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Section 647 (Engine - 5.4L (3V) - F250-F550 Super Duty): Disassembly: Engine

WARNING: This page is about a different car, the 2005 Ford Pickup 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
G03920369
 Locking Tool, Camshaft Phaser Sprocket 303-1046
MATERIAL

Item Specification
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 or flywheel, 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  procedure.
  1. Remove the bolts and the flexplate or flywheel.
    Fig 1: Identifying Flexplate/Flywheel Retainer Bolts
    G03885481Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove and discard the crankshaft rear oil slinger.
    Fig 2: Removing Crankshaft Rear Oil Seal Slinger
    G03920149Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove and discard the crankshaft rear seal.
    Fig 3: Removing Crankshaft Rear Seal
    G03920150Courtesy of FORD MOTOR CO.
  4. 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.
  5. Mount the engine on a suitable work stand.
  6. Remove the special tool.
    Fig 5: Identifying Special Tool
    G03920205Courtesy of FORD MOTOR CO.
  7. Remove the 4 bolts and the RH engine support insulator.
    Fig 6: Removing Bolts And RH Engine Support Insulator
    G03920168Courtesy of FORD MOTOR CO.
  8. Remove the 4 bolts and the RH engine support insulator bracket.
    Fig 7: Removing Bolts And RH Engine Support Insulator Bracket
    G03920165Courtesy of FORD MOTOR CO.
    9. NOTE: LH shown, RH similar.
    Fig 8: Locating Cylinder Block Drain Plugs
    G03885619Courtesy of FORD MOTOR CO.
  9. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
    10. NOTE: LH shown, RH similar.
  10. Install the cylinder block drain plugs.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 9: Locating Cylinder Block Drain Plugs
      G03885619Courtesy of FORD MOTOR CO.
  11. Disconnect the RH camshaft position (CMP) sensor electrical connector.
    Fig 10: Identifying RH CMP Sensor Electrical Connector
    G03919909Courtesy of FORD MOTOR CO.
  12. Remove the stud bolt and the RH radio ignition interference capacitor.
    Fig 11: Identifying RH Radio Ignition Interference Capacitor And Stud Bolt
    G03920219Courtesy of FORD MOTOR CO.
  13. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
    Fig 12: Locating RH VCT Solenoid Electrical Connector
    G03920220Courtesy of FORD MOTOR CO.
  14. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs.
    Fig 13: Locating Engine Wiring Harness Retainers To RH Valve Cover
    G03920221Courtesy of FORD MOTOR CO.
  15. Disconnect the 4 RH ignition coil electrical connectors.
    Fig 14: Locating RH Ignition Coil Electrical Connectors
    G03920223Courtesy of FORD MOTOR CO.
  16. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    Fig 15: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03920224Courtesy of FORD MOTOR CO.
  17. Remove the stud bolt and the LH radio ignition interference capacitor.
    Fig 16: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
    G03920225Courtesy of FORD MOTOR CO.
    18. NOTE: LH shown, RH similar.
    Fig 17: Identifying Ignition Coils And Bolts
    G03920226Courtesy of FORD MOTOR CO.
  18. Remove the 8 bolts and the 8 ignition coils.
  19. Remove the engine wiring harness from the engine assembly.
  20. Remove the 2 bolts and the 2 knock sensors (KS).
    Fig 18: Identifying Knock Sensors (KS)
    G03920293Courtesy of FORD MOTOR CO.
  21. Remove the stud bolt and the coolant tube.
    • Discard the O-ring seal.
      Fig 19: Identifying Coolant Tube Stud Bolt
      G03920263Courtesy of FORD MOTOR CO.
  22. Remove the rear oil level indicator tube bolt.
    Fig 20: Locating Rear Oil Level Indicator Tube Bolt
    G03920295Courtesy of FORD MOTOR CO.
  23. Remove the bolt and the oil level indicator tube.
    • Discard the O-ring seal.
      Fig 21: Locating Front Oil Level Indicator Tube Bolt
      G03920296Courtesy of FORD MOTOR CO.
  24. Disconnect the coolant hoses from the oil cooler.
    Fig 22: Disconnecting Coolant Hoses From Oil Cooler
    G03920297Courtesy of FORD MOTOR CO.
  25. Remove the threaded shaft and discard the oil cooler.
    Fig 23: Identifying Threaded Shaft
    G03920099Courtesy of FORD MOTOR CO.
  26. Disconnect the lower radiator hose from the oil filter adapter.
    Fig 24: Disconnecting Lower Radiator Hose From Oil Filter Adapter
    G03920299Courtesy of FORD MOTOR CO.
  27. Remove the bolt and the RH CMP sensor.
    Fig 25: Identifying Bolt And RH CMP Sensor
    G03920013Courtesy of FORD MOTOR CO.
  28. Remove the bolt and the LH CMP sensor.
    Fig 26: Locating Bolt And LH CMP Sensor
    G03919989Courtesy of FORD MOTOR CO.
  29. Remove the bolt and the CKP sensor.
    Fig 27: Locating Crankshaft Position (CKP) Sensor And Bolt
    G03920231Courtesy 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.
    CAUTION: When removing the valve cover, make sure to avoid damaging the VCT solenoid.
    NOTE: The fasteners are part of the valve cover and should not be removed.
    NOTE: LH shown, RH similar.
  30. Remove the valve covers.
    • Fully loosen the fasteners 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 28: Removing Valve Covers
      G03920232Courtesy of FORD MOTOR CO.
  31. Remove the 8 nuts and the RH exhaust manifold.
  32. Remove the 3 bolts and the LH engine support insulator.
    Fig 30: Removing Bolts And LH Engine Support Insulator
    G03920166Courtesy of FORD MOTOR CO.
  33. Remove the 8 nuts and the LH exhaust manifold.
  34. Remove the nut and 4 bolts retaining the oil filter adapter and oil filter gasket to the cylinder block.
    • Discard the gasket.
      Fig 32: Removing Nut Bolts Retaining Oil Filter Adapter
      G03905800Courtesy of FORD MOTOR CO.
  35. Remove the bolts, coolant pump pulley and accessory drive belt idler pulley.
    Fig 33: Identifying Coolant Pump Pulley and Idler Pulley Bolts
    G03920233Courtesy of FORD MOTOR CO.
  36. Remove the bolts and the accessory drive belt tensioner.
    Fig 34: Identifying Accessory Drive Belt Tensioner Bolts
    G03920234Courtesy of FORD MOTOR CO.
  37. Remove the bolts.
    Fig 35: Identifying Coolant Pump Bolts
    G03885825Courtesy of FORD MOTOR CO.
  38. Remove the coolant pump from the cylinder block.
    Fig 36: Identifying Coolant Pump
    G03885759Courtesy of FORD MOTOR CO.
  39. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    Fig 37: Removing Crankshaft Pulley Using Special Tool
    G03919906Courtesy of FORD MOTOR CO.
  40. Using the special tool, remove and discard the crankshaft front seal.
    Fig 38: Removing Crankshaft Front Seal Using Special Tool
    G03919889Courtesy of FORD MOTOR CO.
  41. Remove the bolts, oil pan and oil pan gasket.
      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 39: Identifying Oil Pan Bolts
      G03885459Courtesy of FORD MOTOR CO.
    • Clean and inspect the sealing surfaces.
    42. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 40: Removing Front Cover Bolts
    G03919913Courtesy of FORD MOTOR CO.
  42. Remove the fasteners.
  43. Remove the engine front cover from the cylinder block.
    Fig 41: Removing Engine Front Cover From Cylinder Block
    G03885740Courtesy of FORD MOTOR CO.
  44. Remove the crankshaft sensor ring from the crankshaft.
    Fig 42: Removing Crankshaft Sensor Ring
    G04583449Courtesy of FORD MOTOR CO.
  45. Position the crankshaft key way at the 12 o'clock position.
    Fig 43: Positioning Crankshaft Keyway At 12 O'Clock Position
    G03919943Courtesy of FORD MOTOR CO.
    46. NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require 1 full additional rotation to 12 o'clock.
    Fig 44: Positioning Camshaft Lobes
    G03919944Courtesy of FORD MOTOR CO.
  46. 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.
    47. 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.
    Fig 45: Locating RH Cylinder Head Camshaft Roller Followers And Bolts
    G03919945Courtesy of FORD MOTOR CO.
  47. Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.
    48. 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 46: Compressing Valve Spring With Special Tool
    G03919946Courtesy of FORD MOTOR CO.
  48. Using the special tool, remove the 3 designated camshaft roller followers in the previous +step from the RH cylinder head.
    49. 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.
    Fig 47: Locating LH Cylinder Head Camshaft Roller Followers And Bolts
    G03919947Courtesy of FORD MOTOR CO.
  49. Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head.
    50. 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 48: Compressing Spring Using Special Tool
    G03919948Courtesy of FORD MOTOR CO.
  50. Using the special tool, remove the 3 designated camshaft roller followers in the previous step from the LH cylinder head.
    51. CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set.
    Fig 49: Positioning Crankshaft Keyway At 6 O'Clock Position
    G03919949Courtesy of FORD MOTOR CO.
  51. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    52. 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 50: Identifying LH Timing Chain Tensioner Bolts
    G03919950Courtesy of FORD MOTOR CO.
  52. Remove the bolts, the LH timing chain tensioner and tensioner arm.
    53. 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 51: Identifying RH Timing Chain Tensioner Bolts
    G03919951Courtesy of FORD MOTOR CO.
  53. Remove the bolts, the RH timing chain tensioner and tensioner arm.
  54. Remove the RH and LH timing chains 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 crankshaft sprocket.
      Fig 52: Removing Timing Chain
      G03919952Courtesy of FORD MOTOR CO.
    55. NOTE: RH shown, LH similar.
  55. Remove the LH and RH timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
      Fig 53: Identifying Timing Chain Guide And Mounting Bolts
      G03919953Courtesy of FORD MOTOR CO.
    56. CAUTION: Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
  56. Using the special tool, remove the bolt and the RH VCT phaser sprocket assembly.
    • Discard the VCT phaser sprocket bolt.
      Fig 54: Identifying VCT Phaser Sprocket Bolt And Holder Tool
      G03919954Courtesy of FORD MOTOR CO.
    57. CAUTION: Damage to the VCT phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the VCT phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
  57. Using the special tool, remove the bolt and the LH VCT phaser sprocket assembly.
    • Discard the VCT phaser sprocket bolt.
      Fig 55: Installing Special Tool
      G03919955Courtesy of FORD MOTOR CO.
  58. Install the special tool onto the LH cylinder head.
    Fig 56: Installing Special Tool Onto LH Cylinder Head
    G03920258Courtesy of FORD MOTOR CO.
  59. Install the special tool onto the RH cylinder head.
    Fig 57: Installing Special Tool Onto RH Cylinder Head
    G03920261Courtesy of FORD MOTOR CO.
    60. 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 58: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequences
    G03919956Courtesy of FORD MOTOR CO.
  60. Remove the bolts in the sequence shown and remove the RH cylinder head front camshaft bearing cap and then the remaining bearing caps.
  61. 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 59: Identifying Camshaft Front Thrust Bearing Cap
      G03919957Courtesy of FORD MOTOR CO.
  62. Remove the RH camshaft.
    63. 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.
  63. Remove the remaining camshaft roller followers from the RH cylinder head.
    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 RH cylinder head.
    65. 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 60: Identifying Camshaft Bearing Cap Bolt Loosening/Tightening Sequences
    G03919956Courtesy of FORD MOTOR CO.
  65. Remove the bolts in the sequence shown and remove the LH cylinder head front camshaft bearing cap and then the remaining bearing caps.
  66. 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 61: Identifying Camshaft Front Thrust Bearing Cap
      G03919957Courtesy of FORD MOTOR CO.
  67. Remove the LH camshaft.
    68. 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.
  68. Remove the remaining camshaft roller followers from the LH cylinder head.
    69. 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.
  69. Remove the hydraulic lash adjusters from the LH cylinder head.
    70. 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.
  70. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 62: Removing Cylinder Head Bolts
      G03885651Courtesy 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.
  71. 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.
    72. 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 63: Identifying Oil Pressure Feed Area Of Deck Face Surface
    G03885653Courtesy of FORD MOTOR CO.
  72. 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).
  73. Remove the bolts, the oil pump screen and pickup tube and the spacer.
    Fig 64: Removing Oil Pump Screen And Pickup Tube Bolts
    G03920339Courtesy of FORD MOTOR CO.
  74. Remove the 3 bolts and the oil pump.
    Fig 65: Identifying Oil Pump Bolts
    G04638972Courtesy of FORD MOTOR CO.
  75. 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.
    76. CAUTION: 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.
    Fig 66: Identifying Bolts And Connecting Rod Caps
    G04583770Courtesy of FORD MOTOR CO.
  76. Remove the bolts and the connecting rod caps. Discard the bolts.
    77. CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod.
    Fig 67: Pushing Piston Through Top Of Cylinder Block
    G03920342Courtesy of FORD MOTOR CO.
  77. Use the special tool to push the piston through the top of the cylinder block.
  78. Disassemble the 8 pistons. For additional information, refer to PISTON .
  79. Remove the fasteners.
    1. Remove and discard the cross-mounted main cap bolts.
    2. Remove the dowels.
    3. Remove and discard the main bearing cap bolts.
      Fig 68: Removing Dowels
      G03920343Courtesy of FORD MOTOR CO.
  80. Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
    Fig 69: Removing Main Bearing Caps
    G03920344Courtesy of FORD MOTOR CO.
  81. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
    Fig 70: Removing Crankshaft And Main Bearings From Cylinder Block
    G03881879Courtesy of FORD MOTOR CO.
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