Removal
Cylinder Head - 5.4LSpecial Tool(s) (Part 1):
Special Tool(s) (Part 2):
Material:
Removal
All cylinder heads
1. Remove the engine.
2. CAUTION: To prevent damage to the oil pan, use care when lowering the engine.
Lower the engine onto wooden blocks.
3. Remove the special tool.
4. Install the special tool.
5. Install the special tool.
6. Mount the engine on a suitable work stand.
7. Remove the 3 bolts and the RH engine support insulator.
8. NOTE: LH shown, RH similar.
Remove the cylinder block drain plugs and drain the coolant in a suitable container.
9. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
10. Disconnect the camshaft position (CMP) sensor electrical connector.
11. Disconnect the RH radio frequency interference capacitor electrical connector.
12. Disconnect the knock sensor (KS) electrical connector.
13. Disconnect the crankshaft position (CKP) sensor electrical connector.
14. Disconnect the engine oil pressure (EOP) switch electrical connector.
15. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
16. NOTE: RH shown, LH similar.
Remove the 2 nuts and the 2 radio interference capacitors.
17. Disconnect the quick connect coupling and remove the crankcase ventilation tube from the LH valve cover. For additional information, refer to Fuel Delivery and Air Induction.
18. Remove the bolt and the oil level indicator tube.
^ Discard the O-ring seal.
19. 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.
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.
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 fasteners are part of the valve cover and should not be removed.
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.
21. Remove the bolt and the accessory drive belt idler pulley.
22. Remove the 4 bolts and the coolant pump pulley.
23. Remove the crankshaft pulley bolt and washer.
^ Discard the crankshaft pulley bolt.
24. Using the special tool, remove the crankshaft pulley.
25. Using the special tool, remove and discard the crankshaft front seal.
26. Remove the 3 bolts and the power steering pump.
27. Remove the 4 front oil pan bolts.
28. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
Remove the fasteners.
29. Remove the engine front cover from the cylinder block.
30. Remove the crankshaft sensor ring from the crankshaft.
31. CAUTION: Use care when removing the spark plugs.
NOTE: Use compressed air to remove any foreign material from the spark plug well before removing the spark plugs.
Remove the 8 spark plugs.
32. NOTE: Camshaft roller follower is shown removed for clarity.
Install the special tool between the valve spring coils to prevent valve stem seal damage.
33. NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.
NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.
Use the special tool to compress the valve springs and remove all of the camshaft roller followers.
34. Position the crankshaft with the keyway at the 12 o'clock position.
35. 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.
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.
36. Remove the timing chains and crankshaft sprocket.
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.
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.
39. Remove and discard the 8 exhaust manifold-to-cylinder head studs.
40. Clean and inspect the exhaust manifold.
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.
42. Remove and discard the 8 exhaust manifold-to-cylinder head studs.
43. Clean and inspect the exhaust manifold.
All cylinder heads
44. Install the special tools on both ends of the cylinder head.
45. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
Remove the hydraulic lash adjusters.
All cylinder heads
46. 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.
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: 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.
Remove the bolts and the cylinder head.
^ Discard the cylinder head gasket.
^ Discard the cylinder head bolts.
47. 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: 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.
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.
48. 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 within 0.005 mm (0.0002 inch) per running foot length. For example, if the straightedge is 61 cm (24 inch) long, the machine edge must be flat within 0.010 mm (0.0004 inch) from end to end.
NOTE: LH shown, RH similar.
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 inch) across a 38.1 mm (1.5 inch) square area, or scratches more than 0.0254 mm (0.001 inch).
