FixVault
Home › Ford › 2004 › Excursion 5.4 L, 4WD › Repair and Diagnosis › External Pages › Different car › Section 1848 (Engine - 4.6L And 5.4L) › Disassembly › Engine - 5.4L

Engine - 5.4L

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000262
 Compressor, Valve Spring 303-567 (T97P-6565-AH)
GF0000434
 Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)
GF0000351
 Installer, Connecting Rod 303-442 (T93P-6136-A)
GF0000339
 Lifting Bracket, Engine 303-F047 (014-00073) or equivalent
GF0011693
 Lifting Bracket Set, Engine 303-DS086 (D93P-6001-A)
GF0000344
 Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
GF0000317
 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
GF0000319
 Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
GF0000385
 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
GF0000345
 Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
GF0000218
 Slide Hammer 100-001 (T50T-100-A)
Material

Item Specification
Motorcraft Metal Surface Prep
ZC-31-A		 -
Silicone Gasket Remover
ZC-30		 -
CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
NOTE: For additional information, refer to the exploded views under engine ASSEMBLY .
NOTE: The flexplate, crankshaft rear seal, the rear oil seal slinger and the crankshaft rear seal retainer plate must be removed before mounting the engine on the engine stand.
  1. Remove the engine. For additional information, refer to Engine .
  2. Remove the 8 bolts and the flexplate.
  3. Using the special tools, remove and discard the crankshaft oil slinger.
    4. Fig 1: Removing Crankshaft Rear Oil Seal Slinger
    G03920149Courtesy of FORD MOTOR CO.
  4. Using the special tools, remove and discard the crankshaft rear seal.
    5. Fig 2: Removing Crankshaft Rear Seal
    G03920150Courtesy of FORD MOTOR CO.
  5. Remove the 2 rear oil pan bolts, the 6 crankshaft rear seal retainer plate bolts and the crankshaft rear seal retainer plate.
    6. Fig 3: Identifying Crankshaft Rear Seal Retainer Plate Bolts
    GF0000352Courtesy of FORD MOTOR CO.
    CAUTION: Use care when lowering the engine, to prevent damage to the oil pan.
  6. Lower the engine onto wooden blocks.
  7. Remove the special tool.
    8. Fig 4: Identifying Special Tool (303-F047)
    G03962845Courtesy of FORD MOTOR CO.
  8. Install the special tool.
    9. Fig 5: Special Tool (303-D087)
    G04612457Courtesy of FORD MOTOR CO.
  9. Install the special tool.
    10. Fig 6: Special Tool (303-D088)
    G04612458Courtesy of FORD MOTOR CO.
  10. Mount the engine on a suitable work stand.
    11. NOTE: RH shown, LH similar.
  11. Remove the 6 bolts and the RH and LH engine support insulators.
    12. Fig 7: RH Engine Support Insulator Bolts
    G04612459Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  12. Remove the cylinder block drain plugs and drain the coolant in a suitable container.
    13. Fig 8: Locating Cylinder Block Drain Plug
    G03885619Courtesy of FORD MOTOR CO.
  13. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    14. Fig 9: Locating LH Radio Ignition Interference Capacitor And Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    G03962635Courtesy of FORD MOTOR CO.
  14. Disconnect the camshaft position (CMP) sensor electrical connector.
    15. Fig 10: Locating Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  15. Disconnect the RH radio frequency interference capacitor electrical connector.
    16. Fig 11: Locating RH Radio Ignition Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  16. Disconnect the knock sensor (KS) electrical connector.
    17. Fig 12: Knock Sensor (KS) Electrical Connector
    G03886734Courtesy of FORD MOTOR CO.
  17. Disconnect the crankshaft position (CKP) sensor electrical connector.
    18. Fig 13: Identifying Crankshaft Position Sensor Electrical Connector
    G03888354Courtesy of FORD MOTOR CO.
  18. Disconnect the engine oil pressure (EOP) sensor electrical connector.
    19. Fig 14: Locating Oil Pressure Switch Electrical Connector
    G03886309Courtesy of FORD MOTOR CO.
  19. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
    20. NOTE: RH shown, LH similar.
  20. Remove the 2 nuts and the 2 radio interference capacitors.
    21. Fig 15: Radio Interference Capacitor And Retaining Nut
    G04612142Courtesy of FORD MOTOR CO.
  21. Remove the nut, bolt and the oil level indicator tube.
    • Discard the O-ring seal.
    22. Fig 16: Oil Level Indicator Tube & Bolt
    GF0011697Courtesy 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.
    NOTE: LH shown, RH similar.
  22. Remove the LH and RH valve covers.
    • Fully loosen the fasteners and remove the valve covers.
    • 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. Fig 17: Locating Valve Cover
    GF0002683Courtesy of FORD MOTOR CO.
  23. Remove the bolt and the accessory drive belt idler pulley.
    24. Fig 18: Accessory Drive Belt Idler Pulley And Retaining Bolt
    G04613548Courtesy of FORD MOTOR CO.
  24. Remove the 4 bolts and the coolant pump pulley.
    25. Fig 19: Identifying Coolant Pump Pulley Bolts
    G04612515Courtesy of FORD MOTOR CO.
  25. Using the special tool, remove the crankshaft pulley.
    26. Fig 20: Removing Crankshaft Pulley Using Special Tool
    G03919906Courtesy of FORD MOTOR CO.
  26. Using the special tool, remove and discard the crankshaft front seal.
    27. Fig 21: Removing Crankshaft Front Seal Using Special Tool
    G03919889Courtesy of FORD MOTOR CO.
  27. Remove the 3 bolts and the power steering pump.
    28. Fig 22: Power Steering Pump Bolts
    GF0011694Courtesy of FORD MOTOR CO.
  28. Remove the 4 front oil pan bolts.
    29. Fig 23: Front Oil Pan Bolts
    GF0000348Courtesy of FORD MOTOR CO.
    NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
  29. Remove the fasteners.
    30. Fig 24: Front Cover Bolts
    GF0011640Courtesy of FORD MOTOR CO.
  30. Remove the engine front cover from the cylinder block.
    31. Fig 25: Removing Engine Front Cover From Cylinder Block
    GF0000349Courtesy of FORD MOTOR CO.
  31. Remove the crankshaft sensor ring from the crankshaft.
    32. Fig 26: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    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.
  32. Remove the 8 spark plugs.
    33. NOTE: Camshaft roller follower is removed for clarity.
  33. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    34. Fig 27: Installing Special Tool Between Valve Spring Coils
    G03962476Courtesy 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.
  34. Use the special tool to compress the valve springs and remove all of the camshaft roller followers.
    35. Fig 28: Compressing Valve Springs Using Special Tool (303-567)
    G04612479Courtesy of FORD MOTOR CO.
  35. Position the crankshaft with the keyway at the 12 o'clock position.
    36. Fig 29: Crankshaft With Keyway At 12 O'clock Position
    GF0002691Courtesy 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.
  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. Fig 30: Identifying Timing Chain Tensioning System
    G03962450Courtesy of FORD MOTOR CO.
  37. Remove the timing chains and crankshaft sprocket.
    38. Fig 31: View Of Left And Right Timing Chains, Sprockets And Crankshaft Gear
    G03885313Courtesy of FORD MOTOR CO.
  38. 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.
    39. Fig 32: Identifying Timing Chain Guides
    G03962452Courtesy of FORD MOTOR CO.
  39. 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 gaskets.
    40. Fig 33: Exhaust Manifold, Nuts & Gasket
    GF0011695Courtesy of FORD MOTOR CO.
  40. Remove the LH exhaust manifold.
    1. Remove and discard the 8 nuts.
    2. Remove the LH exhaust manifold.
    3. Remove and discard the LH exhaust manifold gaskets.
    41. Fig 34: Exhaust Manifold, Nuts & Gasket
    GF0011699Courtesy of FORD MOTOR CO.
  41. Remove and discard the 16 exhaust manifold-to-cylinder head studs.
  42. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  43. Install the special tools on both ends of the cylinder head.
    44. Fig 35: Identifying Special Tool (303-572)
    G04671899Courtesy of FORD MOTOR CO.
    NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
  44. Remove the hydraulic lash adjusters.
    45. Fig 36: Locating Hydraulic Lash Adjusters
    GF0000287Courtesy of FORD MOTOR CO.
    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 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.
  45. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    46. Fig 37: Cylinder Head Bolts
    GF0022046Courtesy 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.
  46. 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.
    47. 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.
  47. 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).
    48. Fig 38: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
    G03885653Courtesy of FORD MOTOR CO.
  48. If required, remove the mounting hardware, the oil filter adapter and discard the oil filter adapter gasket.
    49. Fig 39: Locating Oil Filter Adapter Bolts
    G03885426Courtesy of FORD MOTOR CO.
  49. Clean the oil filter adapter gasket surface at the cylinder block.
    50. Fig 40: Cleaning Gasket Surfaces At Cylinder Block And Oil Filter Adapter
    GF0002694Courtesy of FORD MOTOR CO.
  50. Remove the 4 coolant pump bolts.
    • Discard the O-ring seal.
    51. Fig 41: Coolant Pump Bolts
    GF0000354Courtesy of FORD MOTOR CO.
  51. Remove the coolant pump from the cylinder block.
    52. Fig 42: Identifying Coolant Pump
    G03885759Courtesy of FORD MOTOR CO.
  52. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using an abrasive pad or equivalent following the manufacturer's instructions.
  53. Remove the bolts, the oil pan and the oil pan gasket.
    • Clean and inspect the sealing surfaces.
    54. Fig 43: Locating Oil Pan And Oil Pan Gasket Bolts
    GF0000321Courtesy of FORD MOTOR CO.
  54. Remove the 3 bolts and the oil pump screen and pickup tube.
    55. Fig 44: Oil Pump Screen And Pickup Tube & Bolts
    GF0011701Courtesy of FORD MOTOR CO.
  55. Remove the oil pump screen and pickup tube spacer.
    56. Fig 45: Oil Pump Screen And Pickup Tube Spacer
    GF0011702Courtesy of FORD MOTOR CO.
  56. Remove the 3 bolts and the oil pump.
    57. Fig 46: Locating Oil Pump Bolts
    G03962525Courtesy of FORD MOTOR CO.
    CAUTION: Make sure connecting rods and rod caps are numbered to keep them in the correct orientation. Failure to follow these instructions may result in engine damage.
  57. Remove the bolts and the connecting rod caps.
    • Rotate the crankshaft so that the connecting rod is at bottom dead center.
    • Remove and discard the bolts.
    58. Fig 47: Locating Connecting Rod Caps
    GF0000355Courtesy of FORD MOTOR CO.
    CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow these instructions may result in engine damage.
  58. Use the special tool to push the piston through the top of the cylinder block.
    59. Fig 48: Pushing Piston Through Top Of Cylinder Block
    G03920342Courtesy of FORD MOTOR CO.
  59. Disassemble the 8 pistons. For additional information, refer to Piston .
    60. CAUTION: Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. Failure to do so can result in engine damage.
  60. 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.
    61. Fig 49: Identifying Main Bearing Cap Bolts
    GF0002796Courtesy of FORD MOTOR CO.
  61. Remove the 5 main bearing caps and the lower crankshaft main bearings.
    62. Fig 50: Locating Main Bearing Caps, Lower Crankshaft Main Bearings And Lower Thrust Washer
    GF0000356Courtesy of FORD MOTOR CO.
  62. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.
    63. Fig 51: Removing Crankshaft, Upper Crankshaft Main Bearings And Upper Thrust Washers From Cylinder Block
    GF0000357Courtesy of FORD MOTOR CO.
About FixVault