Cylinder Head - 5.4L: Installation

All cylinder heads 

CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. Failure to follow these instructions may result in engine damage.
CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused. Failure to follow these instructions may result in engine damage.
NOTE: Do not turn the crankshaft until instructed to do so.
NOTE: LH shown, RH similar.
1. Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
Fig 1: Locating Cylinder Head And Gaskets Using Special Tool (303-1040)
Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
2. Tighten the bolts in 3 stages, in the sequence shown.
   • Stage 1: Tighten to 40 Nm (30 lb-ft).
   • Stage 2: Tighten an additional 90 degrees.
   • Stage 3: Tighten an additional 90 degrees.
Fig 2: Identifying Cylinder Head Bolts Tightening Sequence
Courtesy of FORD MOTOR CO.
3. Remove the special tools from both ends of the cylinder head being serviced.
Fig 3: Identifying Special Tool (303-572)
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
4. Install the hydraulic lash adjusters in their original locations.
Fig 4: Locating Hydraulic Lash Adjusters
Courtesy of FORD MOTOR CO.

RH cylinder head 

5. Install 8 new exhaust manifold studs.
   • Tighten to 12 Nm (9 lb-ft).
6. Install the RH exhaust manifold gasket and the exhaust manifold. Tighten the nuts in the sequence shown.
   • Tighten to 25 Nm (18 lb-ft).
Fig 5: Right Exhaust Manifold Torque Sequence
Courtesy of FORD MOTOR CO.

LH cylinder head 

7. Install 8 new exhaust manifold studs.
   • Tighten to 12 Nm (9 lb-ft).
NOTE: Install a new exhaust manifold gasket.
8. Position the gaskets and the LH exhaust manifold and tighten the 8 nuts in the sequence shown.
   • Tighten to 25 Nm (18 lb-ft).
Fig 6: LH Exhaust Manifold Nut Tightening Sequence
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. Failure to follow these instructions may result in engine damage.
9. Using a vise, compress the tensioner plunger.
Fig 7: Compressing Tensioner Plunger
Courtesy of FORD MOTOR CO.
10. Install a retaining clip on the tensioner to hold the plunger in during installation.
Fig 8: Identifying Retaining Clip on Tensioner
Courtesy of FORD MOTOR CO.
11. Remove the tensioner from the vise.
12. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
Fig 9: Locating Timing Chain Marks
Courtesy of FORD MOTOR CO.
13. Install the timing chain guides.
    1. Position the LH timing chain guide.
    2. Install and tighten the LH bolts.
    3. Position the RH timing chain guide.
    4. Install and tighten the RH bolts.
    5. Tighten to 10 Nm (89 lb-in).
Fig 10: Identifying Timing Chain Guides
Courtesy of FORD MOTOR CO.
14. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
Fig 11: Identifying LH And RH Camshaft Timing Mark Position
Courtesy of FORD MOTOR CO.
NOTE: The No. 1 cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
15. Position the crankshaft so the No. 1 cylinder is at TDC with the special tool.
Fig 12: Positioning Crankshaft With Special Tool (303-448)
Courtesy of FORD MOTOR CO.
16. Install the crankshaft sprocket, making sure the flange faces forward.
Fig 13: Identifying Crankshaft Sprocket
Courtesy of FORD MOTOR CO.
17. 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 14: Aligning Timing Mark 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.
18. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the 2 copper (marked) chain links.
Fig 15: Positioning Timing Chain On Camshaft Sprocket
Courtesy of FORD MOTOR CO.
NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
19. Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
Fig 16: Positioning LH Timing Chain Tensioner Arm On Dowel Pin
Courtesy of FORD MOTOR CO.
20. Remove the retaining clip from the LH timing chain tensioner.
Fig 17: Identifying Retaining Clip And Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
21. 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 18: Aligning Timing Mark On Crankshaft Sprocket With Single Copper Chain Link
Courtesy of FORD MOTOR CO.
22. Install the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 copper (marked) chain links.
Fig 19: Aligning Copper-Colored (Marked) Links With Camshaft Sprocket Timing Mark
Courtesy of FORD MOTOR CO.
23. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
    • Tighten to 25 Nm (18 lb-ft).
Fig 20: Positioning RH Timing Chain Tensioner Arm On Dowel Pin
Courtesy of FORD MOTOR CO.
24. Remove the retaining clip from the RH timing chain tensioner.
Fig 21: Identifying Retaining Clip And Timing Chain Tensioner
Courtesy of FORD MOTOR CO.
25. As a post-check, verify correct alignment of all timing marks.
Fig 22: Identifying Alignment Of All Timing Marks
Courtesy of FORD MOTOR CO.
26. Install the crankshaft sensor ring on the crankshaft.
Fig 23: View Of Crankshaft Sensor Ring At Crankshaft
Courtesy of FORD MOTOR CO.
NOTE: Camshaft roller follower is removed for clarity.
27. Install the special tool between the valve spring coils to prevent valve stem seal damage.
Fig 24: Installing Special Tool Between Valve Spring Coils
Courtesy of FORD MOTOR CO.
CAUTION: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Engine .
NOTE: It may be necessary to push the valve down while compressing the spring.
NOTE: Position the cam lobe away from the valve stem prior to installing each camshaft roller follower.
28. Use the special tool to compress the valve springs, and install the camshaft roller follower.
Fig 25: Compressing Valve Springs Using Special Tool (303-567)
Courtesy of FORD MOTOR CO.
NOTE: The camshaft roller followers must be installed in their original locations.
29. Repeat the previous 3 steps for each camshaft roller follower.
CAUTION: Only use hand tools when removing or installing the spark plugs or damage can occur to the cylinder head or spark plug.
NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
NOTE: If an original spark plug is used, make sure it is installed in the same cylinder from which it was taken. New spark plugs can be used in any cylinder.
NOTE: Refer to SPECIFICATIONS  for correct spark plug identification.
30. Install the 8 spark plugs.
    • Tighten to 18 Nm (13 lb-ft).
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: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.
31. 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.
Fig 26: Identifying Area For Silicone Gasket Application
Courtesy of FORD MOTOR CO.
32. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
Fig 27: Installing Engine Front Cover Gasket
Courtesy of FORD MOTOR CO.
33. Tighten the engine front cover fasteners in sequence in 3 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).

    Item	Part Number	Description
    1	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    2	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    3	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    4	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    5	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 53
    6	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30
    7	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 59 - M10 x 1.5 x 30
    8	N808142	Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5
    9	N808142	Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5
    10	N808142	Screw and Washer, Hex Pilot, M10 x 1.5 x 57.5
    11	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
    12	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
    13	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
    14	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27
    15	N808140	Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 - M8 x 1.25 x 27

Fig 28: Engine Front Cover Torque Sequence
Courtesy of FORD MOTOR CO.
34. Loosely install the 4 front oil pan bolts, and tighten the bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten an additional 60 degrees.
Fig 29: Identifying Tightening Sequence Of Front Oil Pan Bolts
Courtesy of FORD MOTOR CO.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.
35. Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
36. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
Fig 30: Identifying Proper Valve Cover Gasket Sealant Application
Courtesy of FORD MOTOR CO.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
37. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
Fig 31: Applying Sealant Where Engine Front Cover Meets Cylinder Head
Courtesy of FORD MOTOR CO.
38. Position the LH valve cover and gasket on the cylinder head and install the fasteners loosely.
Fig 32: View Of LH Valve Cover And Gasket At Cylinder Head
Courtesy of FORD MOTOR CO.
39. Tighten the fasteners in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
Fig 33: Valve Cover Torque Sequence - 5.4L
Courtesy of FORD MOTOR CO.
40. Apply instant adhesive completely around the gasket groove in the RH valve cover. Install the new valve cover gasket.
Fig 34: Valve Cover Gasket
Courtesy of FORD MOTOR CO.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
41. Apply silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
Fig 35: Applying Sealant At Engine Front Cover & Cylinder Head Seam
Courtesy of FORD MOTOR CO.
42. Position the RH valve cover and gasket on the cylinder head and install the fasteners loosely.
Fig 36: Positioning RH Valve Cover And Gasket On Cylinder Head
Courtesy of FORD MOTOR CO.
43. Tighten the fasteners in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
Fig 37: Valve Cover Fastener Torque Sequence
Courtesy of FORD MOTOR CO.
44. Position the accessory drive belt idler pulley and install the bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 38: Accessory Drive Belt Idler Pulley And Retaining Bolt
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
45. Install the camshaft position (CMP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 39: Locating LH CMP Sensor Bolt
Courtesy of FORD MOTOR CO.
46. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
Fig 40: Locating Crankshaft Front Seal
Courtesy of FORD MOTOR CO.
47. Using the special tools, install a new crankshaft front seal.
Fig 41: Installing Crankshaft Front Seal Using Special Tools
Courtesy of FORD MOTOR CO.
NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
48. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
Fig 42: Identifying Woodruff Key Slot On Crankshaft Pulley
Courtesy of FORD MOTOR CO.
49. Using the special tool, install the crankshaft pulley.
Fig 43: 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.
50. Tighten the new crankshaft pulley bolt in 4 stages.
    • Stage 1: Tighten to 90 Nm (66 lb-ft).
    • Stage 2: Loosen one full turn.
    • Stage 3: Tighten to 50 Nm (37 lb-ft).
    • Stage 4: Tighten an additional 90 degrees.
Fig 44: Identifying Crankshaft Pulley Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
51. Install the crankshaft position (CKP) sensor and the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 45: Locating Crankshaft Position (CKP) Sensor Bolt
Courtesy of FORD MOTOR CO.
52. Position the coolant pump pulley on the coolant pump and install the 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 46: Identifying Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
NOTE: The front lower hole in the power steering pump is not used.
53. Position the power steering pump and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 47: Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
54. Install the radio frequency interference capacitors and the nuts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 48: Radio Interference Capacitor And Retaining Nut
Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.
55. Using a new O-ring seal, install the oil level indicator tube and the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 49: Oil Level Indicator Tube & Bolt
Courtesy of FORD MOTOR CO.
56. Install the oil level indicator and tube support bracket nut.
    • Tighten to 25 Nm (18 lb-ft).
Fig 50: Oil Level Indicator Tube Bracket Nut
Courtesy of FORD MOTOR CO.
57. Roughly position the engine control sensor wiring harness and mount it on the valve cover studs.
58. Connect the CKP sensor electrical connector.
Fig 51: Locating CKP Sensor Electrical Connector And Harness Retainer
Courtesy of FORD MOTOR CO.
59. Connect the engine oil pressure (EOP) switch electrical connector.
Fig 52: Locating Oil Pressure Switch Electrical Connector
Courtesy of FORD MOTOR CO.
60. Connect the KS electrical connector.
Fig 53: Knock Sensor (KS) Electrical Connector
Courtesy of FORD MOTOR CO.
61. Connect the RH radio frequency interference capacitor electrical connector.
Fig 54: Locating RH Radio Ignition Interference Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
62. Connect the CMP sensor electrical connector.
Fig 55: Locating Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
63. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.
Fig 56: Locating LH Radio Ignition Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
64. Install the cylinder block drain plugs.
    • Tighten to 20 Nm (15 lb-ft).
Fig 57: Locating Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
65. Position the RH engine support insulator and install the 3 bolts.
    • Tighten to 63 Nm (46 lb-ft).
66. Install the special tool.
Fig 58: Special Tool (303-D087)
Courtesy of FORD MOTOR CO.
67. Install the special tool.
Fig 59: Special Tool (303-D088)
Courtesy of FORD MOTOR CO.
68. Install the special tool and remove the engine from the work stand.
Fig 60: Installing Special Tool (303-D088) & Removing Engine From Work Stand
Courtesy of FORD MOTOR CO.
69. Lower the engine onto wooden blocks.
70. Install the special tool and raise the engine.
Fig 61: Identifying Special Tool (303-F047)
Courtesy of FORD MOTOR CO.
71. Install the flexplate and the 8 bolts. Tighten the bolts in 2 stages in the sequence shown.
    • Stage 1: Tighten to 20 Nm (15 lb-ft).
    • Stage 2: Tighten to 80 Nm (59 lb-ft).
Fig 62: Identifying Tightening Sequence For Flexplate Or Flywheel Bolts
Courtesy of FORD MOTOR CO.
72. Install the engine. For additional information, refer to Engine .