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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 654 (Engine - 6.8L - Excursion & F250-F550 Super Duty) >> Disassembly >> Engine >> Special Tool(s)

Special Tool(s)

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Special Tool(s)
G02771572Courtesy of FORD MOTOR CO.
CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
NOTE: The crankshaft rear seal, the oil seal slinger and the seal retainer plate must be removed before mounting the engine on the engine stand.
  1. Remove the flexplate.
    Fig 2: Removing Flexplate
    G02771573Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove the crankshaft oil slinger.
    Fig 3: Removing Crankshaft Oil Slinger Using Special Tools
    G02771574Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the crankshaft rear seal.
    Fig 4: Removing Crankshaft Rear Seal Using Special Tools
    G02771575Courtesy of FORD MOTOR CO.
  4. Remove the bolts and the crankshaft rear seal retainer plate.
    Fig 5: Removing Bolts And Crankshaft Rear Seal Retainer Plate
    G02771576Courtesy of FORD MOTOR CO.
  5. Place the engine on a suitable engine stand.
  6. Remove the Modular Engine Lift Bracket.
  7. Remove the bolts and the engine mounts.
    Fig 6: Removing Bolts And Engine Mounts
    G02771577Courtesy of FORD MOTOR CO.
  8. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
    Fig 7: Removing Cylinder Block Drain Plugs
    G02771578Courtesy of FORD MOTOR CO.
  9. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 8: Disconnecting LH Radio Frequency Interference Capacitor
    G02771579Courtesy of FORD MOTOR CO.
  10. Disconnect the camshaft position (CMP) electrical connector.
    Fig 9: Disconnecting Camshaft Position (CMP) Electrical Connector
    G02771580Courtesy of FORD MOTOR CO.
  11. Disconnect the RH radio frequency interference capacitor electrical connector.
    Fig 10: Disconnecting RH radio frequency interference capacitor electrical connector
    G02771581Courtesy of FORD MOTOR CO.
  12. Disconnect the knock sensor (KS) electrical connector.
    Fig 11: Disconnecting Knock Sensor (KS) Electrical Connector
    G02771582Courtesy of FORD MOTOR CO.
  13. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 12: Disconnecting Crankshaft Position (CKP) Sensor Electrical Connector
    G02771583Courtesy of FORD MOTOR CO.
  14. Disconnect the oil pressure switch electrical connector.
    Fig 13: Disconnecting Oil Pressure Switch Electrical Connector
    G02771584Courtesy of FORD MOTOR CO.
  15. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
  16. Remove the crankcase ventilation tube from the LH valve cover.
    Fig 14: Removing Crankcase Ventilation Tube From LH Valve Cover
    G02771585Courtesy of FORD MOTOR CO.
  17. Remove the positive crankcase ventilation (PCV) valve and hose from the RH valve cover.
    Fig 15: Removing Positive Crankcase Ventilation (PCV) Valve
    G02771586Courtesy of FORD MOTOR CO.
  18. Remove the bolts, the oil pan, and the oil pan gasket.
    Fig 16: Removing Bolts, Oil Pan, And Oil Pan Gasket
    G02771587Courtesy of FORD MOTOR CO.
  19. Remove the two bolts, the nut, the oil pump screen cover and tube, and the spacer.
    Fig 17: Removing Bolts, Nut And Oil Pump Screen Cover
    G02771588Courtesy of FORD MOTOR CO.
    20. 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.
  20. 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 18: Removing LH Valve Cover
      G02771589Courtesy of FORD MOTOR CO.
    21. 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.
  21. Remove the RH valve cover.
    • Fully loosen the bolts and remove the valve cover.
    • Clean the valve cover mating surfaces 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 19: Removing Rh Valve Cover
      G02771590Courtesy of FORD MOTOR CO.
  22. Remove the coolant pump pulley.
    1. Remove the bolts.
    2. Remove the coolant pump pulley.
      Fig 20: Removing Coolant Pump Pulley
      G02771591Courtesy of FORD MOTOR CO.
  23. Remove the coolant pump bolts.
    Fig 21: Removing Coolant Pump Bolts
    G02771592Courtesy of FORD MOTOR CO.
  24. Remove the coolant pump from the cylinder block.
    Fig 22: Removing Coolant Pump From Cylinder Block
    G02771593Courtesy of FORD MOTOR CO.
  25. Remove the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    Fig 23: Removing Crankshaft Pulley Bolt
    G02771594Courtesy of FORD MOTOR CO.
  26. Using the special tool, remove the crankshaft front seal.
    Fig 24: Removing Crankshaft Front Seal
    G02771595Courtesy of FORD MOTOR CO.
  27. Remove the bolt and the belt idler pulley.
    Fig 25: Removing Bolt And Belt Idler Pulley
    G02771596Courtesy of FORD MOTOR CO.
  28. Remove the four oil pan bolts.
    Fig 26: Removing Four Oil Pan Bolts
    G02771597Courtesy of FORD MOTOR CO.
    29. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 27: Removing Fasteners
    G02771598Courtesy of FORD MOTOR CO.
  29. Remove the fasteners.
  30. Remove the engine front cover from the front cover-to-cylinder block dowels.
    Fig 28: Removing Engine Front Cover From Front Cover
    G02771599Courtesy of FORD MOTOR CO.
  31. Position the piston of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle.
  32. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 29: Installing Special Tool Between Valve Spring Coils
    G02771600Courtesy of FORD MOTOR CO.
    33. NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.
    Fig 30: Compressing Valve Springs Using Special Tool
    G02771601Courtesy of FORD MOTOR CO.
  33. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
  34. Remove the special tool.
    Fig 31: Removing Special Tool
    G02771602Courtesy of FORD MOTOR CO.
  35. Remove the crankshaft sensor ring from the crankshaft.
    Fig 32: Removing Crankshaft Sensor Ring From Crankshaft
    G02771603Courtesy of FORD MOTOR CO.
    36. CAUTION: The bearing caps must be marked for installation in their original locations or engine damage can occur.
    Fig 33: Removing Six Bolts, Bearing Caps And Balance Shaft
    G02771604Courtesy of FORD MOTOR CO.
    Fig 34: Removing Bearing Caps And Balance Shaft
    G02771605Courtesy of FORD MOTOR CO.
  36. Remove the six bolts, the bearing caps and the balance shaft.
    37. CAUTION: Unless otherwise instructed, at no time when the timing chain/belts are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
    Fig 35: Positioning Crankshaft With Keyway
    G02771606Courtesy of FORD MOTOR CO.
  37. Position the crankshaft with the keyway at the 12 o'clock position.
    38. CAUTION: 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.
    Fig 36: Removing Bolts And Timing Chain Tensioners
    G02771607Courtesy of FORD MOTOR CO.
  38. Remove the bolts and the timing chain tensioners. Remove the timing chain tensioner arms from the dowel pins.
    39. CAUTION: Unless otherwise instructed, at no time when the timing chain/belts are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
  39. Remove the LH and RH timing chain and the crankshaft sprocket.
    • 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 the crankshaft sprocket.
      Fig 37: Removing LH And Rh Timing Chain And Crankshaft Sprocket
      G02771608Courtesy of FORD MOTOR CO.
  40. Remove the timing chain guides.
    • Remove the bolts.
    • Remove the timing chain guides.
      Fig 38: Removing Timing Chain Guides
      G02771609Courtesy of FORD MOTOR CO.
  41. Remove the 10 nuts and the RH exhaust manifold and exhaust manifold gasket. Discard the exhaust manifold gasket.
    Fig 39: Removing Nut And Rh Exhaust Manifold
    G02771610Courtesy of FORD MOTOR CO.
  42. Remove the 10 nuts, the LH exhaust manifold and the exhaust manifold gaskets. Discard the exhaust manifold gasket.
    Fig 40: Removing Nuts and LH Exhaust Manifold
    G02771611Courtesy of FORD MOTOR CO.
  43. Remove the oil level indicator, the bolt and the oil level indicator tube.
    Fig 41: Removing Oil Level Indicator Bolt
    G02771612Courtesy of FORD MOTOR CO.
  44. Install the special tools on both ends of the cylinder head.
    Fig 42: Installing Special Tools On Both Ends Of Cylinder Head
    G02771613Courtesy of FORD MOTOR CO.
    45. CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
    CAUTION: Place cylinder head on a cardboard or wood surface to prevent damage to the joint face.
    CAUTION: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: The cylinder heads are cleaned as part of the cylinder head disassembly process.
    NOTE: LH shown; RH similar.
  45. Remove the bolts and the cylinder head.
    • Discard the head gasket and clean the engine block surface.
      Fig 43: Discarding Head Gasket And Clean Engine Block Surface
      G02771614Courtesy of FORD MOTOR CO.
    46. 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 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 surfaces.
  46. 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 surface is normal.
    47. 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 44: Identifying Cylinder Head (LH And Rh)
    G02771615Courtesy of FORD MOTOR CO.
  47. Support the cylinder head on a bench with the head gasket side up. Inspect all areas of the cylinder head deck face and the cylinder block 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).
  48. Remove the bolts and nut retaining the oil filter adapter to the cylinder block. Remove the oil filter adapter and clean the gasket surface.
    Fig 45: Removing Retaining Oil Filter Adapter Bolts
    G02771616Courtesy of FORD MOTOR CO.
  49. Remove the bolts and the oil pump.
    Fig 46: Removing Bolts And Oil Pump
    G02771617Courtesy of FORD MOTOR CO.
    50. CAUTION: Make sure connecting rods and rod caps are numbered, to retain correct orientation.
  50. Remove the bolts and the connecting rod caps.
    • Rotate the crankshaft so that the connecting rod is at bottom dead center.
    • Remove and discard the bolts.
      Fig 47: Removing Bolts
      G02771618Courtesy of FORD MOTOR CO.
    51. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.
  51. Remove the piston and rod assembly.
    • Using the special tools, guide the piston and rod assembly out of the cylinder.
      Fig 48: Removing Piston And Rod Assembly
      G02771619Courtesy of FORD MOTOR CO.
  52. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
  53. Remove and discard the 12 cross-mounted bolts.
    Fig 49: Removing Cross-Mounted Bolts
    G02771620Courtesy of FORD MOTOR CO.
  54. Remove and discard the bolts.
    Fig 50: Removing Bolts
    G02771621Courtesy of FORD MOTOR CO.
  55. Remove the main bearing cap dowel pins.
    Fig 51: Removing Main Bearing Cap Dowel Pins
    G02771622Courtesy of FORD MOTOR CO.
  56. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
    Fig 52: Removing Main Bearing Caps And Lower Crankshaft Main Bearings
    G02771623Courtesy of FORD MOTOR CO.
  57. Remove the crankshaft and the crankshaft main bearings from the cylinder block.
    Fig 53: Removing Crankshaft And Crankshaft Main Bearings From Cylinder Block
    G02771624Courtesy of FORD MOTOR CO.
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