Part 1
Cylinder Head - 5.4L
Installation (Steps 1-36)
All cylinder heads
1. CAUTION: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore. Failure to follow these instructions may result in engine damage.
CAUTION: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry. 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.
NOTE: Do not turn the crankshaft until instructed to do so.
NOTE: LH shown, RH similar.
Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
2. NOTE: RH shown, LH similar.
Tighten the bolts in 3 stages, in the sequence shown.
^ Stage 1: Tighten to 40 Nm (30 lb-ft).
^ Stage 2: Tighten an additional 90 degrees.
^ Stage 3: Tighten an additional 90 degrees.
3. Remove the special tools from both ends of the cylinder head being serviced.
4. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
Install the hydraulic lash adjusters in their original locations.
RH cylinder head
5. Install 8 new exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
6. Install the RH exhaust manifold gasket and the exhaust manifold. Tighten the nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).
LH cylinder head
7. Install 8 new exhaust manifold studs.
^ Tighten to 12 Nm (9 lb-ft).
8. NOTE: Install a new exhaust manifold gasket.
Position the gaskets and the LH exhaust manifold and tighten the 8 nuts in the sequence shown.
^ Tighten to 25 Nm (18 lb-ft).
All cylinder heads
9. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTION: Prior to installation, inspect the tensioner sealing bead 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.
Using a vise, compress the tensioner plunger.
10. Install a retaining clip on the tensioner to hold the plunger in during installation.
11. Remove the tensioner from the vise.
12. If the copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
13. Install the timing chain guides.
1 Position the LH timing chain guide.
2 Install and tighten the LH bolts.
3 Position the RH timing chain guide.
4 Install and tighten the RH bolts.
^ Tighten to 10 Nm (89 lb-in).
14. Rotate the RH camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the LH camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
15. NOTE: The No. 1 cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
Position the crankshaft so the No. 1 cylinder is at TDC with the special tool.
16. Install the crankshaft sprocket, making sure the flange faces forward.
17. Position the lower end of the LH (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.
18. 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 2 copper (marked) chain links.
19. NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.
Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner.
^ Tighten to 25 Nm (18 lb-ft).
20. Remove the retaining clip from the LH timing chain tensioner.
21. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on the sprocket with the single copper (marked) chain link.
22. Install the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positioned between the 2 copper (marked) chain links.
23. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner.
^ Tighten to 25 Nm (18 lb-ft).
24. Remove the retaining clip from the RH timing chain tensioner.
25. As a post-check, verify correct alignment of all timing marks.
26. Install the crankshaft sensor ring on the crankshaft.
27. NOTE: Camshaft roller follower is removed for clarity.
Install the special tool between the valve spring coils to prevent valve stem seal damage.
28. CAUTION: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in engine damage.
NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.
NOTE: It may be necessary to push the valve down while compressing the spring.
NOTE: Position the cam lobe away from the valve stem prior to installing each camshaft roller follower.
Use the special tool to compress the valve springs, and install the camshaft roller follower.
29. NOTE: The camshaft roller followers must be installed in their original locations.
Repeat the previous 3 steps for each camshaft roller follower.
30. 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.
Install the 8 spark plugs.
^ Tighten to 18 Nm (13 lb-ft).
31. 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: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. 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.
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.
32. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight.
33. Tighten the engine front cover fasteners in sequence in 3 stages.
Stage 1: Tighten fasteners 1 through 5 to 25 Nm (18 lb-ft).
Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).
Stage 3: Tighten fasteners 8 through 15 to 48 Nm (35 lb-ft).
34. Loosely install the 4 front oil pan bolts, and tighten the bolts in 2 stages, in the sequence shown.
^ Stage 1: Tighten to 20 Nm (15 lb-ft).
^ Stage 2: Tighten an additional 60 degrees.
35. CAUTION: 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.
Inspect and clean the valve cover sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
36. Apply instant adhesive completely around the gasket groove in the LH valve cover. Install the new valve cover gasket.
