Section 653 (Engine - 5.4L (2V) - Excursion & F250-F350 Super Duty): Disassembly: Engine

Special Tool(s) 

Fig 1: Identifying Special Tool(S)

Courtesy of FORD MOTOR CO.

Material 

CAUTION: Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. Failure to do so can result in engine damage.
1. Remove the engine. Refer to ENGINE .
2. Remove the bolts and the flexplate or the flywheel.
   Fig 2: Removing Bolts And Flexplate Or Flywheel

   Courtesy of FORD MOTOR CO.
3. Using the special tools, remove the crankshaft oil slinger.
   Fig 3: Removing Crankshaft Oil Slinger Using Special Tool

   Courtesy of FORD MOTOR CO.
4. Using the special tools, remove the crankshaft rear seal.
   Fig 4: Removing Crankshaft Rear Seal Using Special Tool

   Courtesy of FORD MOTOR CO.
5. Remove the bolts and the crankshaft rear seal retainer plate.
   Fig 5: Removing Bolts And Crankshaft Rear Seal Retainer Plate

   Courtesy of FORD MOTOR CO.
CAUTION: To prevent damage to the oil pan, use care when lowering the engine.
6. Lower the engine onto wooden blocks.
7. Remove the special tool.
   Fig 6: Removing Special Tool

   Courtesy of FORD MOTOR CO.
8. Install the special tool.
   Fig 7: Installing Special Tool

   Courtesy of FORD MOTOR CO.
9. Install the special tool.
   Fig 8: Installing Special Tool

   Courtesy of FORD MOTOR CO.
10. Mount the engine on a suitable work stand.
11. Remove the special tool.
    Fig 9: Removing Special Tool

    Courtesy of FORD MOTOR CO.
12. Remove the special tool.
    Fig 10: Removing Special Tool

    Courtesy of FORD MOTOR CO.
NOTE: RH shown, LH similar.
Fig 11: Removing LH And RH Engine Mounts
Courtesy of FORD MOTOR CO.
13. Remove the LH and RH engine mounts.
NOTE: LH shown, RH similar.
Fig 12: Removing Cylinder Block Drain Plugs
Courtesy of FORD MOTOR CO.
14. Remove the cylinder block drain plugs, and drain the coolant in a suitable container.
15. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 13: Disconnecting LH Radio Frequency Interference Capacitor

    Courtesy of FORD MOTOR CO.
16. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 14: Disconnecting Camshaft Position (CMP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
17. Disconnect the RH radio frequency interference capacitor electrical connector.
    Fig 15: Disconnecting RH Radio Frequency Interference Capacitor Electrical Connector

    Courtesy of FORD MOTOR CO.
18. Disconnect the knock sensor electrical connector.
    Fig 16: Disconnecting Knock Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 17: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
20. Disconnect the oil pressure switch electrical connector.
    Fig 18: Disconnecting Oil Pressure Switch Electrical Connector

    Courtesy of FORD MOTOR CO.
21. Remove the nuts and position the wiring harness bracket aside.
    Fig 19: Removing Nuts

    Courtesy of FORD MOTOR CO.
22. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
NOTE: RH shown, LH similar.
Fig 20: Removing Nuts And Radio Interference Capacitors
Courtesy of FORD MOTOR CO.
23. Remove the nuts and the two radio interference capacitors.
24. Remove the crankcase ventilation tube from the LH valve cover.
    Fig 21: Removing Crankcase Ventilation Tube From LH Valve Cover

    Courtesy of FORD MOTOR CO.
25. Remove the positive crankcase ventilation (PCV) valve and hose from the RH valve cover.
    Fig 22: Removing Positive Crankcase Ventilation (PCV) Valve And Hose From RH Valve Cover

    Courtesy of FORD MOTOR CO.
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 bolts are part of the valve cover and should not be removed.
26. Remove the LH valve cover.
    • Fully loosen the bolts 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.
      Fig 23: Removing LH Valve Cover

      Courtesy of FORD MOTOR CO.
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 bolts are part of the valve cover and should not be removed.
27. Remove the RH valve cover.
    • Fully loosen the bolts 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.
      Fig 24: Removing RH Valve Cover

      Courtesy of FORD MOTOR CO.
28. Remove the bolt and the belt idler pulley.
    Fig 25: Removing Bolt And Belt Idler Pulley

    Courtesy of FORD MOTOR CO.
29. Remove the coolant pump pulley.
    1. Remove the bolts.
    2. Remove the coolant pump pulley.
       Fig 26: Removing Coolant Pump Pulley

       Courtesy of FORD MOTOR CO.
30. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
    Fig 27: Removing Crankshaft Pulley Bolt

    Courtesy of FORD MOTOR CO.
31. Use the special tool to remove the crankshaft front oil seal.
    Fig 28: Removing Crankshaft Front Oil Seal Using Special Tool

    Courtesy of FORD MOTOR CO.
32. Remove the bolts.
    Fig 29: Removing Bolts

    Courtesy of FORD MOTOR CO.
NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
Fig 30: Removing Fasteners
Courtesy of FORD MOTOR CO.
33. Remove the fasteners.
34. Remove the engine front cover from the cylinder block.
    Fig 31: Removing Engine Front Cover From Cylinder Block

    Courtesy of FORD MOTOR CO.
35. Remove the crankshaft sensor ring from the crankshaft.
    Fig 32: Removing Crankshaft Sensor Ring From Crankshaft

    Courtesy of FORD MOTOR CO.
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.
36. Remove the eight spark plugs.
37. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 33: Installing Special Tool Between Valve Spring Coils To Prevent Valve Stem

    Courtesy of FORD MOTOR CO.
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.
Fig 34: Removing Camshaft Roller Followers Using Special Tool
Courtesy of FORD MOTOR CO.
38. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
39. Remove the special tool.
    Fig 35: Removing Special Tool

    Courtesy of FORD MOTOR CO.
40. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 36: Identifying Crankshaft Keyway Position

    Courtesy of FORD MOTOR CO.
41. 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.
       Fig 37: Removing Timing Chain Tensioning System From Both Timing Chains

       Courtesy of FORD MOTOR CO.
42. Remove the RH and LH timing chains and the crankshaft sprocket(s).
    • Remove the RH timing chain from the camshaft sprocket.
    • Remove the RH timing chain from the crankshaft sprocket.
    • Remove the LH timing chain from the camshaft sprocket.
    • Remove the LH timing chain and crankshaft sprocket(s).
      Fig 38: Removing RH And LH Timing Chains And Crankshaft Sprocket

      Courtesy of FORD MOTOR CO.
43. Remove both timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
      Fig 39: Removing Both Timing Chain Guides

      Courtesy of FORD MOTOR CO.
44. Remove the nuts and the RH exhaust manifold and gasket.
    1. Remove the nuts.
    2. Remove the RH exhaust manifold.
    3. Remove the RH exhaust manifold gasket.
       Fig 40: Removing Nuts And RH Exhaust Manifold And Gasket

       Courtesy of FORD MOTOR CO.
45. Remove the nuts and the LH exhaust manifold and gasket.
    • Discard the LH exhaust manifold gasket.
      Fig 41: Removing Nuts And LH Exhaust Manifold And Gasket

      Courtesy of FORD MOTOR CO.
46. Remove the bolt and the oil level indicator tube.
    Fig 42: Removing Bolt And Oil Level Indicator Tube

    Courtesy of FORD MOTOR CO.
47. Clean and inspect the exhaust manifolds. Refer to ENGINE SYSTEM - GENERAL INFORMATION .
48. Install the special tools on both ends of the cylinder head.
    Fig 43: Installing Special Tools On Both Ends Of Cylinder Head

    Courtesy of FORD MOTOR CO.
NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
Fig 44: Removing Hydraulic Lash Adjusters
Courtesy of FORD MOTOR CO.
49. Remove the hydraulic lash adjusters.
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 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.
50. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 45: Removing Bolts And RH Cylinder Head

      Courtesy of FORD MOTOR CO.
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 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.
51. Remove the bolts and the LH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 46: Removing Bolts And LH Cylinder Head

      Courtesy of FORD MOTOR CO.
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.
52. 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.
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 with 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machined edge must be flat with 0.010 mm (0.0004 in) from end to end.
NOTE: LH is shown, RH is similar.
Fig 47: Identifying Cylinder Head Gasket Position
Courtesy of FORD MOTOR CO.
53. 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 in) across a 38.1 mm (1.5 in) square area, or scratches more than 0.0254 mm (0.001 in).
54. If required, remove the nut and four bolts retaining the oil filter adapter and oil filter gasket to the cylinder block.
    Fig 48: Removing Nut And Bolts Retaining Oil Filter Adapter And Oil Filter Gasket To Cylinder Block

    Courtesy of FORD MOTOR CO.
55. Clean the oil filter adapter gasket surface at the cylinder block.
    Fig 49: Cleaning Oil Filter Adapter Gasket Surface At Cylinder Block

    Courtesy of FORD MOTOR CO.
56. Remove the bolts.
    Fig 50: Removing Bolts

    Courtesy of FORD MOTOR CO.
57. Remove the coolant pump from the cylinder block.
    Fig 51: Removing Coolant Pump From Cylinder Block

    Courtesy of FORD MOTOR CO.
58. 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.
59. Remove the bolts, oil pan and oil pan gasket.
    • Clean and inspect the sealing surfaces.
      Fig 52: Inspecting Sealing Surfaces

      Courtesy of FORD MOTOR CO.
60. Remove the bolts and the oil pump screen and pickup tube.
    Fig 53: Removing Bolts And Oil Pump Screen And Pickup Tube

    Courtesy of FORD MOTOR CO.
61. Remove the oil pump screen and pickup tube spacer.
    Fig 54: Removing Oil Pump Screen And Pickup Tube Spacer

    Courtesy of FORD MOTOR CO.
62. Remove the oil pump.
    1. Remove the bolts.
    2. Remove the oil pump.
       Fig 55: Removing Oil Pump

       Courtesy of FORD MOTOR CO.
CAUTION: Verify that the connecting rods and rod caps have orientation numbers case into them. If not, number the connecting rods and rod caps for correct orientation.
Fig 56: Removing Bolts And Connecting Rod Caps
Courtesy of FORD MOTOR CO.
63. Remove the bolts and the connecting rod caps. Discard the bolts.
CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
Fig 57: Pushing Piston Through Top Of Cylinder Block Using Special Tool
Courtesy of FORD MOTOR CO.
64. Use the special tool to push the piston through the top of the cylinder block.
CAUTION: Servicing the bottom end of the engine (crankshaft, bearings) requires that cylinder heads be removed. Failure to do so can result in engine damage.
65. Remove the fasteners.
    1. Remove and discard the cross-mounted main cap bolts.
    2. Remove the dowels.
    3. Remove and discard the main bearing cap bolts.
       Fig 58: Removing Main Bearing Cap Bolts

       Courtesy of FORD MOTOR CO.
66. Remove the five main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
    Fig 59: Removing Main Bearing Caps, Lower Crankshaft Main Bearings And Lower Thrust Washer

    Courtesy of FORD MOTOR CO.
67. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
    Fig 60: Removing Crankshaft, Upper Crankshaft Main Bearings And Upper Thrust Washers From Cylinder Block

    Courtesy of FORD MOTOR CO.