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Section 798 (Engine - 6.8L- E350 & E450): Disassembly: Engine: Material

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
  1. Remove the engine. For additional information, refer to Engine .
  2. Remove the bolts and the flexplate.
    Fig 1: Removing Bolts Flexplate
    G03886544Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the crankshaft rear slinger.
    Fig 2: Removing Crankshaft Rear Oil Slinger
    G03885490Courtesy of FORD MOTOR CO.
  4. Using the special tools, remove the crankshaft rear seal.
    Fig 3: Removing Crankshaft Rear Seal Using Special Tool
    G03885491Courtesy of FORD MOTOR CO.
  5. Remove the bolts and the crankshaft rear seal retainer plate.
    Fig 4: Identifying Bolts And Crankshaft Rear Seal Retainer Plate
    G03885716Courtesy of FORD MOTOR CO.
    6. 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 5: Identifying Special Tool
    G03885604Courtesy of FORD MOTOR CO.
  8. Install the special tool.
    Fig 6: Identifying Special Tool
    G03905704Courtesy of FORD MOTOR CO.
  9. Install the special tool.
    Fig 7: Identifying Special Tool
    G03905705Courtesy of FORD MOTOR CO.
  10. Mount the engine on a suitable work stand.
  11. Remove the special tool.
    Fig 8: Identifying Special Tool
    G03905704Courtesy of FORD MOTOR CO.
  12. Remove the special tool.
    Fig 9: Identifying Special Tool
    G03905705Courtesy of FORD MOTOR CO.
    13. NOTE: RH shown, LH similar.
    Fig 10: Removing/Installing RH Engine Mount
    G03885618Courtesy of FORD MOTOR CO.
  13. Remove the RH and LH engine mounts.
    14. NOTE: LH shown, RH similar.
    Fig 11: Locating Cylinder Block Drain Plugs
    G03885619Courtesy of FORD MOTOR CO.
  14. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
  15. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    Fig 12: Locating Radio Frequency Interference Capacitor And Cylinder Head Temperature Sensor Electrical Connectors
    G03962635Courtesy of FORD MOTOR CO.
  16. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 13: Identifying Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  17. Disconnect the RH radio frequency interference capacitor electrical connector.
    Fig 14: Locating Radio Frequency Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  18. Disconnect the knock sensor electrical connector, if equipped.
    Fig 15: Locating KS Electrical Connector
    G03886734Courtesy of FORD MOTOR CO.
  19. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 16: Locating CKP Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
  20. Disconnect the oil pressure switch electrical connector.
    Fig 17: Locating Oil Pressure Switch Electrical Connector
    G03886309Courtesy of FORD MOTOR CO.
  21. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
    22. NOTE: RH shown, LH similar.
    Fig 18: Identifying Radio Frequency Interference Capacitors
    G03906363Courtesy of FORD MOTOR CO.
  22. Remove the nuts and the two radio interference capacitors.
  23. Remove the crankcase ventilation tube from the LH valve cover.
    Fig 19: Removing Crankcase Ventilation Tube
    G03886738Courtesy of FORD MOTOR CO.
  24. Remove the nut attaching the oil level indicator tube to the front of the engine.
    Fig 20: Removing Nut Oil Level Indicator Tube
    G03886680Courtesy of FORD MOTOR CO.
  25. Remove the bolt attaching the oil level indicator tube to the rear of the engine.
    Fig 21: Removing Bolt Oil Level Indicator Tube
    G03886681Courtesy of FORD MOTOR CO.
  26. Position the oil level indicator tube aside.
    Fig 22: Positioning Oil Level Indicator Tube
    G03886682Courtesy of FORD MOTOR CO.
    27. 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 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
      G03886378Courtesy of FORD MOTOR CO.
    28. 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.
  28. 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: Identifying RH Valve Cover Bolts
      G03886406Courtesy of FORD MOTOR CO.
  29. Remove the bolt and the idler pulley.
    Fig 25: Identifying Bolt And Belt Idler Pulley
    G03885293Courtesy of FORD MOTOR CO.
  30. Remove the water pump pulley.
    1. Remove the bolts.
    2. Remove the water pump pulley.
      Fig 26: Identifying Coolant Pump Pulley And Bolts
      G03885632Courtesy of FORD MOTOR CO.
  31. Remove and discard the crankshaft pulley bolt. Use the special tool to remove the crankshaft pulley.
    Fig 27: Removing Crankshaft Pulley Bolt Using Special Tool
    G03885277Courtesy of FORD MOTOR CO.
  32. Use the special tool to remove the crankshaft front oil seal.
    Fig 28: Identifying Crankshaft Front Seal And Special Tool
    G03885682Courtesy of FORD MOTOR CO.
  33. Remove the power steering pump.
    Fig 29: Locating Power Steering Pump Bolts
    G03885288Courtesy of FORD MOTOR CO.
  34. Remove the bolts.
    Fig 30: Locating Front Oil Pan Bolts
    G03885636Courtesy of FORD MOTOR CO.
    35. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 31: Identifying Front Cover Fasteners
    G03885685Courtesy of FORD MOTOR CO.
  35. Remove the fasteners.
  36. Remove the engine front cover from the cylinder block.
    Fig 32: Removing Engine Front Cover From Cylinder Block
    G03885740Courtesy of FORD MOTOR CO.
  37. Remove the crankshaft sensor ring from the crankshaft.
    Fig 33: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    38. CAUTION: The caps must be marked for installation in their original location or damage to the engine may occur.
    Fig 34: Removing Bolts
    G03886458Courtesy of FORD MOTOR CO.
  38. Remove the six bolts and remove the balance shaft bearing caps.
  39. Remove the balance shaft.
    Fig 35: Removing Balance Shaft
    G03886459Courtesy of FORD MOTOR CO.
    40. 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.
  40. Remove the 10 spark plugs.
  41. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 36: Installing Special Tool Between Valve Spring Coils
    G03881599Courtesy of FORD MOTOR CO.
    42. 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 37: Compressing Valve Springs
    G03905494Courtesy of FORD MOTOR CO.
  42. Use the special tool to compress the valve springs and remove the camshaft roller followers.
  43. Remove the special tool.
    Fig 38: Removing Special Tool
    G03906024Courtesy of FORD MOTOR CO.
  44. Position the crankshaft with the keyway at the 12 o'clock position.
    Fig 39: Positioning Crankshaft With Keyway At 12 O'Clock Position
    G04583456Courtesy of FORD MOTOR CO.
    45. 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.
  45. 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 40: Identifying Timing Chain Tensioning System Components
      G03885312Courtesy of FORD MOTOR CO.
  46. 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 from the crankshaft sprocket.
      Fig 41: Removing Timing Chain
      G03885313Courtesy of FORD MOTOR CO.
  47. Remove both timing chain guides.
    • Remove the bolts.
    • Remove the timing chain guides.
      Fig 42: Removing Timing Chain Guides
      G03885314Courtesy of FORD MOTOR CO.
  48. Remove the RH exhaust manifold.
    • Remove the nuts.
    • Remove the RH exhaust manifold.
    • Remove the RH exhaust manifold gasket.
      Fig 43: Removing RH Exhaust Manifold
      G03886702Courtesy of FORD MOTOR CO.
  49. Remove the LH exhaust manifold.
    • Remove the nuts.
    • Remove the LH exhaust manifold.
    • Remove the LH exhaust manifold gasket.
      Fig 44: Removing LH Exhaust Manifold
      G03886763Courtesy of FORD MOTOR CO.
  50. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM-GENERAL INFORMATION .
  51. Install the special tools on both ends of the cylinder head.
    Fig 45: Installing/Removing Special Tools On Both Ends Of Cylinder Head
    G03885649Courtesy of FORD MOTOR CO.
    52. NOTE: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations.
  52. Remove the hydraulic lash adjusters.
    53. 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 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 which 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.
    NOTE: RH shown, LH similar.
  53. Remove the bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 46: Removing Bolts RH Cylinder Head
      G03886706Courtesy of FORD MOTOR CO.
    54. 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.
  54. 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.
    55. NOTE: The straightedge used must be flat within 0.0051 mm (0.0002 in) per foot of tool length.
  55. 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).
  56. 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 47: Supporting Cylinder Head On Bench
    G03886766Courtesy of FORD MOTOR CO.
  57. Remove the bolts.
    Fig 48: Identifying Coolant Pump Bolts
    G03885825Courtesy of FORD MOTOR CO.
  58. Remove the water pump from the cylinder block.
    Fig 49: Identifying Coolant Pump
    G03885759Courtesy of FORD MOTOR CO.
  59. Remove the bolts and the A/C compressor.
    Fig 50: Removing Bolts A/C Compressor
    G03885760Courtesy of FORD MOTOR CO.
  60. Before removing the pistons, inspect the top of the cylinder bores. If necessary, remove the ridge or carbon deposits from each cylinder using a cylinder ridge reamer, following the manufacturer's instructions.
    Fig 51: Inspecting Top Of Cylinder Bores
    G03886770Courtesy of FORD MOTOR CO.
  61. Remove the bolts, the oil pan and the oil pan gasket.
    Fig 52: Removing Bolts
    G03886771Courtesy of FORD MOTOR CO.
  62. Remove the bolts, the oil pump screen cover and tube and the spacer.
    Fig 53: Removing Bolts
    G03886519Courtesy of FORD MOTOR CO.
  63. Remove the oil pump.
    1. Remove the bolts.
    2. Remove the oil pump.
      Fig 54: Removing Oil Pump
      G03885764Courtesy of FORD MOTOR CO.
    64. CAUTION: Make sure connecting rods and rod caps are numbered to keep them in the correct orientation.
  64. Remove the bolts and the connecting rod caps.
    • Rotate the crankshaft so that the connecting rod is a bottom dead center.
    • Remove and discard the bolts.
      Fig 55: Removing Bolts
      G03886774Courtesy of FORD MOTOR CO.
    65. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.
  65. Remove the piston and rod assembly.
    • Using the special tool, guide the piston and rod assembly out of the cylinder.
      Fig 56: Removing Piston And Rod Assembly Using Special Tool
      G03886775Courtesy of FORD MOTOR CO.
  66. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
  67. Remove and discard the 12 cross-mounted bolts.
    Fig 57: Removing Bolts
    G03886776Courtesy of FORD MOTOR CO.
  68. Remove and discard the bolts.
    Fig 58: Removing Bolts
    G03886777Courtesy of FORD MOTOR CO.
  69. Remove the main bearing cap dowel pins.
    Fig 59: Removing Main Bearing Cap Dowel Pins
    G03886778Courtesy of FORD MOTOR CO.
  70. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
    Fig 60: Removing Main Bearing Caps
    G03886779Courtesy of FORD MOTOR CO.
  71. Remove the crankshaft and the crankshaft main bearings from the cylinder block.
    Fig 61: Removing Crankshaft And Crankshaft Main Bearings
    G03886780Courtesy of FORD MOTOR CO.
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