I finished changing the spark plugs in my 2002 E350, 5.4L today.

I offer the following information for anyone anticipating performing this operation, although I can't vouch that it would be the same for other year models.

Parts I bought:
1) Coil on Plug Connectors (plug boots) - Eight (8), Part#SPP39
2) Motorcraft spark plugs - Eight (8) - Part#SP-479 (AGSF22WM)
3) Dielectric grease
4) Antiseize compound
5) magnetic pen (extendable)

Tools I used:
1) Flourescent Work light
2) Two small 3/8" extensions
3) Two large 3/8" extensions
4) 3/8" ratchet
5) 1/2" ratchet
6) 1/2" extension
7) 3/8"-1/2" adaptor

I first removed the dog house inside the van, the air filter housing under the hood and then removed the positive and negative leads at the battery terminals.

I then started with the 1st spark plug on the right side as you look into the engine with the dog house off. I removed the connector near the COP to access the COP and then removed the COP connector. I then unbolted the COP and removed the COP.

I then replaced the COP boot and then removed the spark plug. I had already gapped the spark plugs the day before so all I had to do was add anti-seize to the spark plug threads before installing the new spark plug.

I repeated this for each spark plug.

Looking at the engine with the dog cage off: the 2 ^nd spark plug on the left I needed to loosen the fuel rail to access the COP bolt. I loosened it only and did not have to remove the fuel rail

I coated the inside of all the boots with dielectric grease and put grease on the tip of each spark plug.

I gapped each spark plug to 0.054”.

I hand tightened all spark plugs to make sure that I wasn’t going to strip the threads since it is an aluminum block. I then torqued each spark plug to what I believe was ~13 ft-lb, ie. I did so very gently.

The magnetic pen (extendable) I used to remove spark plugs that I loosened but that the spark plug socket would not hold on to. The magnetic pen also came in handy for that time I dropped one of the COP bolts in the engine area.

It took me approximately 6 hours to change all 8 plugs. My advice would be to work slowly and deliberately when changing the spark plugs. Rushing the job only facilitates more mistakes.

Oh and one more thing the COP bolt size was an odd 9/32”.

 

Thanks for the writeup. I need to do the exact same job to my 2002 E150. What torque did you use for the spark plugs?

 

Well where I could get a torque wrench on the spark plug socket I used ~13 ft-lbs of torque.

I remember reading this somewhere but it should be in the owners manual also.