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Home › Ford › 2003 › Excursion 5.4 L, 4WD › Repair and Diagnosis › Engine Mechanical › Mechanical › Engine - 5.4L 2V › Disassembly › Engine › Disassembly

Engine - 5.4L 2V: Disassembly: Engine: Disassembly

NOTE: The crankshaft rear oil seal, the oil seal slinger and the oil seal retainer plate must be removed before mounting the engine on the engine stand.
  1. Remove the bolts and the flexplate.
    Fig 1: Removing Bolts And Flexplate
    G01548645Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove the crankshaft rear oil slinger.
    Fig 2: Removing Crankshaft Rear Oil Slinger Using Special Tool
    G01548646Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the crankshaft rear oil seal.
    Fig 3: Removing Crankshaft Rear Oil Seal Using Special Tool
    G01548647Courtesy of FORD MOTOR CO.
  4. Remove the bolts, oil pan and oil pan gasket.
    • Clean and inspect the sealing surfaces.
    Fig 4: Removing Bolts, Oil Pan And Oil Pan Gasket
    G01548648Courtesy of FORD MOTOR CO.
  5. Remove the bolts and the crankshaft rear oil seal retainer plate.
    • Clean and inspect the sealing surfaces.
    Fig 5: Removing Bolts And Crankshaft Rear Oil Seal Retainer Plate
    G01548649Courtesy of FORD MOTOR CO.
    6. CAUTION: Use care when lowering the engine, to prevent damage to the oil pump screen and pickup tube.
  6. Lower the engine onto wooden blocks.
  7. Remove the special tool.
    Fig 6: Removing Special Tool
    G01548650Courtesy of FORD MOTOR CO.
  8. Install the special tool.
    Fig 7: Installing Special Tool (1 Of 2)
    G01548651Courtesy of FORD MOTOR CO.
  9. Install the special tool.
    Fig 8: Installing Special Tool (2 Of 2)
    G01548652Courtesy of FORD MOTOR CO.
  10. Mount the engine on a suitable work stand.
  11. Remove the special tool.
    Fig 9: Removing Special Tool (1 Of 2)
    G01548653Courtesy of FORD MOTOR CO.
  12. Remove the special tool.
    Fig 10: Removing Special Tool (2 Of 2)
    G01548654Courtesy of FORD MOTOR CO.
  13. With the engine on the engine stand, remove the engine control sensor wiring harness.
    14. NOTE: RH shown, LH similar.
    Fig 11: Removing Nuts And Two Radio Interference Capacitors
    G01548655Courtesy of FORD MOTOR CO.
  14. Remove the nuts and the two radio interference capacitors.
  15. Remove the bolts and the oil pump screen and pickup tube.
    Fig 12: Removing Bolts And Oil Pump Screen And Pickup Tube
    G01548656Courtesy of FORD MOTOR CO.
  16. Remove the oil pump screen and pickup tube spacer.
    Fig 13: Removing Oil Pump Screen
    G01548657Courtesy of FORD MOTOR CO.
  17. Remove the crankcase ventilation tube from the LH valve cover.
    Fig 14: Removing Crankcase Ventilation Tube From LH Valve Cover
    G01548658Courtesy of FORD MOTOR CO.
    18. 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 15: Removing LH Valve Cover
    G01548659Courtesy of FORD MOTOR CO.
  18. 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.
  19. Remove the positive crankcase ventilation (PCV) valve and hose from the RH valve cover.
    Fig 16: Removing Positive Crankcase Ventilation (PCV) Valve And Hose From RH Valve Cover
    G01548660Courtesy of FORD MOTOR CO.
    20. 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.
    NOTE: Windsor engine shown; Romeo engine similar.
    Fig 17: Removing RH Valve Cover
    G01548661Courtesy of FORD MOTOR CO.
  20. 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.
  21. Remove the bolt and the belt idler pulley.
    Fig 18: Removing Bolt And Belt Idler Pulley
    G01548662Courtesy of FORD MOTOR CO.
  22. Remove the coolant pump pulley.
    1. Remove the bolts.
    2. Remove the coolant pump pulley.
    Fig 19: Removing Coolant Pump Pulley
    G01548663Courtesy of FORD MOTOR CO.
  23. Remove the bolts.
    Fig 20: Removing Bolts
    G01548664Courtesy of FORD MOTOR CO.
  24. Remove the coolant pump from the cylinder block.
    Fig 21: Removing Coolant Pump From Cylinder Block
    G01548665Courtesy of FORD MOTOR CO.
  25. Remove and discard the crankshaft pulley bolt.

    Use the special tool to remove the crankshaft pulley.

    Fig 22: Removing Crankshaft Pulley Using Special Tool
    G01548666Courtesy of FORD MOTOR CO.
  26. Use the special tool to remove the crankshaft front oil seal.
    Fig 23: Removing Crankshaft Front Oil Seal Using Special Tool
    G01548667Courtesy of FORD MOTOR CO.
    27. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 24: Removing Fasteners
    G01548668Courtesy of FORD MOTOR CO.
  27. Remove the fasteners.
  28. Remove the engine front cover from the cylinder block.
    Fig 25: Removing Engine Front Cover From Cylinder Block
    G01548669Courtesy of FORD MOTOR CO.
  29. Remove the crankshaft sensor ring from the crankshaft.
    Fig 26: Removing Crankshaft Sensor Ring From Crankshaft
    G01548670Courtesy of FORD MOTOR CO.
  30. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 27: Installing Special Tool Between Valve Spring Coils
    G01548671Courtesy of FORD MOTOR CO.
    31. NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.
    Fig 28: Compressing Valve Springs Using Special Tool
    G01548672Courtesy of FORD MOTOR CO.
  31. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
  32. Remove the special tool.
    Fig 29: Removing Special Tool
    G01548673Courtesy of FORD MOTOR CO.
  33. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 30: Positioning Crankshaft With Keyway At 12 O'Clock Position
    G01548674Courtesy of FORD MOTOR CO.
  34. 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 31: Removing Timing Chain Tensioning System From Both Timing Chains
    G01548675Courtesy of FORD MOTOR CO.
  35. Remove the RH and LH timing chains and the crankshaft sprocket.
    • 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.
    Fig 32: Removing RH And LH Timing Chains And Crankshaft Sprocket
    G01548676Courtesy of FORD MOTOR CO.
  36. Remove both timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
    Fig 33: Removing Both Timing Chain Guides
    G01548677Courtesy of FORD MOTOR CO.
  37. 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
    G01548678Courtesy of FORD MOTOR CO.
  38. 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
    G01548679Courtesy of FORD MOTOR CO.
  39. Clean and inspect the exhaust manifolds. Refer to ENGINE SYSTEM - GENERAL INFORMATION .
  40. Remove the bolt and the oil level indicator tube.
    Fig 36: Removing Bolt And Oil Level Indicator Tube
    G01548680Courtesy of FORD MOTOR CO.
  41. Install the special tools on both ends of the cylinder head.
    Fig 37: Installing Special Tools On Both Ends Of Cylinder Head
    G01548681Courtesy of FORD MOTOR CO.
    42. CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
    CAUTION: Place cylinder head on a cardboard or wood surface to prevent damage to the joint face.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: The cylinder heads are cleaned as part of the cylinder head disassembly process.
    Fig 38: Removing Cylinder Heads Bolts
    G01548682Courtesy of FORD MOTOR CO.
  42. Remove the bolts and discard.
    • RH is shown; LH is similar.
    • Remove the cylinder heads.
    43. 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 scraper to remove all traces of the head gasket.
  43. Discard the cylinder head gaskets. Clean the engine block sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  44. If required, remove the bolts, and remove the LH engine mount.
    Fig 39: Removing Bolts, And Removing LH Engine Mount
    G01548683Courtesy of FORD MOTOR CO.
  45. If required, remove the bolts, and remove the RH engine mount.
    Fig 40: Removing Bolts, And Removing RH Engine Mount
    G01548684Courtesy of FORD MOTOR CO.
  46. If required, remove the nut and four bolts retaining the oil filter adapter and oil filter adapter gasket to the cylinder block.
    Fig 41: Removing Nut And Bolts Retaining
    G01548685Courtesy of FORD MOTOR CO.
  47. Clean the oil filter adapter gasket surface at the cylinder block.
    Fig 42: Cleaning Oil Filter Adapter Gasket Surface At Cylinder Block
    G01548686Courtesy of FORD MOTOR CO.
  48. Remove the oil pump.
    1. Remove the bolts.
    2. Remove the oil pump.
    Fig 43: Removing Oil Pump
    G01548687Courtesy of FORD MOTOR CO.
  49. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer, following the manufacturer's instructions.
    Fig 44: Removing Ridge Or Carbon Deposits From Cylinder Using Cylinder Ridge Reamer
    G01548688Courtesy of FORD MOTOR CO.
    50. 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 45: Removing Bolts And Connecting Rod Caps
    G01548689Courtesy of FORD MOTOR CO.
  50. Remove the bolts and the connecting rod caps. Discard the bolts.
    51. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 46: Pushing Piston Through Top Of Cylinder Block Using Special Tool
    G01548690Courtesy of FORD MOTOR CO.
  51. Use the special tool to push the piston through the top of the cylinder block.
  52. 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 47: Removing And Discarding Cross-Mounted Main Cap Bolts
    G01548691Courtesy of FORD MOTOR CO.
  53. Remove the five main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
    Fig 48: Removing Main Bearing Caps, Lower Crankshaft Main Bearings And Lower Thrust Washer
    G01548692Courtesy of FORD MOTOR CO.
  54. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
    Fig 49: Identifying Special Tool
    G01548693Courtesy of FORD MOTOR CO.
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