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Section 2804 (Engine Mechanical - 6.2L (2V) - F250-F350 Super Duty): Disassembly: Engine

WARNING: This page is about a different car, the 2012 Ford Pickup and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS CHART

G06061933
 3 Jaw Puller
303-D121
G06094613
 Adapter Set, Step Plate
205-DS011 or equivalent
G06126594
 Installer, Connecting Rod
303-442 (T93P-6136-A)
G06126494
 Lifting Bracket, Engine
303-F047 (014-00073) or equivalent
G07441694
 Remover, Oil Seal
303-409 (T92C-6700-CH)
G06061949
 Remover, Crankshaft Rear Oil Seal
303-519 (T95P-6701-DH)
G06064997
 Slide Hammer
100-001 (T50T-100-A)
G06518201
 Support Brackets, Engine
303-1507 or equivalent
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 and crankshaft rear seal must be removed before mounting the engine on the engine stand.
NOTE: For additional information, refer to the exploded view under the Assembly  procedure.
    NOTE: Flexplate shown in illustration, flywheel similar.
    Fig 1: Locating Flexplate And Bolts
    G06518359Courtesy of FORD MOTOR CO.
  1. Remove the 8 bolts and the flexplate or flywheel.
    • Discard the 8 bolts.
  2. Remove the spacer plate.
    Fig 2: Locating Spacer Plate
    G06518360Courtesy of FORD MOTOR CO.
    3. NOTE: Inspect the ignition pulse ring for damage. If the ignition pulse ring has been dropped or has any visual damage, it must be discarded.
    Fig 3: Locating Crankshaft Ignition Pulse Ring
    G06518412Courtesy of FORD MOTOR CO.
  3. Remove the crankshaft ignition pulse ring.
  4. Disconnect the electrical connector and remove the bolt and the Crankshaft Position (CKP) sensor.
    Fig 4: Locating Electrical Connector And Bolt Of Crankshaft Position Sensor
    G06518361Courtesy of FORD MOTOR CO.
  5. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.
    Fig 5: Removing Crankshaft Rear Seal
    G06518414Courtesy of FORD MOTOR CO.
  6. Mount the engine on a work stand.
  7. Remove the Engine Lifting Bracket and Engine Support Brackets.
    Fig 6: Removing Engine Lifting Brackets
    G06518354Courtesy of FORD MOTOR CO.
  8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and wiring harness retainer.
    Fig 7: Locating Engine Oil Pressure Switch Electrical Connector And Wiring Harness Retainer
    G07479682Courtesy of FORD MOTOR CO.
  9. Disconnect the LH Variable Camshaft Timing (VCT) system oil control solenoid electrical connector and the 2 wiring harness retainers.
    Fig 8: Locating LH Variable Camshaft Timing System Oil Control Solenoid Electrical Connector And Wiring Harness Retainers
    G06518364Courtesy of FORD MOTOR CO.
  10. Disconnect the 3 engine wiring harness position retainers from the LH valve cover.
    Fig 9: Locating Engine Wiring Harness Position Retainers Of LH Valve Cover
    G06518365Courtesy of FORD MOTOR CO.
  11. Disconnect the wiring harness retainer, the Knock Sensor (KS) and Cylinder Head Temperature (CHT) sensor electrical connectors.
    Fig 10: Locating Wiring Harness Retainer, Knock Sensor And Cylinder Head Temperature Sensor Electrical Connector
    G06518366Courtesy of FORD MOTOR CO.
  12. Disconnect the LH and RH Camshaft Position (CMP) electrical connectors.
    Fig 11: Locating LH And RH Camshaft Position Sensor Electrical Connectors
    G06518367Courtesy of FORD MOTOR CO.
  13. Remove the nut and the radio interference capacitor.
    Fig 12: Locating Radio Ignition Interference Capacitor Nut
    G06518134Courtesy of FORD MOTOR CO.
  14. Disconnect the RH VCT system oil control solenoid electrical connector and the 2 wiring harness retainers.
    Fig 13: Locating RH Variable Camshaft Timing System Oil Control Solenoid Electrical Connector And Wiring Harness Retainers
    G06518370Courtesy of FORD MOTOR CO.
  15. Disconnect the 3 engine wiring harness position retainers from the RH valve cover and remove the engine wiring harness.
    Fig 14: Locating Engine Wiring Harness Position Retainers
    G06518371Courtesy of FORD MOTOR CO.
    16. NOTE: RH shown in illustration, LH similar.
    Fig 15: Locating Ignition Wires Of Valve Cover Retainers And Lower Spark Plugs
    G06518372Courtesy of FORD MOTOR CO.
  16. Disconnect the 8 ignition wires from the valve cover retainers and the lower spark plugs.
  17. Remove the 2 bolts and the LH and RH CMP sensors.
    Fig 16: Locating LH And RH CMP Sensors Bolts
    G06518373Courtesy of FORD MOTOR CO.
  18. Remove the 2 bolts and the RH and LH KS.
    Fig 17: Locating RH And LH Knock Sensor Bolts
    G06518427Courtesy of FORD MOTOR CO.
  19. Remove the 2 bolts and the LH exhaust manifold heat shield.
    Fig 18: Locating Exhaust Manifold Heat Shield Bolts
    G06518210Courtesy of FORD MOTOR CO.
  20. Remove the 8 nuts, the 8 studs, the LH exhaust manifold and the 2 gaskets.
    Fig 19: Locating LH Exhaust Manifold Nuts And Studs
    G06126576Courtesy of FORD MOTOR CO.
  21. Remove the 2 bolts and the RH exhaust manifold heat shield.
    Fig 20: Locating RH Exhaust Manifold Heat Shield Bolts
    G06518399Courtesy of FORD MOTOR CO.
  22. Remove the 8 nuts, the 8 bolts, the RH exhaust manifold and the 2 gaskets.
    Fig 21: Locating RH Exhaust Manifold Nuts And Studs
    G06518400Courtesy of FORD MOTOR CO.
  23. If not equipped with A/C, remove the 3 bolts and the serpentine belt Idler and bracket assembly.
    Fig 22: Locating Serpentine Belt Idler And Bracket Assembly Bolts
    G07479751Courtesy of FORD MOTOR CO.
    24. NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a tighten-to-yield design and cannot be reused.
    Fig 23: Locating LH Support Insulator-To-Cylinder Block Bolts
    G07479752Courtesy of FORD MOTOR CO.
  24. Remove the 4 bolts and the LH engine support insulator-to-cylinder block bracket.
    • Discard the 4 support insulator-to-cylinder block bolts.
    25. NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a tighten-to-yield design and cannot be reused.
    Fig 24: Locating RH Engine Support Insulator-To-Cylinder Block Bracket And Bolts
    G07479718Courtesy of FORD MOTOR CO.
  25. Remove the 4 bolts and the RH engine support insulator.
    • Discard the 4 support insulator-to-cylinder block bolts.
  26. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
    Fig 25: Locating Oil Level Indicator Tube And Bolt
    G06518374Courtesy of FORD MOTOR CO.
    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: Remove the valve cover carefully, or the Variable Camshaft Timing (VCT) system oil control solenoid may be damaged.
    NOTE: The bolts are part of the valve cover and should not be removed.
    Fig 26: Locating LH Valve Cover And Bolts
    G06518375Courtesy of FORD MOTOR CO.
  27. Loosen the 10 bolts and remove the LH valve cover and discard the 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.
    • 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: Remove the valve cover carefully, or the Variable Camshaft Timing (VCT) system oil control solenoid may be damaged.
    NOTE: The bolts are part of the valve cover and should not be removed.
    Fig 27: Locating RH Valve Cover And Bolts
    G06518376Courtesy of FORD MOTOR CO.
  28. Loosen the 10 bolts and remove the RH valve cover and discard the 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.
    • Clean the valve cover gasket groove with soap and water or a suitable solvent.
  29. Remove the 5 bolts and the oil filter adapter.
    Fig 28: Locating Oil Filter Adapter Bolts
    G07479757Courtesy of FORD MOTOR CO.
  30. Remove the bolt and the heater coolant tube.
    Fig 29: Locating Heater Coolant Tube And Bolt
    G07479758Courtesy of FORD MOTOR CO.
  31. Remove the 6 bolts, coolant pump pulley and the 2 accessory drive belt idler pulleys.
    Fig 30: Locating Coolant Pump Pulley And Accessory Drive Belt Idler Pulleys Bolts
    G06518377Courtesy of FORD MOTOR CO.
  32. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 31: Locating Accessory Drive Belt Tensioner Bolts
    G06126553Courtesy of FORD MOTOR CO.
  33. Remove the 4 bolts and the coolant pump from the cylinder block.
    • Discard the O-ring seal.
    Fig 32: Locating Coolant Pump Bolts Of Cylinder Block
    G06518440Courtesy of FORD MOTOR CO.
  34. Remove the crankshaft pulley bolt.
    • Discard the crankshaft pulley bolt.
  35. Using the 3 Jaw Puller and Step Plate, remove the crankshaft pulley.
    Fig 33: Removing Crankshaft Pulley
    G07404433Courtesy of FORD MOTOR CO.
    36. NOTE: Use care not to damage the engine front cover or the crankshaft when removing the seal.
    Fig 34: Removing Crankshaft Front Oil Seal
    G07408874Courtesy of FORD MOTOR CO.
  36. Using the Oil Seal Remover, remove the crankshaft front oil seal.
  37. Remove the 20 bolts, oil pan and oil pan gasket.
      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 35: Locating Oil Pan Gasket And Bolts
    G06518443Courtesy of FORD MOTOR CO.
    38. 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.
    Fig 36: Locating Crankshaft Rear Seal Retainer Plate And Bolts
    G06518444Courtesy of FORD MOTOR CO.
  38. Remove the 8 bolts and the crankshaft rear seal retainer plate.
    • Clean and inspect the sealing surfaces.
    39. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 37: Locating Engine Front Cover Bolts And Studs
    G06518382Courtesy of FORD MOTOR CO.
  39. Remove the 17 bolts and the 3 studs.
  40. Remove the engine front cover from the front cover-to-cylinder block dowel.
    • Remove and discard the engine front cover gaskets.
    Fig 38: Removing Engine Front Cover From Front Cover-To-Cylinder Block Dowel
    G06518141Courtesy of FORD MOTOR CO.
  41. Rotate the engine clockwise until the No. 1 intake valve is open.
  42. Remove the 10 bolts and the LH intake rocker arm shaft assembly.
    Fig 39: Locating LH Intake Rocker Arm Shaft Assembly Bolts
    G06518384Courtesy of FORD MOTOR CO.
  43. Rotate the engine clockwise until the No. 1 exhaust valve is open.
  44. Remove the 10 bolts and the LH exhaust rocker arm shaft assembly.
    Fig 40: Locating LH Exhaust Rocker Arm Shaft Assembly Bolts
    G06518385Courtesy of FORD MOTOR CO.
  45. Rotate the engine clockwise until the No. 1 intake valve is closed.
  46. Remove the 10 bolts and the RH intake rocker arm shaft assembly.
    Fig 41: Locating RH Intake Rocker Arm Shaft Assembly Bolts
    G06518386Courtesy of FORD MOTOR CO.
  47. Rotate the engine clockwise until the No. 1 exhaust valve is closed.
  48. Remove the 10 bolts and the RH exhaust rocker arm shaft assembly.
    Fig 42: Locating RH Exhaust Rocker Arm Shaft Assembly Bolts
    G06518387Courtesy of FORD MOTOR CO.
  49. Position the crankshaft keyway at the 11 o'clock position.
    Fig 43: Locating Crankshaft Keyway
    G06518157Courtesy of FORD MOTOR CO.
  50. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
    Fig 44: Locating RH Timing Chain Tensioner And Tensioner Arm Bolts
    G06518158Courtesy of FORD MOTOR CO.
  51. Remove the bolt and the RH timing chain guide.
    Fig 45: Locating RH Timing Chain Guide Bolt
    G06518159Courtesy of FORD MOTOR CO.
  52. Remove the RH timing chain.
    Fig 46: Locating RH Timing Chain
    G06518160Courtesy of FORD MOTOR CO.
  53. Remove the 2 bolts and the LH timing chain tensioner.
    Fig 47: Locating LH Timing Chain Tensioner Bolts
    G06518161Courtesy of FORD MOTOR CO.
  54. Remove the LH timing chain tensioner arm.
    Fig 48: Locating LH Timing Chain Tensioner Arm
    G06518162Courtesy of FORD MOTOR CO.
  55. Remove the bolt and the LH timing chain guide.
    Fig 49: Locating LH Timing Chain Guide And Bolt
    G06518163Courtesy of FORD MOTOR CO.
  56. Remove the LH timing chain.
    Fig 50: Locating LH Timing Chain
    G06518164Courtesy of FORD MOTOR CO.
  57. Remove the crankshaft sprocket.
    Fig 51: Locating Crankshaft Sprocket
    G06518165Courtesy of FORD MOTOR CO.
    58. NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage may 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. Failure to follow this instruction may cause engine damage.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. 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, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. Failure to follow this instruction may cause engine damage.
    Fig 52: Locating RH Cylinder Head And Bolts
    G06518402Courtesy of FORD MOTOR CO.
  58. Remove the 10 bolts and the RH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    59. NOTE: The cylinder head must be cool before removing it from the engine. Cylinder head warpage may 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. Failure to follow this instruction may cause engine damage.
    NOTE: The cylinder head bolts must be discarded and new bolts must be installed. 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, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. Failure to follow this instruction may cause engine damage.
    Fig 53: Locating LH Cylinder Head And Bolts
    G07479715Courtesy of FORD MOTOR CO.
  59. Remove the 11 bolts and the LH cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    60. 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: Observe all warnings or cautions and follow all application directions contained on the packaging of the silicone gasket remover and the metal surface prep. Failure to follow this procedure may cause engine damage.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
  60. 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.
  61. 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 SYSTEM - GENERAL INFORMATION .
  62. Remove the oil pump screen and pickup tube support bracket nut.
    Fig 54: Locating Oil Pump Screen And Pickup Tube Support Bracket Nut
    G06518262Courtesy of FORD MOTOR CO.
  63. Remove the 2 bolts and the oil pump screen and pickup tube.
    Fig 55: Locating Oil Pump Screen And Pickup Tube Bolts
    G06518263Courtesy of FORD MOTOR CO.
  64. Remove the 2 upper bolts, the 2 lower stud bolts and the oil pump.
    Fig 56: Locating Oil Pump Upper Bolts And Lower Stud Bolts
    G06518264Courtesy of FORD MOTOR CO.
  65. 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 instructions.
    66. NOTE: Verify that the connecting rods and rod caps have orientation numbers cast into them. If not, number the connecting rods and rod caps for correct orientation. Failure to follow these instructions may result in engine damage.
    Fig 57: Locating Connecting Rod Caps And Bolts
    G06137989Courtesy of FORD MOTOR CO.
  66. Remove the 16 bolts and the 8 connecting rod caps and bearings. Discard the bolts.
    67. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow this instruction may result in engine damage.
    Fig 58: Pushing Piston Through Top Of Cylinder Block
    G07479787Courtesy of FORD MOTOR CO.
  67. Use the Connecting Rod Installer to push the piston through the top of the cylinder block.
  68. Disassemble the 8 pistons. For additional information, refer to Piston .
  69. Remove and discard the 10 cross-mounted main cap bolts.
    Fig 59: Identifying Cross-Mounted Main Cap Bolts
    G07479788Courtesy of FORD MOTOR CO.
    70. NOTE: Correct stud bolt location is essential for assembly procedure. Record the stud bolt location.
    Fig 60: Locating Main Bearing Cap Bolts And Stud Bolt
    G07479789Courtesy of FORD MOTOR CO.
  70. Remove and discard the 19 main bearing cap bolts and the stud bolt.
  71. Remove the main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
    Fig 61: Locating Bearing Caps, Lower Crankshaft Main Bearings And Lower Thrust Washer
    G07479790Courtesy of FORD MOTOR CO.
  72. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
    Fig 62: Locating Crankshaft, Upper Crankshaft Main Bearings And Upper Thrust Washers
    G07479791Courtesy of FORD MOTOR CO.
  73. Remove the 4 bolts and the 4 piston oil cooler valves.
    Fig 63: Locating Piston Oil Cooler Valves And Bolts
    G06518470Courtesy of FORD MOTOR CO.
  74. Inspect the cylinder block. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
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