Section 2746 (Engine Mechanical - 5.4L (3V) -- F250-F350 Super Duty): Disassembly: Engine: Material
WARNING: This page is about a different car, the 2010 Ford Pickup and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
ITEM SPECIFICATION
| 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 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.
- Remove the 8 bolts and the flexplate or flywheel.
- Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger.
- Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.
- Remove the 8 bolts and the crankshaft rear seal retainer plate.
- Clean and inspect the sealing surfaces.
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. - Mount the engine on a suitable work stand.
- Remove the Engine Lifting Bracket.
- Remove the 3 bolts and the RH engine support insulator bracket.
- Discard the bolts.
- If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.
- If equipped, install the cylinder block drain plugs.
- Tighten to 24 Nm (18 lb-ft).
- Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan.
- Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
- Remove the stud bolt and the RH radio ignition interference capacitor.
- Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
- Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
- Remove the stud bolt and the LH radio ignition interference capacitor.
- Disconnect the engine wiring harness position retainers from the front of the RH valve cover.
- Disconnect the engine wiring harness position retainers from the front of the LH valve cover and the LH CMP sensor electrical connector.
- Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
- Disconnect the 2 engine wiring harness retainers from the RH valve cover studs.
- Remove the engine wiring harness from the engine assembly.
- Remove the 8 bolts and the 8 ignition coils.
- Remove the ignition coil, using a twisting motion while pulling up on the ignition coil.
- Remove the 2 bolts and both of the Knock Sensor (KS).
- Remove the stud bolt and the coolant tube.
- Discard the O-ring seal.
- Remove the 2 bolts and the oil level indicator tube.
- Discard the O-ring seal.
- Remove the bolt and the intake manifold vacuum tube support bracket.
- 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.
- Remove the 8 nuts, the 8 studs and the RH exhaust manifold.
- Discard the gaskets, nuts and studs.
- Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
- Remove the 8 nuts, the 8 studs and the LH exhaust manifold.
- Discard the gaskets, nuts and studs.
- Inspect the exhaust manifold. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION .
- Remove the 3 bolts and the LH engine support insulator.
- Discard the bolts.
- Remove the nut, the 4 bolts and the oil filter adapter and gasket.
- Discard the gasket.
- Remove the 5 bolts, coolant pump pulley and accessory drive belt idler pulley.
- Remove the 3 bolts and the accessory drive belt tensioner.
- Remove the 4 bolts.
- Remove the coolant pump from the cylinder block.
- Discard the O-ring seal.
- Remove and discard the crankshaft pulley bolt. Using the 3 Jaw Puller, remove the crankshaft pulley.
- Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft seal.
- Remove the 16 bolts, oil pan and oil pan gasket.
- Clean and inspect the sealing surfaces.
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. - Remove the 15 fasteners.
- Remove the engine front cover from the cylinder block.
- Remove the crankshaft sensor ring from the crankshaft.
- Position the crankshaft keyway 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 Valve Spring Compressor, remove the 3 camshaft roller followers designated in the previous step from the RH cylinder head.
- Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head.
- Using the Valve Spring Compressor, remove the 3 camshaft roller followers designated 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 2 bolts, the LH timing chain tensioner and tensioner arm.
- Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
- 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.
- Remove the LH and RH timing chain guides.
- Remove the 4 bolts.
- Remove both timing chain guides.
- Using the Cam Phaser Locking Tool, remove the bolt and the RH camshaft phaser and sprocket assembly.
- Discard the camshaft phaser and sprocket bolt.
- Using the Cam Phaser Locking Tool, remove the bolt and the LH camshaft phaser and sprocket assembly.
- Discard the camshaft phaser and sprocket bolt.
- Install the Cylinder Head Remover/Installer onto the LH cylinder head.
- Install the Cylinder Head Remover/Installer onto the RH cylinder head.
- Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
- Remove the remaining 8 bolts in the sequence shown in illustration and remove the RH cylinder head camshaft 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 remaining camshaft roller followers from the RH cylinder head.
- Remove the hydraulic lash adjusters from the RH cylinder head.
- Remove the 2 bolts and the LH cylinder head camshaft bearing cap.
- Remove the remaining 8 bolts in the sequence shown in illustration and remove the LH cylinder head camshaft 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 the remaining camshaft roller followers from the LH cylinder head.
- Remove the hydraulic lash adjusters from the LH cylinder head.
- 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 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 .
- Remove the 3 bolts, the oil pump screen and pickup tube and the spacer.
- Remove the 3 bolts and the oil pump.
- 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's instructions.
- Remove the 16 bolts and the 8 connecting rod caps. Discard the bolts.
- Use the Connecting Rod Installer to push the piston through the top of the cylinder block.
- Disassemble the 8 pistons. For additional information, refer to PISTON .
- Remove the fasteners.
- Remove and discard the 10 cross-mounted main cap bolts.
- Remove the 10 dowels.
- Remove and discard the 10 main bearing cap bolts.
- Remove the main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
- Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
NOTE:
LH shown in illustration, RH similar.
NOTE:
LH shown in illustration, RH similar.
NOTE:
Do not side load the cooling fan clutch coil or the cooling fan clutch coil may be damaged.
NOTE:
The large clutch assembly nut has a RH thread and must be rotated counterclockwise to remove it.
NOTE:
RH shown in illustration, LH similar.
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:
When removing the valve cover, make sure to avoid damaging the Variable Camshaft Timing (VCT) solenoid.
NOTE:
The fasteners are part of the valve cover and should not be removed.
NOTE:
LH shown in illustration, RH similar.
NOTE:
Correct fastener location is essential for assembly procedure. Record fastener location.
NOTE:
If the camshaft lobes are not exactly positioned as shown in illustration, the crankshaft will require one full additional rotation to 12 o'clock.
NOTE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.
NOTE:
It may be necessary to push the valve down while compressing the spring.
NOTE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
NOTE:
Do not allow the valve keepers to fall off of the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.
NOTE:
It may be necessary to push the valve down while compressing the spring.
NOTE:
The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.
NOTE:
If one or both 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.
NOTE:
If one or both 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.
NOTE:
RH shown in illustration, LH similar.
NOTE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
NOTE:
Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket.
NOTE:
Damage to the camshaft phaser and sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
NOTE:
Only use hand tools to remove the camshaft phaser and sprocket assembly or damage may occur to the camshaft or camshaft phaser and sprocket.
NOTE:
Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.
NOTE:
The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage.
NOTE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
NOTE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
NOTE:
Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.
NOTE:
The camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. Failure to follow these instructions may result in engine damage.
NOTE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations. Failure to follow these instructions may result in engine damage.
NOTE:
If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. Failure to follow these instructions may result in engine damage.
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 procedure 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 procedure may cause engine damage.
NOTE:
RH shown in illustration, LH similar.
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.
NOTE:
LH shown in illustration, RH similar.
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.
NOTE:
Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow these instructions may result in engine damage.