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 17: Locating Crankcase Ventilation Tube On LH Valve Cover
    G03885676Courtesy of FORD MOTOR CO.
    22. 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.
  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.
      Fig 18: Removing LH Valve Cover
      G04612512Courtesy of FORD MOTOR CO.
    23. 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.
  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.
      Fig 19: Identifying Valve Cover On Cylinder Head
      G03885236Courtesy of FORD MOTOR CO.
  24. Remove the bolt and the belt idler pulley.
    Fig 20: Identifying Bolt And Belt Idler Pulley
    G03885293Courtesy of FORD MOTOR CO.
  25. Remove the coolant pump pulley.
    1. Remove the bolts.
    2. Remove the coolant pump pulley.
      Fig 21: Identifying Coolant Pump Pulley And Bolts
      G03885632Courtesy of FORD MOTOR CO.
  26. Remove and discard the crankshaft pulley bolt.

    Use the special tool to remove the crankshaft pulley.

    Fig 22: Removing Crankshaft Pulley Bolt Using Special Tool
    G03885277Courtesy of FORD MOTOR CO.
  27. Use the special tool to remove the crankshaft front seal.
    Fig 23: Identifying Crankshaft Front Seal And Special Tool
    G03885682Courtesy of FORD MOTOR CO.
  28. Remove the power steering pump.
    Fig 24: Locating Power Steering Pump Bolts
    G03885288Courtesy of FORD MOTOR CO.
  29. Remove the four oil pan bolts.
    Fig 25: Locating Front Oil Pan Bolts
    G03885636Courtesy of FORD MOTOR CO.
    30. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 26: Identifying Front Cover Fasteners
    G03885685Courtesy of FORD MOTOR CO.
  30. Remove the fasteners.
  31. Remove the engine front cover from the cylinder block.
    Fig 27: Removing Engine Front Cover From Cylinder Block
    G03885740Courtesy of FORD MOTOR CO.
  32. Remove the crankshaft sensor ring from the crankshaft.
    Fig 28: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    33. 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 29: Installing Special Tool Between Valve Spring Coils
    G03881599Courtesy of FORD MOTOR CO.
    35. 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 30: Compressing Valve Springs
    G03905494Courtesy 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 31: Positioning Crankshaft With Keyway At 12 O'Clock Position
    G03885811Courtesy of FORD MOTOR CO.
    37. 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.
  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.
      Fig 32: Identifying Timing Chain Tensioning System Components
      G03885312Courtesy of FORD MOTOR CO.
  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 33: Removing Timing Chain
      G03885313Courtesy of FORD MOTOR CO.
  39. Remove both timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
      Fig 34: Removing Timing Chain Guides
      G03885314Courtesy of FORD MOTOR CO.
  40. Remove the nuts, the RH exhaust manifold and gasket.
    • Discard the gasket.
      Fig 35: Removing RH Exhaust Manifold And Gasket
      G03885815Courtesy of FORD MOTOR CO.
  41. Remove the nuts, the LH exhaust manifold and gasket.
    • Discard the gasket.
      Fig 36: Removing LH Exhaust Manifold And Gasket
      G03885816Courtesy of FORD MOTOR CO.
  42. Remove the bolt and the oil level indicator tube.
    Fig 37: Removing Oil Level Indicator Tube
    G03885439Courtesy 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 38: Installing/Removing Special Tools On Both Ends Of Cylinder Head
    G03885649Courtesy of FORD MOTOR CO.
    45. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
    Fig 39: Identifying Hydraulic Lash Adjusters
    G03885650Courtesy of FORD MOTOR CO.
  45. Remove the hydraulic lash adjusters.
    46. 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.
  46. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 40: Locating Cylinder Head Bolts
      G03885651Courtesy of FORD MOTOR CO.
    47. 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.
  47. Remove the bolts and the LH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 41: Identifying LH Cylinder Head Bolts
      G03885652Courtesy of FORD MOTOR CO.
    48. 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.
    49. 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 42: Identifying Oil Pressure Feed Area Of Deck Face Surface
    G03885653Courtesy 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 43: Removing Mounting Hardware, Oil Filter Adapter And Oil Filter Adapter Gasket
    G03885426Courtesy of FORD MOTOR CO.
  51. Clean the oil filter adapter gasket surface at the cylinder block.
    Fig 44: Cleaning Oil Filter Adapter Gasket Surface At Cylinder Block
    G03885427Courtesy of FORD MOTOR CO.
  52. Remove the bolts.
    Fig 45: Identifying Coolant Pump Bolts
    G03885825Courtesy of FORD MOTOR CO.
  53. Remove the coolant pump from the cylinder block.
    Fig 46: Identifying Coolant Pump
    G03885759Courtesy of FORD MOTOR CO.
  54. Remove the bolts and the A/C compressor.
    Fig 47: Removing A/C Compressor
    G03885760Courtesy 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 48: Identifying Oil Pan Bolts
      G03885459Courtesy of FORD MOTOR CO.
  57. Remove the bolts and the oil pump screen and pickup tube.
    Fig 49: Removing Oil Pump Screen And Pickup Tube
    G03885762Courtesy of FORD MOTOR CO.
  58. Remove the oil pump screen and pickup tube spacer.
    Fig 50: Removing Oil Pump Screen And Pickup Tube Spacer
    G03885763Courtesy of FORD MOTOR CO.
  59. Remove the oil pump.
    1. Remove the bolts.
    2. Remove the oil pump.
      Fig 51: Removing Oil Pump
      G03885764Courtesy of FORD MOTOR CO.
    60. 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 52: Identifying Bolts And Connecting Rod Caps
    G04583770Courtesy of FORD MOTOR CO.
  60. Remove the bolts and the connecting rod cap. Discard the bolts.
    61. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 53: Pushing Piston Through Top Of Cylinder Block
    G03885766Courtesy of FORD MOTOR CO.
  61. Use the special tool to push the piston through the top of the cylinder block.
    62. 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.
  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.
      Fig 54: Removing Main Bearing Cap Bolts
      G03905810Courtesy of FORD MOTOR CO.
  63. Remove the five main bearing caps and the lower crankshaft main bearings.
    Fig 55: Removing Main Bearing Caps
    G03920344Courtesy of FORD MOTOR CO.
  64. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.
    Fig 56: Removing Crankshaft And Main Bearings From Cylinder Block
    G03881879Courtesy of FORD MOTOR CO.
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