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Cylinder Head Replacing Procedure for 5.4L engine?


The procedure is similar for both ford and Lincoln car models:-----

Cylinder Head
REMOVAL & INSTALLATION

F150 1/2 ton P/U 2WD/ 4WD
F250 Super Duty P/U 2WD/4WD
F350 Super Duty P/U 2WD/4WD
F450 Super Duty P/U 2WD/4WD
F550 Super Duty P/U 2WD/4WD
AND Lincoln Mark LT Models

5.4L Engine

Before servicing the vehicle, refer to the Precautions Section.
Remove the engine.
Remove the bolts and the flexplate or the flywheel.
Install the engine onto a suitable engine stand.
Remove the special tool.


 image
Fig. Special tools needed for this procedure. These tools are referred to in the following procedure 

Left cylinder head
  1. Remove the left exhaust manifold.
  2. Remove the bolt and the oil level indicator tube.
  3. Remove the engine wiring harness retainers from the left valve cover studs.  
    WARNING
    When removing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.
  4. Remove the bolts and the left valve cover.
Right cylinder head
  1. Remove the right exhaust manifold.
  2. Remove the nuts.
  3. Remove the right exhaust manifold.
  4. Remove and discard the right exhaust manifold gasket.
  5. Remove the engine wiring harness retainers from the right valve cover studs.
    WARNING
    When removing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.
  6. Remove the bolts and the right valve cover.
  7. Remove the stud.
All cylinder heads
  1. Remove the bolts, the coolant pump pulley and the accessory drive belt idler pulleys.
  2. Remove the bolt and washer and using a puller set, remove the crankshaft pulley. Discard the crankshaft bolt.
  3. Using a suitable tool, remove the crankshaft seal.
  4. Remove the bolts and the accessory drive belt tensioner.
  5. Disconnect the left and right radio ignition interference capacitor electrical connectors.
  6. Remove the nuts and the two radio interference capacitors.
  7. Disconnect the camshaft position (CMP) sensor electrical connectors.
  8. Remove the bolt and the right CMP sensor.
  9. Remove the bolt and the left CMP sensor.
  10. Disconnect the crankshaft position (CKP) sensor electrical connector.
  11. Remove the oil pan front bolts.
  12. Remove the bolts.  
    WARNING
    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.
  13. Remove the engine front cover from the front cover-to-cylinder block dowels.
  14. Remove the engine front cover gaskets.
  15. Clean the mating surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  16. Inspect the mating surfaces.
    WARNING
    Do not allow the valve keepers to fall off of the valve or the valve can drop into the cylinder.


    NOTE
    It may be necessary to push the valve down while compressing the valve spring.


    NOTE
    The roller followers must be installed in their original positions.
  17. Using a suitable tool, remove all of the roller followers. Record the roller follower positions.
  18. Position the crankshaft keyway at the 12 o'clock position.
  19. Remove the bolts, the left timing chain tensioner and tensioner arm.
  20. Remove the bolts, the right timing chain tensioner and tensioner arm.
  21. Remove the ignition pulse wheel from the crankshaft.
  22. Remove the right timing chain from the camshaft sprocket.
  23. Remove the right timing chain from the crankshaft sprocket.
  24. Remove the left timing chain from the camshaft sprocket.
  25. Remove the left timing chain and crankshaft sprocket.
  26. Remove both timing chain guides.  
    WARNING
    Use only hand tools to remove the camshaft phaser sprocket assembly or damage can occur to the camshaft or camshaft phaser sprocket.
  27. If disassembly of the cylinder head is required, using a suitable tool, loosen the camshaft phaser sprocket bolt.
  28. Install a suitable tool onto the left cylinder head. Install a suitable tool onto the right cylinder head.  
    WARNING
    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.  


    WARNING
    Do not use the variable camshaft timing (VCT) phaser sprocket as a lifting point or leveraging device when removing the cylinder head or damage to the VCT phaser sprocket can occur.  


    WARNING
    Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine.  


    WARNING
    The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.  


    WARNING
    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.  


    WARNING
    Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
  29. Remove the bolts and the cylinder head. Discard the cylinder head gasket. Discard the cylinder head bolts.  
    WARNING
    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.  


    WARNING
    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.
  30. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
  31. Remove any large deposits of silicone or gasket material with a plastic scraper.
  32. Apply silicone gasket remover, following package directions, and allow to set for several minutes.
  33. 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.
  34. 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 and engine block surfaces are clear of any gasket material, RTV, oil and coolant. The cylinder head and engine block surfaces must be clean and dry before running a flatness check.


    NOTE
    Use a straightedge that is calibrated by the manufacturer to be flat within 0.005 mm (0.0002 in.) per running foot of length. For example, if the straightedge is 61 cm (24 in.) long, the machined edge must be flat with 0.010 mm (0.0004 in.) from end to end.
  35. 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.).
To install:
All cylinder heads  

WARNING
Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore.  


WARNING
The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasket must be installed dry.  


WARNING
The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.  


WARNING
Do not allow the cylinder head alignment pins to contact the cylinder head gasket or cylinder head sealing surfaces or damage can occur to the cylinder head or cylinder head gasket.


NOTE
Do not turn the crankshaft until instructed to do so.

  1. Using the cylinder head alignment pins, position the cylinder head gasket and cylinder head onto the dowels and install the cylinder head bolts loosely.
  2. Tighten the bolts in the sequence shown.
    1. Stage 1: Tighten to 40 Nm (30 ft. lbs.).
    2. Stage 2: Tighten an additional 90 degrees.
    3. Stage 3: Tighten an additional 90 degrees.

      Click image to see an enlarged view
      Fig. Left cylinder head torque sequence-5.4L engine (RH cylinder head similar)
  3. Remove the cylinder head lifting handle tools.
  4. Remove the special tool from the cylinder head.
  5. Install the hydraulic lash adjusters into the cylinder head. Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
  6. Position a new gasket and the exhaust manifold and tighten the 8 nuts in the sequence shown. Tighten to 18 ft. lbs. (25 Nm).
  7. Install the exhaust manifold shield and the 2 nuts. Tighten to 89 inch lbs. (10 Nm).
  8. Position the crankshaft with the special tool, then remove the tool.

    Click image to see an enlarged view
    Fig. Position the crankshaft with the special tool, then remove the tool
  9. Install the LH and RH camshafts. Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
  10. Install the LH and RH camshaft bearing caps in their original locations.
    1. Lubricate the camshaft bearing caps with clean engine oil.
    2. Position the front camshaft bearing cap.
    3. Position the remaining camshaft bearing caps.
    4. Install the bolts loosely.
    5. Tighten to 89 inch lbs. (10 Nm) in the sequence shown.
      CAUTION
      Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.



      Click image to see an enlarged view
      Fig. Install the camshafts and tighten the bearing caps in the sequence shown
  11. Install the VCT phaser sprockets and new VCT phaser sprocket bolts finger tight.
    CAUTION
    Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.



    Click image to see an enlarged view
    Fig. Install the VCT phaser sprockets and new VCT phaser sprocket bolts finger tight
  12. Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages:
    1. Stage 1: Tighten to 30 ft. lbs. (40 Nm).
    2. Stage 2: Tighten an additional 90 degrees.
      WARNING
      Timing chain procedures must be followed exactly or damage to valves and pistons will result.



      Click image to see an enlarged view
      Fig. Using the special tool, tighten the LH and RH VCT phaser sprocket bolts in 2 stages
  13. Compress the tensioner plunger, using a vice.

    Click image to see an enlarged view
    Fig. Plunger held by a retaining clip
  14. Install a retaining clip on the tensioner to hold the plunger in during installation.
  15. Remove the tensioner from the vise. If the copper links are not visible, mark two links on one end and one link on the other end, and use as timing marks.
    WARNING
    Crankshaft keyway must be in the 12 o'clock position.



    Click image to see an enlarged view
    Fig. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks
  16. Install the timing chain guides.

    Click image to see an enlarged view
    Fig. Install the crankshaft sprocket, making sure the flange faces forward
  17. Position the left timing chain guide.

    Click image to see an enlarged view
    Fig. Timing chain guide installation
  18. Install the crankshaft sprocket, making sure the flange faces forward.
    WARNING
    Only use hand tools to install the camshaft phaser sprocket assembly or damage may occur to the camshaft or camshaft phaser unit.


    NOTE
    This step is only required if cylinder head was disassembled.
  19. Using a suitable tool, tighten the bolts in two stages:
    1. Stage 1: Tighten to 40 Nm (30 ft. lbs.).
    2. Stage 2: Tighten an additional 90 degrees.
  20. Remove the special tool.

    Click image to see an enlarged view
    Fig. Camshaft phaser sprocket holding tool-5.4L engine
  21. Position the lower end of the left (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.
    NOTE
    Make sure the upper half of the timing chain is below the tensioner arm dowel. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links.


    NOTE
    The left timing chain tensioner arm has a bump near the dowel hole for identification.



    Click image to see an enlarged view
    Fig. Position the lower end of the left (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-5.4L engine


    Click image to see an enlarged view
    Fig. Position the timing chain on the camshaft sprocket with the camshaft sprocket timing mark positioned between the two copper (marked) chain links-5.4L engine
  22. Position the left timing chain tensioner arm on the dowel pin and install the left timing chain tensioner.
  23. Remove the retaining clip from the left timing chain tensioner.
  24. Position the lower end of the right (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
    NOTE
    The lower half of the timing chain must be positioned above the tensioner arm dowel.



    Click image to see an enlarged view
    Fig. Position the lower end of the right (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link
  25. Position the right timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links.

    Click image to see an enlarged view
    Fig. Position the right timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the two copper (marked) chain links
  26. Position the right timing chain tensioner arm on the dowel pin and install the right timing chain tensioner.
  27. Remove the retaining clip from the right timing chain tensioner.
    NOTE
    Both camshaft phaser sprockets are identical. Refer to the R timing mark to identify the right camshaft phaser sprocket and the L timing mark to identify the left camshaft phaser sprocket.
  28. As a post-check, verify correct alignment of all timing marks. Make sure the R and L timing marks on the sprockets correspond to the above note.
  29. Install the crankshaft sensor ring on the crankshaft.
    NOTE
    Lubricate the camshaft roller followers using clean engine oil.


    NOTE
    Using the mark on each camshaft roller follower, make sure it is returned to its original position.
  30. Using a suitable tool, install all of the camshaft roller followers.
    WARNING
    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 four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. 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.

    Click image to see an enlarged view
    Fig. 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-5.4L engine
  32. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.

    Click image to see an enlarged view
    Fig. Front cover fastener tightening sequence
  33. Tighten the engine front cover fasteners in sequence in two stages.
    1. Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 ft. lbs.).
    2. Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 ft. lbs.).
    3. Loosely install the pan-to-case bolts, then tighten the bolts in two stages, in the sequence shown.
    4. Stage 1: Tighten to 20 Nm (15 ft. lbs.).
    5. Stage 2: Tighten an additional 60 degrees.

      Click image to see an enlarged view
      Fig. Loosely install the pan-to-case bolts, then tighten the bolts in two stages, in the sequence shown
  34. Install the left camshaft position (CMP) sensor and the bolt.
  35. Lubricate the new O-ring seal with clean engine oil prior to installation.
  36. Install the right CMP sensor and the bolt.
  37. Lubricate the new O-ring seal with clean engine oil prior to installation.
  38. Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
  39. Use the special tools to install the crankshaft seal into the engine front cover.

    Click image to see an enlarged view
    Fig. Crankshaft seal installation tools
  40. If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
  41. Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley. Use a suitable tool to install the crankshaft pulley.
  42. Tighten the new crankshaft pulley bolt in four stages.
    1. Stage 1: Tighten to 90 Nm (66 ft. lbs.).
    2. Stage 2: Loosen 360 degrees.
    3. Stage 3: Tighten to 50 Nm (37 ft. lbs.).
    4. Stage 4: Tighten an additional 90 degrees.
  43. Install the three accessory drive belt idler pulleys, the coolant pump pulley and the bolts. Torque all bolts to 18 ft. lbs. (25 Nm).
  44. Position the accessory drive belt tensioner and install the bolts. Torque all bolts to 18 ft. lbs. (25 Nm).
  45. Install the radio frequency interference capacitors.
Left cylinder head  

WARNING
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. Use a plastic scraping tool to remove all traces of old sealant. Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.


NOTE
If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

  1. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
    WARNING
    When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.



    Click image to see an enlarged view
    Fig. Left valve cover torque sequence-5.4L engine
  2. Position the left valve cover and gasket on the cylinder head and install the bolts loosely. Tighten the bolts in the sequence shown.
    NOTE
    Lubricate the O-ring seal with clean engine oil.
  3. Install the oil level indicator tube.
  4. Install a new O-ring seal on the oil level indicator tube.
  5. Install the oil level indicator tube.
  6. Install the bolt.
Right cylinder head  

WARNING
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. Use a plastic scraping tool to remove all traces of old sealant. Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.


NOTE
If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.

  1. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
    WARNING
    When installing the valve cover, make sure to avoid damaging the variable camshaft timing (VCT) solenoid.



    Click image to see an enlarged view
    Fig. Right valve cover torque sequence-5.4L engine
  2. Position the right valve cover and gasket on the cylinder head and install the bolts loosely. Tighten the bolts in the sequence shown.
  3. Install the heater outlet tube stud.
All cylinder heads
  1. Position the electrical harness on the valve cover and connect the engine wiring harness retainers to the valve cover studs.
  2. Connect the right radio ignition interference capacitor electrical connector.
  3. Connect the left radio ignition interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
  4. Connect the CMP sensor electrical connectors.
  5. Connect the CKP sensor electrical connector.
  6. Install a suitable tool.
  7. Using a suitable floor crane remove the engine from the engine stand.
  8. Install the flexplate or the flywheel and bolts. Tighten the bolts in the sequence shown.

    Click image to see an enlarged view
    Fig. Flywheel torque sequence-5.4L engine
  9. Install the engine.


These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html

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