Cylinder Heads - 5.4L: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

All cylinder heads

CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to CYLINDER HEADS - 5.4L .

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do not scratch the gasket.

NOTE: RH head gasket shown; LH head gasket similar.

Fig 1: Installing Head Gasket Over Dowel Pins (5.4L)

Courtesy of FORD MOTOR CO.

Install the head gasket over the dowel pins.

CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder head flatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.

CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. For additional information, refer to CYLINDER HEADS - 5.4L .

CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.

CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder head installation.

NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior to installation.

NOTE: RH cylinder head shown; LH cylinder head similar.

Fig 2: Installing Cylinder Head On Dowels

Courtesy of FORD MOTOR CO.

Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.

LH cylinder head

NOTE: Make sure to tighten the bolts in the following three stages.

Tighten the LH bolts in the sequence shown in Fig 3.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 3: Identifying Tightening Sequence Of LH Cylinder Head Bolts
  Courtesy of FORD MOTOR CO.

RH cylinder head

NOTE: Make sure to tighten the bolts in the following three stages.

Tighten the RH bolts in the sequence shown in Fig 4.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Tighten an additional 90 degrees.
  
  Fig 4: Identifying Tightening Sequence Of RH Cylinder Head Bolts
  Courtesy of FORD MOTOR CO.

All cylinder heads

Remove the special tools from both ends of the cylinder head.

Fig 5: Installing/Removing Special Tools On Both Ends Of Cylinder Head
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.

Fig 6: Identifying Hydraulic Lash Adjusters

Courtesy of FORD MOTOR CO.

Install the hydraulic lash adjusters in their original locations.

RH cylinder head

Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown in Fig 7.

Fig 7: Identifying Tightening Sequence Of RH Exhaust Manifold Bolts
Courtesy of FORD MOTOR CO.

LH cylinder head

NOTE: Lubricate the O-ring seal with clean engine oil.

Install the oil level indicator tube.
- Install a new O-ring seal on the oil level indicator tube.
- Install the oil level indicator tube.
- Install the bolt.
  
  Fig 8: Installing Oil Level Indicator Tube
  Courtesy of FORD MOTOR CO.
Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence shown in Fig 9.

Fig 9: Identifying Tightening Sequence Of LH Exhaust Manifold Bolts
Courtesy of FORD MOTOR CO.

All cylinder heads

CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

CAUTION: Prior to installation, inspect the tensioner-sealing bead 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 10: Compressing Tensioner Plunger Using Edge Of Vise

Courtesy of FORD MOTOR CO.

Compress the tensioner plunger, using a vise.
Install a retaining clip on the tensioner to hold the plunger in during installation.

Fig 11: Installing Retaining Clip On Tensioner
Courtesy of FORD MOTOR CO.
Remove the tensioner from the vise.
If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.

Fig 12: Marking Links When Copper Link Is Not Visible
Courtesy of FORD MOTOR CO.
Install the timing chain guides.

Fig 13: View Of Timing Chain Guides With Torque Specifications
Courtesy of FORD MOTOR CO.
Pre-position the camshafts.
1. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock.
2. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.
  
  Fig 14: Identifying Camshaft Timing Marks
  Courtesy of FORD MOTOR CO.

CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe piston and valve damage can occur.

NOTE: The number one piston is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.

Fig 15: Positioning Crankshaft

Courtesy of FORD MOTOR CO.

Position the crankshaft so the number one cylinder is at TDC with the special tool.
Remove the special tool.
Install the crankshaft sprocket, making sure the flange faces forward.

Fig 16: Identifying Crankshaft Sprocket Flange
Courtesy of FORD MOTOR CO.
Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outer flange of the crankshaft sprocket with the single copper (marked) link on the chain.

Fig 17: Aligning Timing Mark On Outer Flange Of Crankshaft Sprocket With Single Copper Link On Chain
Courtesy of FORD MOTOR CO.

NOTE: Make sure the upper half of the timing chain is below the tensioner arm dowel.

Fig 18: Positioning Timing Chain On Camshaft Sprocket

Courtesy of FORD MOTOR CO.

Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.

NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Fig 19: LH Timing Chain Tensioner And Guide - With Torque Specification

Courtesy of FORD MOTOR CO.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
Remove the retaining clip from the LH timing chain tensioner.

Fig 20: Timing Chain Tensioner Retaining Clip
Courtesy of FORD MOTOR CO.
Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.

Fig 21: Aligning Timing Mark On Crankshaft Sprocket With Single Copper Chain Link
Courtesy of FORD MOTOR CO.
Install the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.

Fig 22: Aligning Copper-Colored (Marked) Links With Camshaft Sprocket Timing Mark
Courtesy of FORD MOTOR CO.
Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.

Fig 23: View Of RH Timing Chain Tensioner - With Torque Specification
Courtesy of FORD MOTOR CO.
Remove the retaining clip from the RH timing chain tensioner.

Fig 24: Timing Chain Tensioner Retaining Clip
Courtesy of FORD MOTOR CO.
As a post-check, verify correct alignment of all timing marks.

Fig 25: Identifying Correct Alignment Of All Timing Marks
Courtesy of FORD MOTOR CO.
Install the special tool between the valve spring coils to prevent valve stem seal damage.

Fig 26: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.

NOTE: Lubricate the camshaft roller followers using clean engine oil.

NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft roller follower.

Install the camshaft roller followers.
1. Install the special tool.
2. Compress the valve spring.
3. Install the camshaft roller followers in their original locations.
  
  Fig 27: Installing Camshaft Roller Followers
  Courtesy of FORD MOTOR CO.

CAUTION: When installing the spark plugs, use care not to exceed the recommended torque.

Install the eight spark plugs.
- Tighten to 18 Nm (13 lb-ft).
Install the crankshaft sensor ring on the crankshaft.

Fig 28: Crankshaft Sensor Ring
Courtesy of FORD MOTOR CO.

NOTE: If the front cover is not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Fig 29: Locating Sealant Application Areas

Courtesy of FORD MOTOR CO.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown in Fig 29.
Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.

Fig 30: Installing Engine Front Cover
Courtesy of FORD MOTOR CO.
Tighten the engine front cover fasteners in sequence in three stages.
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).

Fig 31: Identifying Tightening Sequence Of Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
Loosely install the bolts, then tighten the bolts in two stages, in the sequence shown in Fig 32.
- Stage 1: Tighten to 20 Nm (15 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 32: Identifying Tightening Sequence Of Bolts
  Courtesy of FORD MOTOR CO.
Position the belt idler pulley and install the bolt.

Fig 33: View Of Belt Idler Pulley Bolt With Torque Specification
Courtesy of FORD MOTOR CO.
Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.

Fig 34: Installing Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
Use the special tools to install the crankshaft front seal into the engine front cover.

Fig 35: Installing Crankshaft Front Seal Into Engine Front Cover Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

Fig 36: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant to the woodruff key slot on the crankshaft pulley.
Use the special tool to install the crankshaft pulley.

Fig 37: Installing Crankshaft Pulley Using Special Tool
Courtesy of FORD MOTOR CO.

NOTE: Use a suitable strap wrench (303-D055) to hold the pulley while tightening the bolt.

Tighten the new crankshaft pulley bolt in four stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.
  
  Fig 38: Installing Crankshaft Pulley Bolt & Washer
  Courtesy of FORD MOTOR CO.
Position the coolant pump pulley on the coolant pump and install the bolts.

Fig 39: Installing Coolant Pump Pulley On Coolant Pump With Torque Specification
Courtesy of FORD MOTOR CO.

NOTE: The front lower hole in the power steering pump is not used.

Fig 40: Identifying Tightening Torque Of Power Steering Pump Bolts

Courtesy of FORD MOTOR CO.

Position the power steering pump and install the bolts.
If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.

Fig 41: Identifying Proper Valve Cover Gasket Sealant Application
Courtesy of FORD MOTOR CO.

Fig 42: Applying Silicone Gasket And Sealant To Front Cover

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
Position the LH valve cover and gasket on the cylinder head and install the bolts loosely.

Fig 43: Installing LH Valve Cover And Gasket On Cylinder Head
Courtesy of FORD MOTOR CO.
Tighten the bolts in the sequence shown in Fig 44.

Fig 44: Identifying Tightening Sequence Of LH Valve Cover Bolts
Courtesy of FORD MOTOR CO.
If a new gasket is being installed, apply instant gel adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.

Fig 45: Applying Instant Adhesive Around Gasket Groove In Valve Cover
Courtesy of FORD MOTOR CO.

Fig 46: Applying Silicone Gasket And Sealant To Engine Front Cover

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
Position the RH valve cover and gasket on the cylinder head and install the bolts loosely.

Fig 47: Identifying RH Valve Cover
Courtesy of FORD MOTOR CO.
Tighten the bolts in the sequence shown in Fig 48.

Fig 48: Identifying Tightening Sequence Of RH Valve Cover Bolts
Courtesy of FORD MOTOR CO.
Install the crankcase ventilation tube on the LH valve cover.

Fig 49: Locating Crankcase Ventilation Tube On LH Valve Cover
Courtesy of FORD MOTOR CO.

NOTE: RH shown; LH similar.

Fig 50: Identifying Radio Frequency Interference Capacitor

Courtesy of FORD MOTOR CO.

Install the radio frequency interference capacitors.
Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
Connect the CKP sensor electrical connector.

Fig 51: Locating CKP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the oil pressure switch electrical connector.

Fig 52: Locating Oil Pressure Switch Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the KS electrical connector.

Fig 53: Locating KS Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the RH radio frequency interference capacitor electrical connector.

Fig 54: Locating Radio Frequency Interference Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the CMP sensor electrical connector.

Fig 55: Identifying Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.

Fig 56: Locating Radio Frequency Interference Capacitor And Cylinder Head Temperature Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.

NOTE: LH shown; RH similar.

Fig 57: Installing Cylinder Block Drain Plugs

Courtesy of FORD MOTOR CO.

Install the cylinder block drain plugs.
Install the RH engine mount.
- Tighten to 63 Nm (46 lb-ft).
Install the special tool.

Fig 58: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Install the special tool.

Fig 59: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Install the special tool and remove the engine from the work stand.

Fig 60: Installing Special Tool
Courtesy of FORD MOTOR CO.
Lower the engine onto wooden blocks.
Install the special tool and raise the engine.

Fig 61: Identifying Special Tool
Courtesy of FORD MOTOR CO.
Install the flexplate or the flywheel and bolts. Tighten the bolts in the sequence shown in Fig 62.

Fig 62: Identifying Flexplate Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
Install the engine. For additional information, refer to ENGINE .