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Cylinder Heads - 5.4L: Removal

WARNING: This page is about a different car, the 2004 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.

    ALL CYLINDER HEADS 

  1. Remove the engine. For additional information, refer to ENGINE .
  2. Remove the bolts and the flexplate.
    Fig 1: Removing Bolts And Flexplate
    G02763151Courtesy of FORD MOTOR CO.
    3. CAUTION: To prevent damage to the oil pan, use care when lowering the engine.
  3. Lower the engine onto wooden blocks.
  4. Remove the special tool.
    Fig 2: Removing Special Tool
    G02763152Courtesy of FORD MOTOR CO.
  5. Install the special tool.
    Fig 3: Installing Special Tool
    G02763153Courtesy of FORD MOTOR CO.
  6. Install the special tool.
    Fig 4: Installing Special Tool
    G02763154Courtesy of FORD MOTOR CO.
  7. Mount the engine on a suitable work stand.
  8. Remove the special tool.
    Fig 5: Removing Special Tool
    G02763155Courtesy of FORD MOTOR CO.
  9. Remove the special tool.
    Fig 6: Removing Special Tool
    G02763156Courtesy of FORD MOTOR CO.
  10. Remove the RH engine mount.
    Fig 7: Removing RH Engine Mount
    G02763157Courtesy of FORD MOTOR CO.
    11. NOTE: LH shown; RH similar.
    Fig 8: Removing Cylinder Block Drain Plug
    G02763158Courtesy of FORD MOTOR CO.
  11. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
  12. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 9: Disconnecting LH Radio Frequency Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    G02763159Courtesy of FORD MOTOR CO.
  13. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 10: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector
    G02763160Courtesy of FORD MOTOR CO.
  14. Disconnect the RH radio frequency interference capacitor electrical connector.
    Fig 11: Disconnecting RH Radio Frequency Interference Capacitor Electrical Connector
    G02763161Courtesy of FORD MOTOR CO.
  15. Disconnect the knock sensor electrical connector.
    Fig 12: Disconnecting Knock Sensor Electrical Connector
    G02763162Courtesy of FORD MOTOR CO.
  16. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 13: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
    G02763163Courtesy of FORD MOTOR CO.
  17. Disconnect the oil pressure switch electrical connector.
    Fig 14: Disconnecting Oil Pressure Switch Electrical Connector
    G02763164Courtesy of FORD MOTOR CO.
  18. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
    19. NOTE: RH shown; LH similar.
    Fig 15: Removing Nuts And Radio Interference Capacitors
    G02763165Courtesy of FORD MOTOR CO.
  19. Remove the nuts and the two radio interference capacitors.
  20. Remove the crankcase ventilation tube from the LH valve cover.
    Fig 16: Removing Crankcase Ventilation Tube From LH Valve Cover
    G02763166Courtesy of FORD MOTOR CO.
    21. 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 17: Removing LH Valve Cover
    G02763167Courtesy of FORD MOTOR CO.
  21. 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.
    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.
    Fig 18: Removing RH Valve Cover
    G02763168Courtesy of FORD MOTOR CO.
  22. 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.
  23. Remove the bolt and the belt idler pulley.
    Fig 19: Removing Bolt And Belt Idler Pulley
    G02763169Courtesy of FORD MOTOR CO.
  24. Remove the coolant pump pulley.
    1. Remove the bolts.
    2. Remove the coolant pump pulley.
    Fig 20: Removing Coolant Pump Pulley
    G02763170Courtesy of FORD MOTOR CO.
  25. Remove and discard the crankshaft pulley bolt.

    Use the special tool to remove the crankshaft pulley.

    Fig 21: Removing Crankshaft Pulley Using Special Tool
    G02763171Courtesy of FORD MOTOR CO.
  26. Use the special tool to remove the crankshaft front seal.
    Fig 22: Removing Crankshaft Front Seal Using Special Tool
    G02763172Courtesy of FORD MOTOR CO.
  27. Remove the power steering pump.
    Fig 23: Removing Power Steering Pump
    G02763173Courtesy of FORD MOTOR CO.
  28. Remove the bolts.
    Fig 24: Removing Bolts
    G02763174Courtesy of FORD MOTOR CO.
    29. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 25: Removing Fasteners
    G02763175Courtesy of FORD MOTOR CO.
  29. Remove the fasteners.
  30. Remove the engine front cover from the cylinder block.
    Fig 26: Removing Engine Front Cover From Cylinder Block
    G02763176Courtesy of FORD MOTOR CO.
  31. Remove the crankshaft sensor ring from the crankshaft.
    Fig 27: Removing Crankshaft Sensor Ring From Crankshaft
    G02763177Courtesy of FORD MOTOR CO.
    32. 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.
  32. Remove the eight spark plugs.
  33. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 28: Installing Special Tool Between Valve Spring Coils
    G02763178Courtesy of FORD MOTOR CO.
    34. 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 29: Removing Camshaft Roller Followers
    G02763179Courtesy of FORD MOTOR CO.
  34. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
  35. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 30: Identifying Crankshaft Keyway Position
    G02763180Courtesy of FORD MOTOR CO.
    36. 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 31: Removing Timing Chain Tensioning System From Both Timing Chains
    G02763181Courtesy of FORD MOTOR CO.
  36. 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.
  37. 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 32: Removing RH And LH Timing Chains And Crankshaft Sprocket
    G02763182Courtesy of FORD MOTOR CO.
  38. Remove both timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
    Fig 33: Removing Both Timing Chain Guides
    G02763183Courtesy of FORD MOTOR CO.

    39. RH CYLINDER HEAD 

  39. Remove the RH exhaust manifold.
    1. Remove the nuts.
    2. Remove the RH exhaust manifold.
    3. Remove the RH exhaust manifold gasket.
    Fig 34: Removing RH Exhaust Manifold
    G02763184Courtesy of FORD MOTOR CO.

    40. LH CYLINDER HEAD 

  40. Remove the LH exhaust manifold.
    1. Remove the nuts.
    2. Remove the LH exhaust manifold.
    3. Remove the LH exhaust manifold gasket.
    Fig 35: Removing LH Exhaust Manifold
    G02763185Courtesy of FORD MOTOR CO.
  41. Remove the bolt and the oil level indicator tube.
    Fig 36: Removing Bolt And Oil Level Indicator Tube
    G02763186Courtesy of FORD MOTOR CO.

    42. ALL CYLINDER HEADS 

  42. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  43. Install the special tools on both ends of the cylinder head.
    Fig 37: Installing Special Tools On Both Ends Of Cylinder Head
    G02763187Courtesy of FORD MOTOR CO.
    44. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
    Fig 38: Removing Hydraulic Lash Adjusters
    G02763188Courtesy of FORD MOTOR CO.
  44. Remove the hydraulic lash adjusters.

    45. RH CYLINDER HEAD 

    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 39: Removing Bolts And RH Cylinder Head
    G02763189Courtesy of FORD MOTOR CO.
  45. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.

    46. LH CYLINDER HEAD 

    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 40: Removing Bolts And LH Cylinder Head
    G02763190Courtesy of FORD MOTOR CO.
  46. Remove the bolts and the LH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.

    47. ALL CYLINDER HEADS 

    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.
  47. 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.
    48. 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 41: Identifying Cylinder Head Gasket Position
    G02763191Courtesy of FORD MOTOR CO.
  48. 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).
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