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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2581 (Engine Mechanical - 6.8L (3V) -- F450 & F550 Super Duty) >> Disassembly >> Engine >> Material Specifications

Material Specifications

WARNING: This page is about a different car, the 2011 Ford F550 Super Duty and 2011 Ford F450 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® Metal Surface Prep
ZC-31-A		 -
Motorcraft® Silicone Gasket Remover
ZC-30		 -
NOTE: Remove the cylinder heads before removing the crankshaft. Failure to do so may result in engine damage.
NOTE: 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, may 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 in the ENGINE  Assembly portion of this service information.
  1. Remove the engine. For additional information, refer to ENGINE  in the Removal portion of this service information.
  2. Remove the 8 bolts and the flexplate.
    Fig 1: Locating Flexplate Bolts
    G07480421Courtesy of FORD MOTOR CO.
  3. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger.
    Fig 2: Removing Crankshaft Rear Oil Seal Slinger Using Special Tools
    G07480422Courtesy of FORD MOTOR CO.
  4. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.
    Fig 3: Removing Crankshaft Rear Seal Using Special Tools
    G07480423Courtesy of FORD MOTOR CO.
  5. Remove the 8 bolts and the crankshaft rear seal retainer plate.
      NOTE: 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.
    • Clean and inspect the sealing surfaces.
    Fig 4: Locating Crankshaft Rear Seal Retainer Plate Bolts
    G07480424Courtesy of FORD MOTOR CO.
    6. NOTE: Do not use the oil pan to support the engine, or oil pan and oil pan gasket damage may occur.
  6. Lower and support the engine assembly on wood blocks.
  7. Remove the Engine Lifting Bracket.
    Fig 5: Identifying Engine Lifting Bracket
    G07480425Courtesy of FORD MOTOR CO.
  8. Install the engine assembly onto a suitable engine stand.
    9. NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
    Fig 6: Locating Engine Support Insulator Bracket Bolts
    G07480426Courtesy of FORD MOTOR CO.
  9. Remove the 3 bolts and the RH engine support insulator bracket.
    • Discard the engine support insulator bracket bolts.
    10. NOTE: LH shown, RH similar.
    Fig 7: Locating Cylinder Block Drain Plug
    G07480427Courtesy of FORD MOTOR CO.
  10. If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.
    11. NOTE: The large clutch assembly nut has a RH thread and must be rotated counterclockwise to remove it.
    Fig 8: Remove/Install Engine Cooling Fan From Coolant Pump Pulley Using Special Tools
    G07480428Courtesy of FORD MOTOR CO.
  11. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the engine cooling fan from the coolant pump pulley.
  12. Disconnect the Camshaft Position (CMP) sensor electrical connector.
    Fig 9: Locating CMP Electrical Connector
    G07480429Courtesy of FORD MOTOR CO.
  13. Remove the nut and the RH radio ignition interference capacitor.
    Fig 10: Locating RH Radio Ignition Interference Capacitor Nut
    G07480430Courtesy of FORD MOTOR CO.
  14. Disconnect the 10 ignition coil electrical connectors.
    Fig 11: Locating Ignition Coil Electrical Connector
    G07480431Courtesy of FORD MOTOR CO.
  15. Remove the 10 bolts and the 10 ignition coils.
    • Remove the ignition coil by using a twisting motion while pulling up on the ignition coil.
    Fig 12: Locating Ignition Coil Bolt
    G07480432Courtesy of FORD MOTOR CO.
  16. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 13: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G07480433Courtesy of FORD MOTOR CO.
  17. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    Fig 14: Locating Engine Oil Pressure Switch Electrical Connector
    G07480434Courtesy of FORD MOTOR CO.
  18. Remove the nut and the LH radio ignition interference capacitor.
    Fig 15: Locating LH Radio Ignition Interference Capacitor Nut
    G07480435Courtesy of FORD MOTOR CO.
  19. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
    Fig 16: Locating CKP Sensor Electrical Connector
    G07480436Courtesy of FORD MOTOR CO.
  20. Disconnect the engine harness retainers and remove the engine wiring harness from the engine assembly.
  21. Remove the 2 bolts and the oil level indicator tube.
    • Discard the O-ring seal.
    Fig 17: Locating Oil Level Indicator Tube Bolts
    G07480437Courtesy of FORD MOTOR CO.
  22. Remove the 2 bolts and the exhaust manifold heat shield.
    Fig 18: Locating Exhaust Manifold Heat Shield Bolts
    G07480438Courtesy of FORD MOTOR CO.
  23. Remove the 10 nuts and the RH exhaust manifold.
    Fig 19: Removing RH Exhaust Manifold
    G07480439Courtesy of FORD MOTOR CO.
  24. Remove the 3 bolts and the exhaust manifold heat shield.
    Fig 20: Locating Exhaust Manifold Heat Shield Bolts
    G07480440Courtesy of FORD MOTOR CO.
  25. Remove the 10 nuts and the LH exhaust manifold.
    Fig 21: Removing LH Exhaust Manifold
    G07480441Courtesy of FORD MOTOR CO.
    26. NOTE: LH shown, RH similar.
    Fig 22: Locating Exhaust Manifold-To-Cylinder Head Studs
    G07480442Courtesy of FORD MOTOR CO.
  26. Remove and discard the 20 exhaust manifold-to-cylinder head studs.
    27. NOTE: 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.
    Fig 23: Valve Cover Fasteners Loosening/Tightening Sequence (RH)
    G07480443Courtesy of FORD MOTOR CO.
  27. 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.
    28. NOTE: 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.
    Fig 24: Identifying Valve Cover Fasteners Loosening/Tightening Sequence (LH)
    G07480444Courtesy of FORD MOTOR CO.
  28. 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.
  29. Remove the 5 bolts, the coolant pump pulley and the accessory drive belt idler pulley.
    Fig 25: Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulley Bolts
    G07480445Courtesy of FORD MOTOR CO.
  30. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 26: Locating Accessory Drive Belt Tensioner Bolts
    G07480446Courtesy of FORD MOTOR CO.
  31. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
    Fig 27: Removing Crankshaft Pulley Using Crankshaft Vibration Damper Remover
    G07480447Courtesy of FORD MOTOR CO.
  32. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.
    Fig 28: Removing Crankshaft Front Seal Using Crankshaft Front Oil Seal Remover
    G07480448Courtesy of FORD MOTOR CO.
  33. Remove the front 4 oil pan bolts.
    Fig 29: Locating Front Oil Pan Bolts
    G07480449Courtesy of FORD MOTOR CO.
    34. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 30: Locating Front Cover Fastener
    G07480450Courtesy of FORD MOTOR CO.
  34. Remove the 15 fasteners.
  35. Remove the engine front cover from the cylinder block.
    Fig 31: Removing Engine Front Cover From Cylinder Block
    G07480451Courtesy of FORD MOTOR CO.
    36. NOTE: Only use hand tools to loosen the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.
    Fig 32: Locating RH Camshaft Sprocket Bolt
    G07480452Courtesy of FORD MOTOR CO.
  36. Loosen and back off the RH camshaft sprocket bolt one full turn.
    37. NOTE: Only use hand tools to loosen the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.
    Fig 33: Locating LH Camshaft Sprocket Bolt
    G07480453Courtesy of FORD MOTOR CO.
  37. Loosen and back off the LH camshaft sprocket bolt one full turn.
    38. NOTE: The balance shaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
    Fig 34: Identifying Balance Shaft Bearing Cap Bolt Loosening/Tightening Sequence
    G07480454Courtesy of FORD MOTOR CO.
  38. Using the sequence shown, remove the 6 bolts, then the 3 balance shaft bearing caps and the balance shaft.
  39. Remove the crankshaft sensor ring from the crankshaft.
    Fig 35: Remove/Install Crankshaft Sensor Ring
    G07480455Courtesy of FORD MOTOR CO.
  40. Position the crankshaft keyway at the 12 o'clock position.
    Fig 36: Identifying Crankshaft Keyway Position
    G07480456Courtesy of FORD MOTOR CO.
    41. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.
    Fig 37: Identifying No. 1 Cylinder Camshaft Exhaust Lobe Is On The Exhaust Stroke
    G07480457Courtesy of FORD MOTOR CO.
  41. The No. 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 No. 1 cylinder.
    42. NOTE: If the components are to be reinstalled, they must be installed in their original locations or engine damage may occur. Mark the components for installation into their original locations.
    Fig 38: Locating Camshaft Roller Followers
    G07480458Courtesy of FORD MOTOR CO.
  42. Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.
    43. NOTE: It may be necessary to push the valve down while compressing the spring.
    Fig 39: Remove/Install Camshaft Roller Followers From RH Cylinder Head Using Valve Spring Compressor
    G07480459Courtesy of FORD MOTOR CO.
  43. Using the Valve Spring Compressor, remove the 3 camshaft roller followers designated in the previous step from the RH cylinder head.
    44. NOTE: If the components are to be reinstalled, they must be installed in their original locations or engine damage may occur. Mark the components for installation into their original locations.
    Fig 40: Remove/Install Camshaft Roller Followers From LH Cylinder Head Using Valve Spring Compressor
    G07480460Courtesy of FORD MOTOR CO.
  44. Remove only the 4 camshaft roller followers shown in the illustration from the LH cylinder head.
    45. NOTE: It may be necessary to push the valve down while compressing the spring.
    Fig 41: Remove/Install Camshaft Roller Follower From LH Cylinder Head Using Valve Spring Compressor
    G07480461Courtesy of FORD MOTOR CO.
  45. Using the Valve Spring Compressor, remove the 4 camshaft roller followers designated in the previous step from the LH cylinder head.
    46. NOTE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.
    Fig 42: Identifying Crankshaft Keyway Position
    G07480462Courtesy of FORD MOTOR CO.
  46. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    47. NOTE: 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 or engine damage may occur.
    Fig 43: Locating LH Timing Chain Tensioner Arm And Bolts
    G07480463Courtesy of FORD MOTOR CO.
  47. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
    48. NOTE: 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 or engine damage may occur.
    Fig 44: Locating RH Timing Chain Tensioner Arm And Bolts
    G07480464Courtesy of FORD MOTOR CO.
  48. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
  49. 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 45: Removing LH/RH Timing Chain
    G07480465Courtesy of FORD MOTOR CO.
  50. Remove the 4 bolts and the timing chain guides.
    Fig 46: Locating Timing Chain Guides Bolts
    G07480466Courtesy of FORD MOTOR CO.
  51. Remove the bolts and the RH and LH camshaft sprockets.
  52. Remove the balance shaft drive gear from the LH camshaft.
    Fig 47: Locating Balance Shaft Drive Gear Of LH Camshaft
    G07480467Courtesy of FORD MOTOR CO.
    53. NOTE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.
    Fig 48: Locating RH Camshaft Front Bearing Cap Bolts
    G07480468Courtesy of FORD MOTOR CO.
  53. Remove the 2 bolts and the RH camshaft front bearing cap.
    54. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations or engine damage may occur.
    Fig 49: Removing Sequence Of RH Cylinder Head Camshaft Bearing Caps Bolts
    G07480469Courtesy of FORD MOTOR CO.
  54. Remove the 10 remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.
  55. 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: Locating Camshaft Front Thrust Bearing Cap Oil Metering Groove
    G07480470Courtesy of FORD MOTOR CO.
  56. Remove the RH camshaft.
    57. NOTE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from side loading.
    Fig 51: Locating LH Camshaft Front Bearing Cap Bolts
    G07480471Courtesy of FORD MOTOR CO.
  57. Remove the 2 bolts and the LH camshaft front bearing cap.
    58. NOTE: The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations or engine damage may occur.
    Fig 52: Removing Sequence Of LH Cylinder Head Camshaft Bearing Caps Bolts
    G07480472Courtesy of FORD MOTOR CO.
  58. Remove the 10 remaining bolts in the sequence shown and remove the LH cylinder head camshaft 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 53: Locating Camshaft Front Thrust Bearing Cap Oil Metering Groove
    G07480473Courtesy of FORD MOTOR CO.
  60. Remove the LH camshaft.
    61. NOTE: If the components are to be reinstalled, they must be installed in their original locations or engine damage may occur. 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 Sensor (KS)s.
    Fig 54: Locating Knock Sensors
    G07480474Courtesy of FORD MOTOR CO.
    63. NOTE: If the components are to be reinstalled, they must be installed in their original locations or engine damage may occur. Mark the components for installation into their original locations.
  63. Remove the hydraulic lash adjusters from the LH cylinder head.
  64. Install the Cylinder Head Remover/Installer onto the LH cylinder head.
    Fig 55: Identifying Cylinder Head Remover/Installer Onto Cylinder Head
    G07480475Courtesy of FORD MOTOR CO.
  65. Install the Cylinder Head Remover/Installer onto the RH cylinder head.
    Fig 56: Identifying Cylinder Head Remover/Installer Onto RH Cylinder Head
    G07480476Courtesy of FORD MOTOR CO.
  66. Remove the stud bolt and the coolant tube.
    • Discard the O-ring seals.
    Fig 57: Locating Heater Coolant Tube Stud Bolts
    G07480477Courtesy of FORD MOTOR CO.
    67. NOTE: 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.
    NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine or engine damage may occur.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed or engine damage may occur. They are a tighten-to-yield design and cannot be reused.
    NOTE: 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.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface or cylinder head damage may occur.
    NOTE: RH shown, LH similar.
    Fig 58: Removing Cylinder Head
    G07480478Courtesy of FORD MOTOR CO.
  67. Remove the 12 bolts and the cylinder heads.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    68. NOTE: 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.
    NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep or engine damage may occur.
    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 in the following sequence.
    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: LH shown, RH similar.
    Fig 59: Locating Cylinder Head And Cylinder Block Distortion
    G07480479Courtesy of FORD MOTOR CO.
  69. Support the cylinder heads on a bench with the head gasket side up. Check the cylinder head distortion and the cylinder block distortion, paying particular attention to the oil pressure feed area. For additional information, refer to ENGINE MECHANICAL SYSTEM - GENERAL INFORMATION article.
    70. NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.
    Fig 60: Locating Engine Support Bracket Bolts
    G07480480Courtesy of FORD MOTOR CO.
  70. Remove the 3 bolts and the LH engine support insulator bracket.
    • Discard the 3 engine support bracket bolts.
    71. NOTE: 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.
    NOTE: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep, or engine damage may occur.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces. Follow the directions on the packaging.
    Fig 61: Locating Oil Filter Adapter Bolts
    G07480481Courtesy of FORD MOTOR CO.
  71. Remove the 4 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 12 bolts, the oil pan and discard the oil pan gasket.
    Fig 62: Removing Oil Pan Gasket
    G07480482Courtesy of FORD MOTOR CO.
  73. Remove the 3 bolts, the oil pump screen and pickup tube and the spacer.
    Fig 63: Locating Oil Pump Screen, Pickup Tube, Spacer And Bolts
    G07480483Courtesy of FORD MOTOR CO.
  74. Remove the 3 bolts and the oil pump.
    Fig 64: Locating Oil Pump Bolts
    G07480484Courtesy of FORD MOTOR CO.
    75. NOTE: Make sure connecting rods and rod caps are numbered, to retain correct orientation.
    Fig 65: Locating Connecting Rod Cap Bolts
    G07480485Courtesy of FORD MOTOR CO.
  75. Remove the 20 bolts and the connecting rod caps.
    • Rotate the crankshaft so that the connecting rod is at bottom dead center.
    • Remove and discard the bolts.
    76. NOTE: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod, or engine damage may occur.
    Fig 66: Removing Piston And Rod Assembly
    G07480486Courtesy of FORD MOTOR CO.
  76. Remove the piston and rod assembly.
    • Using the Connecting Rod Installer, guide the piston and rod assembly out of the cylinder.
  77. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
  78. Disassemble the 10 pistons. For additional information, refer to PISTON  in this service information.
  79. Remove and discard the 12 cross-mounted bolts.
    Fig 67: Removing Cross-Mounted Bolts
    G07480487Courtesy of FORD MOTOR CO.
  80. Remove and discard the 12 bolts.
    Fig 68: Removing Main Bearing Cap Bolts
    G07480488Courtesy of FORD MOTOR CO.
  81. Remove the 12 main bearing cap dowel pins.
    Fig 69: Removing Main Bearing Cap Dowel Pins
    G07480489Courtesy of FORD MOTOR CO.
  82. Remove the 6 main bearing caps, the lower crankshaft main bearings and the thrust washer.
    Fig 70: Removing Main Bearing Caps, The Lower Crankshaft Main Bearings And The Thrust Washer
    G07480490Courtesy of FORD MOTOR CO.
  83. Remove the crankshaft and the crankshaft main bearings from the cylinder block.
    Fig 71: Removing Crankshaft And The Crankshaft Main Bearings
    G07480491Courtesy of FORD MOTOR CO.
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