Section 927 (Engine - 6.8L (3V) -- F250-F550 Super Duty): Disassembly: Engine
WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOL(S) SPECIFICATIONS
| Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH) |
|
| Slide Hammer 100-001 (T50T-100-A) |
|
| Installer, Connecting Rod 303-442 (T93P-6136-A) |
|
| Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent |
|
| Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D) |
|
| Remover/Installer, Cylinder Head 303-572 (T97T-6000-A) |
|
| Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A) |
|
| Remover, Crankshaft Rear Seal 303-519 (T95P-6701-DH) |
|
| Compressor, Valve Spring 303-1039 |
MATERIAL SPECIFICATIONS
| 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.
- Remove the engine. For additional information, refer to ENGINE in the Removal portion of this section.
- Remove the bolts and the flexplate.
- Lower and support the engine assembly on wood blocks.
- Using the special tools, remove and discard the crankshaft rear oil slinger.
- Using the special tools, remove and discard the crankshaft rear seal.
- Remove the bolts and the crankshaft rear seal retainer plate.
- Clean and inspect the sealing surfaces.
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. - Lower and support the engine assembly on wood blocks.
- Remove the special tool.
- Install the engine assembly onto a suitable engine stand.
- Remove the bolts and the RH engine mount.
- Remove the cylinder block drain plugs and drain the coolant into a suitable container.
- Disconnect the camshaft position (CMP) sensor electrical connector.
- Disconnect the RH radio ignition interference capacitor electrical connector.
- Remove the nut and the RH radio ignition interference capacitor.
- Disconnect the electrical connector retainer from the coolant tube support bracket.
- Disconnect the 10 ignition coil electrical connectors.
- Remove the 10 bolts and the 10 ignition coils.
- Disconnect the cylinder head temperature (CHT) sensor electrical connector.
- Disconnect the engine oil pressure (EOP) sensor electrical connector.
- Remove the nut and the LH radio ignition interference capacitor.
- Disconnect the crankshaft position (CKP) sensor electrical connector.
- Disconnect the engine harness retainers and remove the engine wiring harness from the engine assembly.
- Remove the rear oil level indicator tube bolt.
- Remove the bolt and the oil level indicator tube.
- Discard the O-ring seal.
- Remove the bolt and the CMP sensor.
- Remove the bolt and the CKP sensor.
- Remove the 10 nuts and the RH exhaust manifold.
- Discard the gasket.
- Remove the 10 nuts and the LH exhaust manifold.
- Discard the gasket.
- 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.
- 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.
- Remove the bolts, coolant pump pulley and accessory drive belt idler pulley.
- Remove the bolts and the accessory drive belt tensioner.
- Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
- Using the special tool, remove and discard the crankshaft seal.
- Remove the front 4 oil pan bolts.
- Remove the fasteners.
- Remove the engine front cover from the cylinder block.
- Loosen and backoff the RH camshaft sprocket bolt 1 full turn.
- Loosen the LH camshaft sprocket bolt.
- Remove the 6 bolts in the sequence shown, the 3 bearing caps and the balance shaft.
- Remove the crankshaft sensor ring from the crankshaft.
- Position the crankshaft key way at the 12 o'clock position.
- 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.
- Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.
- Using the special tool, remove the 3 designated camshaft roller followers in the previous step from the RH cylinder head.
- Remove only the 4 camshaft roller followers shown in the illustration from the LH cylinder head.
- Using the special tool, remove the 4 designated camshaft roller followers in the previous step from the LH cylinder head.
- Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
- Remove the bolts, the LH timing chain tensioner and tensioner arm.
- Remove the bolts, the RH timing chain tensioner and tensioner arm.
- 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.
- Remove the 4 bolts and the timing chain guides.
- Remove the bolts and the RH and LH camshaft sprockets.
- Remove the balance shaft drive gear from the LH camshaft.
- Remove the bolts in the sequence shown and remove the RH cylinder head front camshaft bearing cap and then the remaining bearing caps.
- 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.
- Remove the RH camshaft.
- Remove the bolts in the sequence shown and remove the LH cylinder head front camshaft bearing cap and then the remaining bearing caps.
- 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.
- Remove the LH camshaft.
- Remove all of the remaining roller followers from the cylinder heads.
- Remove the 2 bolts and the 2 knock sensors (KS).
- Remove the stud bolt and the coolant tube.
- Discard the O-ring seal.
- Remove the hydraulic lash adjusters from the LH cylinder head.
- Install the special tool onto the LH cylinder head.
- Install the special tool onto the RH cylinder head.
- Remove the stud bolt and the coolant tube.
- Discard the O-ring seals.
- Remove the bolts and the cylinder head.
- Discard the cylinder head gasket.
- Discard the cylinder head bolts.
- 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.
- 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).
- Remove the 4 bolts and the LH engine mount.
- Remove the bolts and nut retaining the oil filter adapter to the cylinder block. Remove the oil filter adapter and clean the gasket surface.
- Remove the bolts, the oil pan and discard the oil pan gasket.
- Remove the 3 bolts, the oil pump screen and pickup tube and the spacer.
- Remove the 3 bolts and the oil pump.
- 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.
- Remove the piston and rod assembly.
- Using the special tools, guide the piston and rod assembly out of the cylinder.
- Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
- Disassemble the 10 pistons. For additional information, refer to PISTON .
- Remove and discard the 12 cross-mounted bolts.
- Remove and discard the bolts.
- Remove the main bearing cap dowel pins.
- Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
- Remove the crankshaft and the crankshaft main bearings from the cylinder block.
CAUTION:
Do not use the oil pan to support the engine.
CAUTION:
Do not use the oil pan to support the engine.
NOTE:
LH shown, RH similar.
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.
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.
NOTE:
Correct fastener location is essential for assembly procedure. Record fastener location.
CAUTION:
Only use hand tools to loosen the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
CAUTION:
Only use hand tools to loosen the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket.
NOTE:
The balance shaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations.
NOTE:
If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.
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.
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.
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.
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.
CAUTION:
The crankshaft cannot be moved past the 6 o'clock position once set.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
CAUTION:
Make sure connecting rods and rod caps are numbered, to retain correct orientation.
CAUTION:
Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.