3/23/2020 Engine — 5.4L (2V) - Cylinder Heads .

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogicApplies to:Report a problem with this article5.4L (2V)SECTION 303-01A: Engine — 5.4L (2V) 2003 F-Super Duty 250-550/Excursion Workshop ManualINSTALLATIONProcedure revision date: 10/19/2002Cylinder HeadsSpecial Tool(s)Compressor, Valve Spring303-567 (T97P-6565-AH)Compressor Spacer, Valve Spring303-382 (T91P-6565-AH)Installer, Crankshaft Vibration Damper303-102 (T74P-6316-B)Installer, Crankshaft Front Oil Seal303-635Installer, Front Cover Oil Seal303-335 (T88T-6701-A)Holding Tool, Crankshaft303-448 (T93P-6303-A)Remover/Installer, Cylinder Head303-572 (T97T-6000-A)Lifting Bracket Set, Engine303-DS086 0-012a-061f-faf5cb6e7446?returnPath %2Fcar%2Ff1 1/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogicModular Engine Lift Bracket303-F047 (014-00073) or equivalentStrap Wrench303-D055 (D85L-6000-A)MaterialItemSpecificationMotorcraft Silicone Gasket RemoverZC-30—Motorcraft Metal Surface PrepZC-31—Silicone Gasket and SealantWSE-M4G323-A4F7AZ-19554-EA or equivalentInstant AdhesiveWSK-M2G402-A4E8AZ-19554-ASAE 5W-20 Premium Synthetic Blend Engine OilWSS-M2C153-HXO-5W20-QSP or equivalentMotorcraft Premium Engine CoolantVC-4-A (in Canada CXC-10; in Oregon VC-5) or equivalent. Do not mix coolant types.Motorcraft Premium Gold Engine CoolantVC-7-A (in Oregon VC-7-B) or equivalent. Do not mix coolant types.Hydraulic Chain Tensioner Retaining ClipESE-M97B44-A (green in color)WSS-M97B51-A1 (yellow in color)1L3Z-6P250-AAInstallationAll cylinder heads1. CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. Foradditional information, refer to Cylinder Heads in the Removal portion of this section.CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasketmust be installed dry.CAUTION: The new gasket has a film coating which is crucial to the gasket's ability to seal correctly. Do notscratch the gasket.NOTE: The RH head gasket is shown; the LH head gasket is a-061f-faf5cb6e7446?returnPath %2Fcar%2Ff1 2/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogicInstall the head gasket over the dowel pins.2. CAUTION: Cylinder head machining or milling is not authorized by the Ford Motor Company. Cylinder headflatness must be within 0.0254 mm (0.001 in) across a 38.1 mm (1.5 in) square area.CAUTION: The gasket sealing surfaces on the cylinder head and cylinder block must be clean. Foradditional information, refer to Cylinder Heads in the Removal portion of this section.CAUTION: The use of sealing aids (aviation cement, copper spray, and glue) is not permitted. The gasketmust be installed dry.CAUTION: Do not allow the dowels to scratch the sealing surface of the cylinder head during cylinder headinstallation.NOTE: The new cylinder head bolts must be lightly oiled with a rag, and allowed to drain for a few minutes prior toinstallation.NOTE: The RH cylinder head is shown; the LH cylinder head is similar.Install the cylinder head on the dowels and the head gasket. Loosely install new bolts.LH cylinder head3. NOTE: Make sure to tighten the bolts in sequence in three stages.Tighten the LH bolts 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 a-061f-faf5cb6e7446?returnPath %2Fcar%2Ff1 3/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogicRH cylinder head4. NOTE: Make sure to tighten the bolts in the following three stages.Tighten the RH bolts 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.All cylinder heads5. Remove the special tools from both ends of the cylinder 61f-faf5cb6e7446?returnPath %2Fcar%2Ff1 4/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogic6. NOTE: Lubricate the hydraulic lash adjusters with clean engine oil.Install the hydraulic lash adjusters in their original locations.RH cylinder head7. Install the RH exhaust manifold gaskets and the exhaust manifold. Tighten the nuts in the sequence shown.LH cylinder head8. NOTE: Lubricate the O-ring seal with clean engine oil.Install the oil level indicator tube.Install a new O-ring seal on the oil level indicator tube.Install the oil level indicator tube.Install the bolt.9. Install the LH exhaust manifold and the exhaust manifold gaskets. Tighten the nuts in the sequence 061f-faf5cb6e7446?returnPath %2Fcar%2Ff1 5/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogicAll cylinder heads10. CAUTION: Timing chain procedures must be followed exactly or damage to valves and pistons will result.Compress the tensioner plunger, using a vise.11. Install a retaining clip on the tensioner to hold the plunger in during installation.12. Remove the tensioner from the vise.13. 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.14. Install the timing chain -061f-faf5cb6e7446?returnPath %2Fcar%2Ff1 6/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogic15. Pre-position the camshafts.1. Rotate the LH camshaft until the timing mark is approximately at 12 o'clock.2. Rotate the RH camshaft until the timing mark is approximately at 11 o'clock.16. CAUTION: Rotate the crankshaft counterclockwise only. Do not rotate past position shown or severe pistonand valve damage can occur.NOTE: The number one piston is at top dead center (TDC) when the stud on the engine block fits into the slot in thehandle of the special tool.Position the crankshaft so the number one cylinder is at TDC with the special 61f-faf5cb6e7446?returnPath %2Fcar%2Ff1 7/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogic17. Remove the Crankshaft Holding Tool.18. Install the crankshaft sprocket, making sure the flange faces forward.19. Position the lower end of the LH (inner) timing chain on the crankshaft sprocket, aligning the timing mark on the outerflange of the crankshaft sprocket with the single copper (marked) link on the chain.20. 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 thetwo copper (marked) chain 061f-faf5cb6e7446?returnPath %2Fcar%2Ff1 8/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogic21. 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.22. Remove the retaining clip from the LH timing chain tensioner.23. Position the lower end of the RH (outer) timing chain on the crankshaft sprocket, aligning the timing mark on thesprocket with the single copper (marked) chain link.24. NOTE: The lower half of the timing chain must be positioned above the tensioner arm dowel.Position the RH timing chain on the camshaft sprocket. Make sure the camshaft sprocket timing mark is positionedbetween the two copper (marked) chain links.25. Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain 12a-061f-faf5cb6e7446?returnPath %2Fcar%2Ff1 9/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogic26. Remove the retaining clip from the RH timing chain tensioner.27. As a post-check, verify correct alignment of all timing marks.28. Install the special tool between the valve spring coils to prevent valve stem seal damage.29. NOTE: Lubricate the camshaft roller followers using clean engine oil.NOTE: Position the cam lobe away from the camshaft roller follower location prior to installing each camshaft rollerfollower.Install the camshaft roller followers.1. Install the special tool.2. Compress the valve spring.3. Install the camshaft roller followers in their original 12a-061f-faf5cb6e7446?returnPath %2Fcar%2Ff 10/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogic30. Remove the special tool.31. CAUTION: When installing the spark plugs, use care not to exceed the recommended torque.Install the eight spark plugs.Tighten the spark plugs to 18 Nm (13 lb-ft).32. Install the crankshaft sensor ring on the crankshaft.33. NOTE: If the front cover is not secured within four minutes, the sealant must be removed and the sealing areacleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on thepackaging. Failure to follow this procedure can cause future oil leakage.Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-tocylinder block surface, at the locations 061f-faf5cb6e7446?returnPath %2Fcar%2Ff 11/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogic34. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fastenersfinger-tight.35. Tighten the engine front cover fasteners in sequence in three 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 -061f-faf5cb6e7446?returnPath %2Fcar%2Ff 12/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogicItem Part Number Description1N806177Bolt, Hex Flange Head Pilot, M8 x 1.25 x 532N806177Bolt, Hex Flange Head Pilot, M8 x 1.25 x 533N806177Bolt, Hex Flange Head Pilot, M8 x 1.25 x 534N806177Bolt, Hex Flange Head Pilot, M8 x 1.25 x 535N806177Bolt, Hex Flange Head Pilot, M8 x 1.25 x 536N808529Stud, Hex Head Pilot, M10 x 1.5 x 59 — M10 x 1.5 x 307N808529Stud, Hex Head Pilot, M10 x 1.5 x 59 — M10 x 1.5 x 308N808142Screw and Washer, Hex Pilot, M10 x 1.5 x 57.59N808142Screw and Washer, Hex Pilot, M10 x 1.5 x 57.510N808142Screw and Washer, Hex Pilot, M10 x 1.5 x 57.511N808140Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 2712N808140Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 2713N808140Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 2714N808140Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 2715N808140Stud and Washer, Hex Head Pilot, M10 x 1.5 x 68 — M8 x 1.25 x 2736. Loosely install the bolts, then tighten the bolts in two stages, in the sequence shown.Stage 1: Tighten to 20 Nm (15 lb-ft).Stage 2: Tighten an additional 90 degrees.37. Position the belt idler pulley and install the 61f-faf5cb6e7446?returnPath %2Fcar%2Ff 13/22

3/23/2020Engine — 5.4L (2V) - Cylinder Heads - Installation 2003 Ford F-250 MotoLogic38. Lubricate the engine front cover and the front oil seal inner lip with clean engine oil.39. Use the special tools to install the crankshaft front oil seal into the engine front cover.40. NOTE: If not secured within four minutes, the sealant must be removed and the sealing area cleaned. To clean thesealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure tofollow this procedure can cause future oil leakage.Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.41. Use the special tool to install the crankshaft -061f-faf5cb6e7446?returnPath %2Fcar%2Ff 14/22