Cylinder Head - 5.4L: Removal

All cylinder heads 

1. Remove the engine. For additional information, refer to Engine .
CAUTION: To prevent damage to the oil pan, use care when lowering the engine.
2. Lower the engine onto wooden blocks.
3. Remove the special tool.
Fig 1: Identifying Special Tool (303-F047)
Courtesy of FORD MOTOR CO.
4. Install the special tool.
Fig 2: Special Tool (303-D087)
Courtesy of FORD MOTOR CO.
5. Install the special tool.
Fig 3: Special Tool (303-D088)
Courtesy of FORD MOTOR CO.
6. Mount the engine on a suitable work stand.
7. Remove the 3 bolts and the RH engine support insulator.
Fig 4: RH Engine Support Insulator Bolts
Courtesy of FORD MOTOR CO.
NOTE: LH shown, RH similar.
8. Remove the cylinder block drain plugs and drain the coolant in a suitable container.
Fig 5: Locating Cylinder Block Drain Plug
Courtesy of FORD MOTOR CO.
9. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
Fig 6: Locating LH Radio Ignition Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
10. Disconnect the camshaft position (CMP) sensor electrical connector.
Fig 7: Locating Camshaft Position (CMP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
11. Disconnect the RH radio frequency interference capacitor electrical connector.
Fig 8: Locating RH Radio Ignition Interference Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
12. Disconnect the knock sensor (KS) electrical connector.
Fig 9: Knock Sensor (KS) Electrical Connector
Courtesy of FORD MOTOR CO.
13. Disconnect the crankshaft position (CKP) sensor electrical connector.
Fig 10: A/C Compressor Electrical Connector
Courtesy of FORD MOTOR CO.
14. Disconnect the engine oil pressure (EOP) switch electrical connector.
Fig 11: Locating Oil Pressure Switch Electrical Connector
Courtesy of FORD MOTOR CO.
15. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
NOTE: RH shown, LH similar.
16. Remove the 2 nuts and the 2 radio interference capacitors.
Fig 12: Radio Interference Capacitor And Retaining Nut
Courtesy of FORD MOTOR CO.
17. Disconnect the quick connect coupling and remove the crankcase ventilation tube from the LH valve cover. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
Fig 13: Crankcase Ventilation Tube Quick Connect Coupling
Courtesy of FORD MOTOR CO.
18. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
Fig 14: Oil Level Indicator Tube & Bolt
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 fasteners are part of the valve cover and should not be removed.
19. Remove the LH valve cover.
    • Fully loosen the fasteners 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 15: Locating 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 fasteners are part of the valve cover and should not be removed.
20. Remove the RH valve cover.
    • Fully loosen the fasteners 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 16: Valve Cover
Courtesy of FORD MOTOR CO.
21. Remove the bolt and the accessory drive belt idler pulley.
Fig 17: Accessory Drive Belt Idler Pulley And Retaining Bolt
Courtesy of FORD MOTOR CO.
22. Remove the 4 bolts and the coolant pump pulley.
Fig 18: Identifying Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
23. Remove the crankshaft pulley bolt and washer.
    • Discard the crankshaft pulley bolt.
24. Using the special tool, remove the crankshaft pulley.
Fig 19: Removing Crankshaft Pulley Using Special Tool
Courtesy of FORD MOTOR CO.
25. Using the special tool, remove and discard the crankshaft front seal.
Fig 20: Removing Crankshaft Front Seal Using Special Tool
Courtesy of FORD MOTOR CO.
26. Remove the 3 bolts and the power steering pump.
Fig 21: Power Steering Pump Bolts
Courtesy of FORD MOTOR CO.
27. Remove the 4 front oil pan bolts.
Fig 22: Front Oil Pan Bolts
Courtesy of FORD MOTOR CO.
NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
28. Remove the fasteners.
Fig 23: Front Cover Bolts
Courtesy of FORD MOTOR CO.
29. Remove the engine front cover from the cylinder block.
Fig 24: Removing Engine Front Cover From Cylinder Block
Courtesy of FORD MOTOR CO.
30. Remove the crankshaft sensor ring from the crankshaft.
Fig 25: View Of Crankshaft Sensor Ring At Crankshaft
Courtesy of FORD MOTOR CO.
31. Remove the 8 spark plugs. For additional information, refer to ENGINE IGNITION - 4.6L (2V) AND 5.4L (2V) article.
CAUTION: Camshaft roller follower is shown removed for clarity.
32. 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.
CAUTION: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations. Failure to follow these instructions may result in engine damage.
NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.
33. Use the special tool to compress the valve springs and remove all of the camshaft roller followers.
Fig 27: Compressing Valve Springs Using Special Tool (303-567)
Courtesy of FORD MOTOR CO.
34. Position the crankshaft with the keyway at the 12 o'clock position.
Fig 28: Crankshaft With Keyway At 12 O'clock 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. Failure to follow these instructions may result in engine damage.
35. 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 29: Identifying Timing Chain Tensioning System
Courtesy of FORD MOTOR CO.
36. Remove the timing chains and crankshaft sprocket.
Fig 30: View Of Left And Right Timing Chains, Sprockets And Crankshaft Gear
Courtesy of FORD MOTOR CO.
37. Remove the timing chain guides.
    1. Remove the bolts.
    2. Remove the LH timing chain guide.
    3. Remove the bolts.
    4. Remove the RH timing chain guide.
Fig 31: Identifying Timing Chain Guides
Courtesy of FORD MOTOR CO.

RH cylinder head 

38. Remove the RH exhaust manifold.
    1. Remove and discard the 8 nuts.
    2. Remove the RH exhaust manifold.
    3. Remove and discard the RH exhaust manifold gasket.
Fig 32: Exhaust Manifold, Nuts & Gasket
Courtesy of FORD MOTOR CO.
39. Remove and discard the 8 exhaust manifold-to-cylinder head studs.
40. Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.

LH cylinder head 

41. Remove the LH exhaust manifold.
    1. Remove and discard the nuts.
    2. Remove the LH exhaust manifold.
    3. Remove and discard the LH exhaust manifold gasket.
Fig 33: Exhaust Manifold, Nuts & Gasket
Courtesy of FORD MOTOR CO.
42. Remove and discard the 8 exhaust manifold-to-cylinder head studs.
43. Clean and inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.

All cylinder heads 

44. Install the special tools on both ends of the cylinder head.
Fig 34: Identifying Special Tool (303-572)
Courtesy of FORD MOTOR CO.
CAUTION: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations. Failure to follow these instructions may result in engine damage.
45. Remove the hydraulic lash adjusters.
Fig 35: Locating Hydraulic Lash Adjusters
Courtesy of FORD MOTOR CO.

All cylinder heads 

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. Failure to follow these instructions may result in engine damage.
CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused. Failure to follow these instructions may result in engine damage.
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.
NOTE: LH shown, RH similar.
46. Remove the bolts and the cylinder heads.
    • Discard the cylinder head gaskets.
    • Discard the cylinder head bolts.
Fig 36: Cylinder Head Bolts
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 that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
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.
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, such as Snap-On® GA438A or equivalent. 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 shown, RH similar.
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).
Fig 37: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
Courtesy of FORD MOTOR CO.