Engine - Disassembly

Engine - 5.4L (2V)













NOTICE: Remove the cylinder heads before removing the crankshaft. Failure to do so may result in engine damage.

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTE: The flexplate, the spacer plate, the crankshaft rear seal, the crankshaft rear oil slinger and the rear seal retainer plate must be removed before mounting the engine on the engine stand.

NOTE: For additional information, refer to the exploded view under the Assembly procedure.

1. Remove the engine. For additional information, refer to Engine Engine - Removal.

2. Remove the 8 bolts and the flexplate.

3. Using the Crankshaft Rear Oil Slinger Remover and the Slide Hammer, remove the crankshaft rear oil slinger.





4. Using the Crankshaft Rear Oil Seal Remover and the Slide Hammer, remove the crankshaft rear seal.





5. Remove the 2 rear oil pan bolts, the 6 crankshaft rear seal retainer plate bolts and the crankshaft rear seal retainer plate.





6. NOTICE: Use care when lowering the engine, to prevent damage to the oil pan.

Lower the engine onto wooden blocks.

7. Remove the Engine Lifting Bracket.





8. Install the Engine Lifting Bracket Set.





9. Install the Engine Lifting Bracket Set.





10. Mount the engine on a suitable work stand.

11. NOTE: RH shown, LH similar.

Remove the 6 bolts and the RH and LH engine support insulators.





12. NOTE: LH shown, RH similar.

If equipped, remove the cylinder block drain plugs and drain the coolant in a suitable container.





13. Disconnect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.





14. Disconnect the Camshaft Position (CMP) sensor electrical connector.





15. Disconnect the RH radio frequency interference capacitor electrical connector.





16. Disconnect the Knock Sensor (KS) electrical connector.





17. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and wiring harness retainer.





18. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.

19. NOTE: RH shown, LH similar.

Remove the 2 nuts and the 2 radio interference capacitors.





20. Remove the nut, bolt and the oil level indicator tube.
- Discard the O-ring seal.





21. NOTICE: 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.

Remove the LH and RH valve covers.
- Fully loosen the 28 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.





22. Remove the bolt and the CMP sensor.





23. Remove the bolt and the accessory drive belt idler pulley.





24. Remove the 4 bolts and the coolant pump pulley.





25. Remove the bolt and the Camshaft Position (CMP) sensor.





26. Remove the crankshaft pulley bolt and washer.
- Discard the crankshaft pulley bolt.

27. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.





28. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.





29. Remove the 4 front oil pan bolts.





30. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.

Remove the 15 fasteners.





31. Remove the engine front cover from the cylinder block.





32. Remove the crankshaft sensor ring from the crankshaft.





33. Remove the 8 spark plugs.

34. NOTICE: Camshaft roller follower is shown removed for clarity.

Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.





35. NOTICE: 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.

Use the Valve Spring Compressor to compress the valve springs and remove all of the camshaft roller followers.





36. Position the crankshaft with the keyway at the 12 o'clock position.





37. NOTICE: 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 or engine damage may occur.

Remove the timing chain tensioning system from both timing chains.

1. Remove the 4 bolts.

2. Remove the 2 timing chain tensioners.

3. Remove the 2 timing chain tensioner arms.





38. Remove the 2 timing chains and crankshaft sprocket.





39. Remove the timing chain guides.

1. Remove the 2 bolts.

2. Remove the LH timing chain guide.

3. Remove the 2 bolts.

4. Remove the RH timing chain guide.





40. Remove the RH exhaust manifold.

1. Remove and discard the 8 nuts.

2. Remove the RH exhaust manifold.

3. Remove and discard the 2 RH exhaust manifold gaskets.





41. Remove the LH exhaust manifold.

1. Remove and discard the 8 nuts.

2. Remove the LH exhaust manifold.

3. Remove and discard the 2 LH exhaust manifold gaskets.





42. Remove and discard the 16 exhaust manifold-to-cylinder head studs.

43. Clean and inspect the exhaust manifolds.

44. Install the Cylinder Head Remover/Installer 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 16 hydraulic lash adjusters.





46. NOTICE: 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.

NOTICE: 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.

NOTICE: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused. Failure to follow these instructions may result in engine damage.

NOTICE: 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.

NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. Failure to follow these instructions may result in engine damage.

NOTE: LH shown, RH similar.

Remove the 20 bolts and the cylinder head.
- Discard the cylinder head gasket.

- Discard the cylinder head bolts.





47. NOTICE: 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.

NOTICE: Observe all warnings or notices and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow these instructions may result in engine damage.

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 in the following sequence.

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: LH shown, RH similar.

Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area.





49. Remove the 5 fasteners, the oil filter adapter and discard the oil filter adapter gasket.





50. Clean the oil filter adapter gasket surface at the cylinder block.





51. Remove the 4 coolant pump bolts.
- Discard the O-ring seal.





52. Remove the coolant pump from the cylinder block.





53. 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.

54. Remove the 14 bolts, the oil pan and the oil pan gasket.
- Clean and inspect the sealing surfaces.





55. Remove the 3 bolts and the oil pump screen and pickup tube.





56. Remove the oil pump screen and pickup tube spacer.





57. Remove the 3 bolts and the oil pump.





58. NOTICE: 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.

Remove the 16 bolts and the 8 connecting rod caps.

- Rotate the crankshaft so that the connecting rod is at bottom dead center.

- Remove and discard the bolts.





59. NOTICE: Remove the piston and connecting rod assemblies carefully, or the cylinder walls or crankshaft journals may be damaged.

Use the Connecting Rod Installer to push the piston through the top of the cylinder block.





60. Disassemble the 8 pistons. For additional information, refer to Piston Piston - Disassembly and Assembly.

61. NOTICE: Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. Failure to do so can result in engine damage.

Remove the fasteners.

1. Remove and discard the 10 cross-mounted main cap bolts.

2. Remove the 10 dowels.

3. Remove and discard the 10 main bearing cap bolts.





62. Remove the 5 main bearing caps and the lower crankshaft main bearings.





63. Remove the crankshaft and the upper crankshaft main bearings from the cylinder block.