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Section 1157 (Engine - 6.8L (3V) -- F250-F550 Super Duty): Disassembly: Engine

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G03905604
 Remover, Crankshaft Rear Oil Slinger 303--514 (T95P-6701-AH)
G03885061
 Slide Hammer 100-001 (T50T-100-A)
G03905862
 Installer, Connecting Rod 303--442 (T93P-6136-A)
G03886715
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
G03886657
 Remover, Crankshaft Vibration Damper
303-009 (T58P-6316-D)
G03886005
 Remover/Installer, Cylinder Head
303--572 (T97T-6000-A)
G03905746
 Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
G03886718
 Remover, Crankshaft Rear Seal 303--519 (T95P-6701-DH)
G03920070
 Compressor, Valve Spring 303--1039
MATERIAL

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent WSS-M2C930-A
Silicone Gasket Remover ZC-30 -
Motorcraft Metal Surface Prep ZC-31 -
CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so can result in engine damage.
CAUTION: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, can cause engine failure.
NOTE: The flexplate, crankshaft rear seal and the crankshaft rear oil slinger must be removed before mounting the engine on the engine stand.
NOTE: For additional information, refer to the exploded view under the ASSEMBLY .
  1. Remove the engine. For additional information, refer to ENGINE .
  2. Remove the bolts and the flexplate.
    Fig 1: Identifying Flexplate/Flywheel Retainer Bolts
    G03885481Courtesy of FORD MOTOR CO.
    3. CAUTION: Do not use the oil pan to support the engine.
  3. Lower and support the engine assembly on wood blocks.
  4. Using the special tools, remove the crankshaft rear oil slinger.
    Fig 2: Removing Crankshaft Rear Oil Seal Slinger
    G03920149Courtesy of FORD MOTOR CO.
  5. Using the special tools, remove the crankshaft rear seal.
    Fig 3: Removing Crankshaft Rear Seal
    G03920150Courtesy of FORD MOTOR CO.
  6. Remove the bolts and the crankshaft rear seal retainer plate.
      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.
      Fig 4: Identifying Bolts And Crankshaft Rear Seal Retainer Plate
      G03885716Courtesy of FORD MOTOR CO.
    • Clean and inspect the sealing surfaces.
    7. CAUTION: Do not use the oil pan to support the engine.
  7. Lower and support the engine assembly on wood blocks.
  8. Remove the special tool.
    Fig 5: Removing Special Tool
    G03920932Courtesy of FORD MOTOR CO.
  9. Install the engine assembly onto a suitable engine stand.
  10. Remove the bolts and the RH engine mount.
    Fig 6: Removing Bolts And RH Engine Mount
    G04647883Courtesy of FORD MOTOR CO.
    11. NOTE: LH shown, RH similar.
    Fig 7: Locating Cylinder Block Drain Plugs
    G03885619Courtesy of FORD MOTOR CO.
  11. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
  12. Disconnect the camshaft position (CMP) sensor electrical connector.
    Fig 8: Identifying RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
  13. Disconnect the RH radio ignition interference capacitor electrical connector.
    Fig 9: Locating Radio Frequency Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  14. Remove the nut and the RH radio ignition interference capacitor.
    Fig 10: Identifying RH Radio Ignition Interference Capacitor And Stud Bolt
    G03920219Courtesy of FORD MOTOR CO.
  15. Disconnect the electrical connector retainer from the coolant tube support bracket.
    Fig 11: Locating Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
  16. Disconnect the 10 ignition coil electrical connectors.
    Fig 12: Disconnecting Ignition Coil Electrical Connectors
    G03920939Courtesy of FORD MOTOR CO.
  17. Remove the 10 bolts and the 10 ignition coils.
    Fig 13: Removing Bolts And Ignition Coils
    G03920940Courtesy of FORD MOTOR CO.
  18. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 14: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03920224Courtesy of FORD MOTOR CO.
  19. Disconnect the engine oil pressure (EOP) sensor electrical connector.
    Fig 15: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
    G03919846Courtesy of FORD MOTOR CO.
  20. Remove the nut and the LH radio ignition interference capacitor.
    Fig 16: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
    G03920225Courtesy of FORD MOTOR CO.
  21. Disconnect the crankshaft position (CKP) sensor electrical connector.
    Fig 17: Locating CKP Sensor Electrical Connector
    G04612789Courtesy of FORD MOTOR CO.
  22. Disconnect the engine harness retainers and remove the engine wiring harness from the engine assembly.
  23. Remove the rear oil level indicator tube bolt.
    Fig 18: Locating Rear Oil Level Indicator Tube Bolt
    G03920295Courtesy of FORD MOTOR CO.
  24. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
      Fig 19: Locating Front Oil Level Indicator Tube Bolt
      G03920296Courtesy of FORD MOTOR CO.
  25. Remove the bolt and the CMP sensor.
    Fig 20: Identifying Bolt And RH CMP Sensor
    G03920013Courtesy of FORD MOTOR CO.
  26. Remove the bolt and the CKP sensor.
    Fig 21: Locating Crankshaft Position (CKP) Sensor And Bolt
    G03920231Courtesy of FORD MOTOR CO.
  27. Remove the 10 nuts and the RH exhaust manifold.
    • Discard the gasket.
      Fig 22: Removing Nuts And RH Exhaust Manifold
      G03886702Courtesy of FORD MOTOR CO.
  28. Remove the 10 nuts and the LH exhaust manifold.
    • Discard the gasket.
      Fig 23: Removing Nuts And LH Exhaust Manifold
      G03886703Courtesy of FORD MOTOR CO.
    29. 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.
  29. Loosen the 16 fasteners in the sequence shown and remove the RH valve cover and gasket.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
      Fig 24: Identifying RH Valve Cover Fasteners Loosening Sequence
      G03920595Courtesy of FORD MOTOR CO.
    30. 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.
  30. Loosen the 17 fasteners in the sequence shown and remove the LH valve cover and gasket.
    • Clean the valve cover mating surface of the cylinder head with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
    • Discard the valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
      Fig 25: Identifying LH Valve CoverFasteners Loosening Sequence
      G03920580Courtesy of FORD MOTOR CO.
  31. Remove the bolts, coolant pump pulley and accessory drive belt idler pulley.
    Fig 26: Identifying Coolant Pump Pulley And Idler Pulley Bolts
    G03920233Courtesy of FORD MOTOR CO.
  32. Remove the bolts and the accessory drive belt tensioner.
    Fig 27: Identifying Accessory Drive Belt Tensioner Bolts
    G03920234Courtesy of FORD MOTOR CO.
  33. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    Fig 28: Removing Crankshaft Pulley Using Special Tool
    G03919906Courtesy of FORD MOTOR CO.
  34. Using the special tool, remove the crankshaft seal.
    Fig 29: Removing Crankshaft Front Seal Using Special Tool
    G03919889Courtesy of FORD MOTOR CO.
  35. Remove the front 4 oil pan bolts.
    Fig 30: Locating Oil Pan Bolts-To-Front Cover
    G03885636Courtesy of FORD MOTOR CO.
    36. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 31: Removing Front Cover Fasteners
    G03919913Courtesy of FORD MOTOR CO.
  36. Remove the fasteners.
  37. Remove the engine front cover from the cylinder block.
    Fig 32: Removing Engine Front Cover From Cylinder Block
    G03885740Courtesy of FORD MOTOR CO.
    38. CAUTION: Only use hand tools to loosen the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
    Fig 33: Locating RH Camshaft Sprocket Bolt
    G03920660Courtesy of FORD MOTOR CO.
  38. Loosen and backoff the RH camshaft sprocket bolt 1 full turn.
    39. CAUTION: Only use hand tools to loosen the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
    Fig 34: Identifying LH Camshaft Sprocket Bolt
    G03920661Courtesy of FORD MOTOR CO.
  39. Loosen the LH camshaft sprocket bolt.
    40. NOTE: The balance shaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
    Fig 35: Identifying Balance Shaft Bearing Cap Bolt Loosening/Tightening Sequence
    G03920712Courtesy of FORD MOTOR CO.
  40. Remove the 6 bolts in the sequence shown, the 3 bearing caps and the balance shaft.
  41. Remove the crankshaft sensor ring from the crankshaft.
    Fig 36: Removing Crankshaft Sensor Ring
    G04583449Courtesy of FORD MOTOR CO.
  42. Position the crankshaft keyway at the 12 o'clock position.
    Fig 37: Positioning Crankshaft Keyway At 12 O'Clock Position
    G03919943Courtesy of FORD MOTOR CO.
    43. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.
    Fig 38: Positioning Camshaft Lobes
    G03919944Courtesy of FORD MOTOR CO.
  43. The number 1 cylinder camshaft exhaust lobe must be coming up on the exhaust stroke. Verify by noting the position of the 2 intake camshaft lobes and the exhaust lobe on the number 1 cylinder.
    44. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
    Fig 39: Removing Roller Followers
    G03920666Courtesy of FORD MOTOR CO.
  44. Remove only the 3 roller followers shown in the illustration from the RH cylinder head.
    45. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.
    NOTE: It may be necessary to push the valve down while compressing the spring.
    Fig 40: Compressing Valve Spring With Special Tool
    G03919946Courtesy of FORD MOTOR CO.
  45. Using the special tool, remove the 3 designated roller followers in the previous step from the RH cylinder head.
    46. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
    Fig 41: Removing Roller Followers
    G03920668Courtesy of FORD MOTOR CO.
  46. Remove only the 4 roller followers shown in the illustration from the LH cylinder head.
    47. CAUTION: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.
    NOTE: It may be necessary to push the valve down while compressing the spring.
    Fig 42: Compressing Spring Using Special Tool
    G03919948Courtesy of FORD MOTOR CO.
  47. Using the special tool, remove the 4 designated roller followers in the previous step from the LH cylinder head.
    48. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set.
    Fig 43: Positioning Crankshaft Keyway To 6 O'Clock
    G03919949Courtesy of FORD MOTOR CO.
  48. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    49. 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 44: Identifying LH Timing Chain Tensioner Bolts
    G03919950Courtesy of FORD MOTOR CO.
  49. Remove the bolts, the LH timing chain tensioner and tensioner arm.
    50. 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 45: Removing Bolts, RH Timing Chain Tensioner And Tensioner Arm
    G03920672Courtesy of FORD MOTOR CO.
  50. Remove the bolts, the RH timing chain tensioner and tensioner arm.
  51. Remove the LH and RH timing chain and the crankshaft sprockets.
    • 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 46: Removing Timing Chain
      G03885313Courtesy of FORD MOTOR CO.
  52. Remove the 4 bolts and the timing chain guides.
    Fig 47: Removing Bolts And Timing Chain Guides
    G03920972Courtesy of FORD MOTOR CO.
  53. Remove the bolts and the RH and LH camshaft sprockets.
  54. Remove the balance shaft drive gear from the LH camshaft.
    Fig 48: Removing Balance Shaft Drive Gear From LH Camshaft
    G03920675Courtesy of FORD MOTOR CO.
    55. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from sideloading.
    NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
    Fig 49: Identifying RH Camshaft Bearing Bolt Removing/Installation Sequence
    G03920676Courtesy of FORD MOTOR CO.
  55. Remove the bolts in the sequence shown and remove the RH cylinder head front camshaft bearing cap and then the remaining bearing caps.
  56. Clean and inspect the RH camshaft bearing caps.
    • The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
      Fig 50: Identifying Camshaft Front Thrust Bearing Cap
      G03919957Courtesy of FORD MOTOR CO.
  57. Remove the RH camshaft.
    58. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from sideloading.
    NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
    Fig 51: Identifying LH Camshaft Bearing Cap Bolt Removing/Installation Sequence
    G03920678Courtesy of FORD MOTOR CO.
  58. Remove the bolts in the sequence shown and remove the LH cylinder head front camshaft bearing cap and then the remaining bearing caps.
  59. Clean and inspect the LH camshaft bearing caps.
    • The camshaft front thrust bearing cap contains an oil metering groove. Make sure the groove is free of foreign material.
      Fig 52: Identifying Camshaft Front Thrust Bearing Cap
      G03919957Courtesy of FORD MOTOR CO.
  60. Remove the LH camshaft.
    61. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
  61. Remove all of the remaining roller followers from the cylinder heads.
  62. Remove the 2 bolts and the 2 knock sensors.
    Fig 53: Identifying Knock Sensors (KS)
    G03920293Courtesy of FORD MOTOR CO.
  63. Remove the stud bolt and the coolant tube.
    • Discard the O-ring seal.
      Fig 54: Identifying Coolant Tube Stud Bolt
      G03920263Courtesy of FORD MOTOR CO.
    64. CAUTION: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.
  64. Remove the hydraulic lash adjusters from the LH cylinder head.
  65. Install the special tool onto the LH cylinder head.
    Fig 55: Installing Special Tool Onto LH Cylinder Head
    G03920258Courtesy of FORD MOTOR CO.
  66. Install the special tool onto the RH cylinder head.
    Fig 56: Installing Special Tool Onto RH Cylinder Head
    G03920261Courtesy of FORD MOTOR CO.
    67. 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 must be 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.
    NOTE: RH shown, LH similar.
  67. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 57: Removing Bolts And Cylinder Head
      G03906467Courtesy of FORD MOTOR CO.
    68. 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.
  68. 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.
    69. 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 within 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 within 0.010 mm (0.0004 in) from end to end.
    NOTE: LH shown, RH similar.
    Fig 58: Identifying Oil Pressure Feed Area Of Deck Face Surface
    G03885653Courtesy of FORD MOTOR CO.
  69. 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 longer than 0.0254 mm (0.001 in).
  70. Remove the 4 bolts and the LH engine mount.
    Fig 59: Removing Bolts And LH Engine Mount
    G03920884Courtesy of FORD MOTOR CO.
    71. 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.
    Fig 60: Removing Bolts And Nut Retaining Oil Filter Adapter To Cylinder Block
    G03886766Courtesy of FORD MOTOR CO.
  71. Remove the bolts and nut retaining the oil filter adapter to the cylinder block. Remove the oil filter adapter and clean the gasket surface.
  72. Remove the 3 bolts and the oil pump.
    Fig 61: Removing Bolts And Oil Pump
    G03885478Courtesy of FORD MOTOR CO.
    73. CAUTION: Make sure connecting rods and rod caps are numbered, to retain correct orientation.
  73. 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 62: Removing Connecting Rod Cap Bolts
      G03886774Courtesy of FORD MOTOR CO.
    74. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.
  74. Remove the piston and rod assembly.
    • Using the special tools, guide the piston and rod assembly out of the cylinder.
      Fig 63: Removing Piston And Rod Assembly
      G03921056Courtesy of FORD MOTOR CO.
  75. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
  76. Disassemble the 10 pistons. For additional information, refer to PISTON .
  77. Remove and discard the 12 cross-mounted bolts.
    Fig 64: Removing Cross-Mounted Bolts
    G03886776Courtesy of FORD MOTOR CO.
  78. Remove and discard the bolts.
    Fig 65: Removing Bolts
    G03886777Courtesy of FORD MOTOR CO.
  79. Remove the main bearing cap dowel pins.
    Fig 66: Removing Main Bearing Cap Dowel Pins
    G03886778Courtesy of FORD MOTOR CO.
  80. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
    Fig 67: Removing Main Bearing Caps, Lower Crankshaft Main Bearings And Thrust Washer
    G03886779Courtesy of FORD MOTOR CO.
  81. Remove the crankshaft and the crankshaft main bearings from the cylinder block.
    Fig 68: Removing Crankshaft And Crankshaft Main Bearings From Cylinder Block
    G03886780Courtesy of FORD MOTOR CO.
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