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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.
  1. Remove the 8 bolts and the flexplate or flywheel.
    Fig 1: Locating Flexplate Bolts
    G06461750Courtesy of FORD MOTOR CO.
  2. Using the Slide Hammer and the Crankshaft Rear Oil Slinger Remover, remove and discard the crankshaft oil slinger.
    Fig 2: Removing Crankshaft Oil Slinger
    G06126453Courtesy of FORD MOTOR CO.
  3. Using the Slide Hammer and the Crankshaft Rear Oil Seal Remover, remove and discard the crankshaft rear seal.
    Fig 3: Removing Crankshaft Rear Seal Using Special Tools
    G06126454Courtesy of FORD MOTOR CO.
  4. Remove the 8 bolts and the crankshaft rear seal retainer plate.
      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 4: Inspecting Sealing Surfaces
      G06392622Courtesy of FORD MOTOR CO.
    • Clean and inspect the sealing surfaces.
  5. Mount the engine on a suitable work stand.
  6. Remove the Engine Lifting Bracket.
    Fig 5: Removing Engine Lifting Bracket
    G06126539Courtesy of FORD MOTOR CO.
  7. Remove the 3 bolts and the RH engine support insulator bracket.
    • Discard the bolts.
      Fig 6: Locating RH Engine Support Insulator Bracket Bolts
      G06772896Courtesy of FORD MOTOR CO.
  8. NOTE: LH shown in illustration, RH similar.
    Fig 7: Locating Cylinder Block Drain Plugs
    G06126542Courtesy of FORD MOTOR CO.
  9. If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.
  10. NOTE: LH shown in illustration, RH similar.
  11. If equipped, install the cylinder block drain plugs.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 8: Locating Cylinder Block Drain Plugs
      G06126542Courtesy of FORD MOTOR CO.
  12. 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.
    Fig 9: Removing Cooling Fan And Clutch Assembly
    G06126544Courtesy of FORD MOTOR CO.
  13. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, remove the cooling fan.
  14. Disconnect the RH Camshaft Position (CMP) sensor electrical connector.
    Fig 10: Locating RH Camshaft Position Sensor Electrical Connector
    G06126319Courtesy of FORD MOTOR CO.
  15. Remove the stud bolt and the RH radio ignition interference capacitor.
    Fig 11: Locating Radio Ignition Interference Capacitor And Stud Bolt
    G06126545Courtesy of FORD MOTOR CO.
  16. Disconnect the RH Variable Camshaft Timing (VCT) solenoid electrical connector.
    Fig 12: Locating VCT Solenoid Electrical Connector
    G06392555Courtesy of FORD MOTOR CO.
  17. Disconnect the Cylinder Head Temperature (CHT) sensor electrical connector.
    Fig 13: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G06126523Courtesy of FORD MOTOR CO.
  18. Remove the stud bolt and the LH radio ignition interference capacitor.
    Fig 14: Locating Radio Ignition Interference Capacitor And Stud Bolt
    G06126546Courtesy of FORD MOTOR CO.
  19. Disconnect the engine wiring harness position retainers from the front of the RH valve cover.
    Fig 15: Locating RH Valve Cover
    G06772905Courtesy of FORD MOTOR CO.
  20. Disconnect the engine wiring harness position retainers from the front of the LH valve cover and the LH CMP  sensor electrical connector.
    Fig 16: Locating Engine Wiring Harness Position Retainers
    G06772906Courtesy of FORD MOTOR CO.
  21. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
    Fig 17: Locating Engine Oil Pressure Switch Electrical Connector
    G06772907Courtesy of FORD MOTOR CO.
  22. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs.
    Fig 18: Locating Engine Wiring Harness Retainers
    G06396318Courtesy of FORD MOTOR CO.
  23. Remove the engine wiring harness from the engine assembly.
  24. NOTE: RH shown in illustration, LH similar.
  25. Remove the 8 bolts and the 8 ignition coils.
    • Remove the ignition coil, using a twisting motion while pulling up on the ignition coil.
      Fig 19: Locating Ignition Coil Bolts
      G06772909Courtesy of FORD MOTOR CO.
  26. Remove the 2 bolts and both of the Knock Sensor (KS).
    Fig 20: Locating Knock Sensors (KS) And Bolts
    G06126616Courtesy of FORD MOTOR CO.
  27. Remove the stud bolt and the coolant tube.
    • Discard the O-ring seal.
      Fig 21: Identifying Coolant Tube Stud Bolt
      G06126587Courtesy of FORD MOTOR CO.
  28. Remove the 2 bolts and the oil level indicator tube.
    • Discard the O-ring seal.
      Fig 22: Locating Oil Level Indicator Tube And Bolts
      G06772910Courtesy of FORD MOTOR CO.
  29. Remove the bolt and the intake manifold vacuum tube support bracket.
    Fig 23: Locating Intake Manifold Vacuum Tube Support Bracket And Bolt
    G06772938Courtesy of FORD MOTOR CO.
  30. 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.
  31. 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 24: Locating Valve Covers
      G06772911Courtesy of FORD MOTOR CO.
  32. 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 .
      Fig 25: Locating RH Exhaust Manifold
      G06126584Courtesy of FORD MOTOR CO.
  33. 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 .
      Fig 26: Locating Exhaust Manifold Bolt
      G06126576Courtesy of FORD MOTOR CO.
  34. Remove the 3 bolts and the LH engine support insulator.
    • Discard the bolts.
      Fig 27: Locating LH Engine Support Insulator And Bolts
      G06772984Courtesy of FORD MOTOR CO.
  35. Remove the nut, the 4 bolts and the oil filter adapter and gasket.
    • Discard the gasket.
      Fig 28: Locating Oil Filter Adapter, Gasket And Nuts
      G06772985Courtesy of FORD MOTOR CO.
  36. Remove the 5 bolts, coolant pump pulley and accessory drive belt idler pulley.
    Fig 29: Locating Coolant Pump Pulley And Idler Pulley Bolts
    G06772912Courtesy of FORD MOTOR CO.
  37. Remove the 3 bolts and the accessory drive belt tensioner.
    Fig 30: Locating Accessory Drive Belt Tensioner And Bolts
    G06126553Courtesy of FORD MOTOR CO.
  38. Remove the 4 bolts.
    Fig 31: Locating Accessory Drive Belt Tensioner Bolts
    G06396292Courtesy of FORD MOTOR CO.
  39. Remove the coolant pump from the cylinder block.
    • Discard the O-ring seal.
      Fig 32: Locating Coolant Pump
      G06137984Courtesy of FORD MOTOR CO.
  40. Remove and discard the crankshaft pulley bolt. Using the 3 Jaw Puller, remove the crankshaft pulley.
    Fig 33: Removing Crankshaft Pulley
    G06095503Courtesy of FORD MOTOR CO.
  41. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft seal.
    Fig 34: Removing Crankshaft Front Seal Using Special Tool
    G06126204Courtesy of FORD MOTOR CO.
  42. Remove the 16 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.
      Fig 35: Locating Oil Pan Sealing Surfaces
      G06392259Courtesy of FORD MOTOR CO.
    • Clean and inspect the sealing surfaces.
  43. NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
    Fig 36: Removing Front Cover Bolts
    G06772609Courtesy of FORD MOTOR CO.
  44. Remove the 15 fasteners.
  45. Remove the engine front cover from the cylinder block.
    Fig 37: Removing Engine Front Cover From Cylinder Block
    G06392579Courtesy of FORD MOTOR CO.
  46. Remove the crankshaft sensor ring from the crankshaft.
    Fig 38: Locating Crankshaft Sensor Ring
    G06126250Courtesy of FORD MOTOR CO.
  47. Position the crankshaft keyway at the 12 o'clock position.
    Fig 39: Positioning Crankshaft Keyway At 12 O'Clock Position
    G06126639Courtesy of FORD MOTOR CO.
  48. 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.
    Fig 40: Identifying Position Of Intake Camshaft Lobes And Exhaust Lobe On No. 1 Cylinder
    G06126252Courtesy of FORD MOTOR CO.
  49. 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.
  50. 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.
    Fig 41: Locating RH Cylinder Head Camshaft Roller Followers And Bolts
    G06126253Courtesy of FORD MOTOR CO.
  51. Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.
  52. 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.
    Fig 42: Removing Camshaft Roller Followers
    G06126254Courtesy of FORD MOTOR CO.
  53. Using the Valve Spring Compressor, remove the 3 camshaft roller followers designated in the previous step from the RH cylinder head.
  54. 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.
    Fig 43: Locating LH Cylinder Head Camshaft Roller Followers And Bolts
    G06126255Courtesy of FORD MOTOR CO.
  55. Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head.
  56. 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.
    Fig 44: Removing Camshaft Roller Followers
    G06126256Courtesy of FORD MOTOR CO.
  57. Using the Valve Spring Compressor, remove the 3 camshaft roller followers designated in the previous step from the LH cylinder head.
  58. NOTE: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.
    Fig 45: Positioning Crankshaft Keyway
    G06126257Courtesy of FORD MOTOR CO.
  59. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
  60. 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.
    Fig 46: Identifying LH Timing Chain Tensioner Bolts
    G06126258Courtesy of FORD MOTOR CO.
  61. Remove the 2 bolts, the LH timing chain tensioner and tensioner arm.
  62. 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.
    Fig 47: Locating RH Timing Chain Tensioner Bolts
    G06126259Courtesy of FORD MOTOR CO.
  63. Remove the 2 bolts, the RH timing chain tensioner and tensioner arm.
  64. 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 48: Locating Timing Chains And Crankshaft Sprocket (RH And LH)
      G06126260Courtesy of FORD MOTOR CO.
  65. NOTE: RH shown in illustration, LH similar.
  66. Remove the LH and RH timing chain guides.
    • Remove the 4 bolts.
    • Remove both timing chain guides.
      Fig 49: Locating Timing Chain Guide And Mounting Bolts
      G06126261Courtesy of FORD MOTOR CO.
  67. 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.
  68. Using the Cam Phaser Locking Tool, remove the bolt and the RH camshaft phaser and sprocket assembly.
    • Discard the camshaft phaser and sprocket bolt.
      Fig 50: Removing RH Camshaft Phaser And Sprocket Assembly
      G06126262Courtesy of FORD MOTOR CO.
  69. 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.
  70. Using the Cam Phaser Locking Tool, remove the bolt and the LH camshaft phaser and sprocket assembly.
    • Discard the camshaft phaser and sprocket bolt.
      Fig 51: Removing LH Camshaft Phaser And Sprocket Assembly
      G06126263Courtesy of FORD MOTOR CO.
  71. Install the Cylinder Head Remover/Installer onto the LH cylinder head.
    Fig 52: Installing Cylinder Head Remover/Installer Onto LH Cylinder Head
    G06126575Courtesy of FORD MOTOR CO.
  72. Install the Cylinder Head Remover/Installer onto the RH cylinder head.
    Fig 53: Installing Cylinder Head Remover/Installer Onto RH Cylinder Head
    G06126653Courtesy of FORD MOTOR CO.
  73. NOTE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.
    Fig 54: Locating Camshaft Front Bearing Cap And Bolts
    G06126264Courtesy of FORD MOTOR CO.
  74. Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
  75. 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.
    Fig 55: Identifying Camshaft Bearing Caps Bolts In Tightening Sequence
    G06126268Courtesy of FORD MOTOR CO.
  76. Remove the remaining 8 bolts in the sequence shown in illustration and remove the RH cylinder head camshaft bearing caps.
  77. 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 56: Locating Camshaft Front Thrust Bearing Cap Oil Metering Groove
      G06126266Courtesy of FORD MOTOR CO.
  78. Remove the RH camshaft.
  79. 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.
  80. Remove the remaining camshaft roller followers from the RH cylinder head.
  81. 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.
  82. Remove the hydraulic lash adjusters from the RH cylinder head.
  83. NOTE: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.
    Fig 57: Locating Camshaft Front Bearing Cap And Bolts
    G06126264Courtesy of FORD MOTOR CO.
  84. Remove the 2 bolts and the LH cylinder head camshaft bearing cap.
  85. 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.
    Fig 58: Identifying Camshaft Bearing Caps Bolts In Tightening Sequence
    G06126268Courtesy of FORD MOTOR CO.
  86. Remove the remaining 8 bolts in the sequence shown in illustration and remove the LH cylinder head camshaft bearing caps.
  87. 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 59: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
      G06126266Courtesy of FORD MOTOR CO.
  88. Remove the LH camshaft.
  89. 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.
  90. Remove the remaining camshaft roller followers from the LH cylinder head.
  91. 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.
  92. Remove the hydraulic lash adjusters from the LH cylinder head.
  93. 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.
  94. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
      Fig 60: Locating Cylinder Head Bolts
      G06137885Courtesy of FORD MOTOR CO.
  95. 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.
  96. 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.
  97. NOTE: LH shown in illustration, RH similar.
    Fig 61: Locating Oil Pressure Feed Area
    G06126589Courtesy of FORD MOTOR CO.
  98. 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 .
  99. Remove the 3 bolts, the oil pump screen and pickup tube and the spacer.
    Fig 62: Locating Bolts And Oil Pump Screen
    G06126662Courtesy of FORD MOTOR CO.
  100. Remove the 3 bolts and the oil pump.
    Fig 63: Locating Oil Pump And Bolts
    G06126437Courtesy of FORD MOTOR CO.
  101. 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.
  102. 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 64: Locating Connecting Rod Caps And Bolts
    G06461806Courtesy of FORD MOTOR CO.
  103. Remove the 16 bolts and the 8 connecting rod caps. Discard the bolts.
  104. NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow these instructions may result in engine damage.
    Fig 65: Pushing Piston Through Top Of Cylinder Block
    G06126665Courtesy of FORD MOTOR CO.
  105. Use the Connecting Rod Installer to push the piston through the top of the cylinder block.
  106. Disassemble the 8 pistons. For additional information, refer to PISTON .
  107. Remove the fasteners.
    1. Remove and discard the 10 cross-mounted main cap bolts.
    2. Remove the 10 dowels.
    3. Remove and discard the 10 main bearing cap bolts.
      Fig 66: Removing Main Bearing Cap Fasteners
      G06138053Courtesy of FORD MOTOR CO.
  108. Remove the main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
    Fig 67: Identifying Main Bearing Caps, Lower Crankshaft Main Bearings And Lower Thrust Washer
    G06392691Courtesy of FORD MOTOR CO.
  109. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
    Fig 68: Locating Upper Crankshaft Main Bearings, Upper Thrust Washers And Cylinder Block
    G06461810Courtesy of FORD MOTOR CO.