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Section 795 (Engine - 6.8L (3V) -- F250-F550 Super Duty): Disassembly: Engine

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000319
 Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
GF0000218
 Slide Hammer 100-001 (T50T-100-A)
GF0000351
 Installer, Connecting Rod 303-442 (T93P-6136-A)
GF0000339
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
GF0000385
 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
GF0000345
 Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
GF0000344
 Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
GF0000317
 Remover, Crankshaft Rear Seal 303-519 (T95P-6701-DH)
GF0000329
 Compressor, Valve Spring 303-1039
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, 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 in this article.
  1. Remove the engine. For additional information, refer to Engine  in the Removal portion of this article.
  2. Remove the bolts and the flexplate.
    Fig 1: Identifying Flexplate Bolts
    GF0002789Courtesy 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 and discard the crankshaft rear oil slinger.
    Fig 2: Removing Crankshaft Rear Oil Seal Slinger
    G03920149Courtesy of FORD MOTOR CO.
  5. Using the special tools, remove and discard 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.
    • Clean and inspect the sealing surfaces.
    Fig 4: Identifying Crankshaft Rear Seal Retainer Plate Bolts
    GF0000352Courtesy of FORD MOTOR CO.
    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: Identifying Special Tool
    GF0005612Courtesy 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: Locating RH Engine Mount Bolts
    G04647883Courtesy of FORD MOTOR CO.
    11. NOTE: LH shown, RH similar.
    Fig 7: Locating Cylinder Block Drain Plug
    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 RH Radio Ignition 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 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: Locating Ignition Coil Electrical Connectors
    GF0005613Courtesy of FORD MOTOR CO.
  17. Remove the 10 bolts and the 10 ignition coils.
    Fig 13: Locating Ignition Coils Bolts
    GF0005614Courtesy 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: Identifying 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 Crankshaft Position (CKP) Sensor Electrical Connector
    GF0002667Courtesy 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: Locating Camshaft (CMP) Sensor Bolt
    G03920013Courtesy of FORD MOTOR CO.
  26. Remove the bolt and the CKP sensor.
    Fig 21: Locating Crankshaft Position (CKP) Sensor Bolt
    G03920231Courtesy of FORD MOTOR CO.
  27. Remove the 10 nuts and the RH exhaust manifold.
    • Discard the gasket.
    Fig 22: Removing RH Exhaust Manifold
    GF0005616Courtesy of FORD MOTOR CO.
  28. Remove the 10 nuts and the LH exhaust manifold.
    • Discard the gasket.
    Fig 23: Removing LH Exhaust Manifold
    GF0005615Courtesy 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.
    Fig 24: Identifying Valve Cover Fasteners Loosening/Tightening Sequence
    G03920595Courtesy of FORD MOTOR CO.
  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.
    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.
    Fig 25: Identifying Valve Cover Fasteners Tightening Sequence
    G03920580Courtesy of FORD MOTOR CO.
  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.
  31. Remove the bolts, coolant pump pulley and accessory drive belt idler pulley.
    Fig 26: Identifying Coolant Pump Pulley Bolts And Idler Pulley Bolt
    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 and discard 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: Identifying Front Oil Pan Bolts
    GF0000348Courtesy of FORD MOTOR CO.
    36. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 31: Locating Fasteners
    GF0005525Courtesy 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
    GF0000349Courtesy 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: Identifying 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 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: View Of Crankshaft Sensor Ring At Crankshaft
    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: Identifying Camshaft Lobe Position
    G03919944Courtesy of FORD MOTOR CO.
  43. 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.
    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: Identifying Camshaft Roller Followers On RH Cylinder Head
    GF0005576Courtesy of FORD MOTOR CO.
  44. Remove only the 3 camshaft 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: Identifying Special Tool For Removing/Installing Camshaft Roller Followers
    G03919946Courtesy of FORD MOTOR CO.
  45. Using the special tool, remove the 3 designated camshaft 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: Identifying Camshaft Roller Followers On LH Cylinder Head
    GF0005577Courtesy of FORD MOTOR CO.
  46. Remove only the 4 camshaft 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 camshaft 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: Crankshaft Positioned With Keyway At 6 O'clock Position
    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 & Tensioner Arm
    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: Locating RH Timing Chain Tensioner And Tensioner Arm
    GF0005578Courtesy 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: View Of Left And Right Timing Chains, Sprockets And Crankshaft Gear
    G03885313Courtesy of FORD MOTOR CO.
  52. Remove the 4 bolts and the timing chain guides.
    Fig 47: Locating Timing Chain Guides Bolts
    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
    GF0005579Courtesy 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 Cap Bolt Removal/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 Oil Metering Groove
    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 Removal/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 Oil Metering Groove
    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 (KS).
    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: Identifying Special Tool Onto Cylinder Head
    G03920258Courtesy of FORD MOTOR CO.
  66. Install the special tool onto the RH cylinder head.
    Fig 56: Identifying Special Tool On Cylinder Head
    G03920261Courtesy of FORD MOTOR CO.
  67. Remove the stud bolt and the coolant tube.
    • Discard the O-ring seals.
    Fig 57: Identifying Coolant Tube Stud Bolt
    G03920263Courtesy of FORD MOTOR CO.
    68. 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.
    Fig 58: Removing Cylinder Head Bolts
    GF0005617Courtesy of FORD MOTOR CO.
  68. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    69. 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.
  69. Clean the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block.
    • Remove any large deposits of silicone or gasket material with a plastic scraper.
    • Apply silicone gasket remover, following package directions, and allow to set for several minutes.
    • 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.
    • 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.
    70. 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 59: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
    G03885653Courtesy of FORD MOTOR CO.
  70. 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).
  71. Remove the 4 bolts and the LH engine mount.
    Fig 60: Locating LH Engine Mount Bolts
    GF0005607Courtesy of FORD MOTOR CO.
    72. 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. Follow the directions on the packaging.
    Fig 61: Identifying Oil Filter Adapter Bolts And Nut
    GF0005618Courtesy of FORD MOTOR CO.
  72. Remove the bolts and nut retaining the oil filter adapter to the cylinder block. Remove the oil filter adapter and clean the gasket surface.
  73. Remove the bolts, the oil pan and discard the oil pan gasket.
    Fig 62: Locating Oil Pan Gasket
    GF0005619Courtesy of FORD MOTOR CO.
  74. Remove the 3 bolts, the oil pump screen and pickup tube and the spacer.
    Fig 63: Identifying Oil Pump Screen, Pickup Tube And Spacer
    GF0005620Courtesy of FORD MOTOR CO.
  75. Remove the 3 bolts and the oil pump.
    Fig 64: Removing Oil Pump Bolts
    GF0005621Courtesy of FORD MOTOR CO.
    76. CAUTION: Make sure connecting rods and rod caps are numbered, to retain correct orientation.
    Fig 65: Identifying Connecting Rod Caps Bolts
    GF0005622Courtesy of FORD MOTOR CO.
  76. 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.
    77. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.
    Fig 66: Removing Piston And Rod Assembly
    GF0005623Courtesy of FORD MOTOR CO.
  77. Remove the piston and rod assembly.
    • Using the special tools, guide the piston and rod assembly out of the cylinder.
  78. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
  79. Disassemble the 10 pistons. For additional information, refer to Piston  in this article.
  80. Remove and discard the 12 cross-mounted bolts.
    Fig 67: Removing Cross-Mounted Bolts
    GF0005624Courtesy of FORD MOTOR CO.
  81. Remove and discard the bolts.
    Fig 68: Removing Bolts
    GF0005625Courtesy of FORD MOTOR CO.
  82. Remove the main bearing cap dowel pins.
    Fig 69: Removing Main Bearing Cap Dowel Pins
    GF0005626Courtesy of FORD MOTOR CO.
  83. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
    Fig 70: Removing Main Bearing Caps, Lower Crankshaft Main Bearings And Thrust Washer
    GF0005627Courtesy of FORD MOTOR CO.
  84. Remove the crankshaft and the crankshaft main bearings from the cylinder block.
    Fig 71: Removing Crankshaft And Crankshaft Main Bearings
    GF0005628Courtesy of FORD MOTOR CO.
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