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Section 2100 (Engine - 5.4L (3V) -- F-250 & F350 Super Duty): Disassembly: Engine

WARNING: This page is about a different car, the 2008 Ford Pickup and 2008 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
GF0000319Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
GF0000218Courtesy of FORD MOTOR CO.
 Slide Hammer 100-001 (T50T-100-A)
GF0000351Courtesy of FORD MOTOR CO.
 Installer, Connecting Rod 303-442 (T93P-6136-A)
GF0000339Courtesy of FORD MOTOR CO.
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
GF0000385Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
GF0000345Courtesy of FORD MOTOR CO.
 Remover/Installer, Cylinder Head 303-572 (T97T-6000-A)
GF0000344Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
GF0000317Courtesy of FORD MOTOR CO.
 Remover, Crankshaft Rear Seal 303-519 (T95P-6701-DH)
GF0000329Courtesy of FORD MOTOR CO.
 Compressor, Valve Spring 303-1039
GF0000330Courtesy of FORD MOTOR CO.
 Locking Tool, Camshaft Phaser Sprocket 303-1046
GF0005877Courtesy of FORD MOTOR CO.
 Fan Pulley Holding Wrench 303-239 (T84T-6312-C)
GF0002829Courtesy of FORD MOTOR CO.
 Fan Clutch Nut Wrench 303-240 (T84T-6312-D)
Material

Item Specification
Motorcraft Metal Surface Prep
ZC-31		 -
Silicone Gasket Remover
ZC-30		 -
CAUTION: Remove the cylinder heads before removing the crankshaft. Failure to do so may 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, 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 .
  1. Remove the bolts and the flexplate or flywheel.
    2. Fig 1: Identifying Flexplate Bolts
    GF0002789Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove and discard the crankshaft rear oil slinger.
    3. 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.
    4. 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.
    • Clean and inspect the sealing surfaces.
    5. Fig 4: Identifying Crankshaft Rear Seal Retainer Plate Bolts
    GF0000352Courtesy of FORD MOTOR CO.
  5. Mount the engine on a suitable work stand.
  6. Remove the special tool.
    7. Fig 5: Identifying Special Tool (303-F047)
    G03920205Courtesy of FORD MOTOR CO.
  7. Remove the 3 bolts and the RH engine support insulator bracket.
    • Discard the bolts.
    8. Fig 6: Locating RH Engine Support Insulator Bracket Bolts
    GF0048365Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  8. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
    9. Fig 7: Locating Cylinder Block Drain Plug
    G03885619Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  9. Install the cylinder block drain plugs.
    • Tighten to 24 Nm (18 lb-ft).
    10. Fig 8: Locating Cylinder Block Drain Plug
    G03885619Courtesy of FORD MOTOR CO.
    NOTE: The large clutch assembly nut has a RH thread and must be rotated counterclockwise to remove it.
  10. Using the special tools, remove the engine cooling fan from the coolant pump pulley.
    11. Fig 9: Fan Clutch Assembly Nut - 4.6L, 5.4L
    GF0005880Courtesy of FORD MOTOR CO.
  11. Disconnect the RH camshaft position (CMP) sensor electrical connector.
    12. 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.
    13. Fig 11: Identifying RH Radio Ignition Interference Capacitor Stud Bolt
    G03920219Courtesy of FORD MOTOR CO.
  13. Disconnect the RH variable camshaft timing (VCT) solenoid electrical connector.
    14. Fig 12: Locating Camshaft Timing (VCT) Solenoid Electrical Connectors
    G03920220Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  14. Disconnect the 8 ignition coil electrical connectors.
    15. Fig 13: Locating Ignition Coil Electrical Connectors
    GF0048366Courtesy of FORD MOTOR CO.
  15. Disconnect the cylinder head temperature (CHT) sensor electrical connector.
    16. Fig 14: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector
    G03920224Courtesy of FORD MOTOR CO.
  16. Remove the stud bolt and the LH radio ignition interference capacitor.
    17. Fig 15: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt
    G03920225Courtesy of FORD MOTOR CO.
  17. Disconnect the engine wiring harness position retainers from the front of the RH valve cover.
    18. Fig 16: Locating Engine Wiring Harness Position Retainers From Front Of RH Valve Cover
    GF0048367Courtesy of FORD MOTOR CO.
  18. Disconnect the engine wiring harness position retainers from the front of the LH valve cover and the LH CMP sensor electrical connector.
    19. Fig 17: Locating Engine Wiring Harness Position Retainers From Front Of LH Valve Cover
    GF0048368Courtesy of FORD MOTOR CO.
  19. Disconnect the engine oil pressure (EOP) switch electrical connector.
    20. Fig 18: Locating Engine Oil Pressure (EOP) Switch Electrical Connector
    GF0048369Courtesy of FORD MOTOR CO.
  20. Disconnect the 2 engine wiring harness retainers from the LH valve cover studs.
    21. Fig 19: Locating Engine Wiring Harness Retainers From LH Valve Cover Studs
    GF0048370Courtesy of FORD MOTOR CO.
  21. Disconnect the 2 engine wiring harness retainers from the RH valve cover studs.
    22. Fig 20: Locating Engine Wiring Harness Retainers At RH Valve Cover
    G03920221Courtesy of FORD MOTOR CO.
  22. Remove the engine wiring harness from the engine assembly.
    23. NOTE: RH shown, LH similar.
  23. Remove the 8 bolts and the 8 ignition coils.
    • Remove the ignition coil, using a twisting motion while pulling up on the ignition coil.
    24. Fig 21: Locating Ignition Coils & Bolts
    GF0040926Courtesy of FORD MOTOR CO.
  24. Remove the 2 bolts and the 2 knock sensors (KS).
    25. Fig 22: Identifying Knock Sensors (KS)
    G03920293Courtesy of FORD MOTOR CO.
  25. Remove the stud bolt and the coolant tube.
    • Discard the O-ring seal.
    26. Fig 23: Identifying Coolant Tube Stud Bolt
    G03920263Courtesy of FORD MOTOR CO.
  26. Remove the 2 bolts and the oil level indicator tube.
    • Discard the O-ring seal.
    27. Fig 24: Locating Bolts & Oil Level Indicator Tube
    GF0048371Courtesy of FORD MOTOR CO.
  27. Remove the bolt and the RH CMP sensor.
    28. Fig 25: Locating Camshaft (CMP) Sensor Bolt
    G03920013Courtesy of FORD MOTOR CO.
  28. Remove the bolt and the LH CMP sensor.
    29. Fig 26: Locating LH CMP Sensor Bolt
    G03919989Courtesy of FORD MOTOR CO.
  29. Remove the bolt and the CKP sensor.
    30. Fig 27: Locating Crankshaft Position (CKP) Sensor Bolt
    G03920231Courtesy of FORD MOTOR CO.
  30. Disconnect the intake manifold vacuum tube from the valve cover stud and the support bracket.
    31. Fig 28: Locating Intake Manifold Vacuum Tube From Valve Cover Stud & Support Bracket
    GF0048372Courtesy of FORD MOTOR CO.
  31. Remove the bolt and the intake manifold vacuum tube support bracket.
    32. Fig 29: Locating Bolt & Intake Manifold Vacuum Tube Support Bracket
    GF0048373Courtesy of FORD MOTOR CO.
    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 variable camshaft timing (VCT) solenoid.
    NOTE: The fasteners are part of the valve cover and should not be removed.
    NOTE: LH shown, RH similar.
  32. 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 Motorcraft 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.
    33. Fig 30: Locating Valve Cover Bolts
    GF0002791Courtesy of FORD MOTOR CO.
  33. Remove the 2 bolts and the RH exhaust manifold heat shield.
    34. Fig 31: Locating Bolts & RH Exhaust Manifold Heat Shield
    GF0048375Courtesy of FORD MOTOR CO.
  34. Remove the 8 nuts, the 8 studs and the RH exhaust manifold.
    35. Fig 32: Locating Exhaust Manifold
    GF0002794Courtesy of FORD MOTOR CO.
  35. Remove the 3 bolts and the LH exhaust manifold shield.
    36. Fig 33: Locating Bolts & LH Exhaust Manifold Shield
    GF0048374Courtesy of FORD MOTOR CO.
  36. Remove the 8 nuts, the 8 studs and the LH exhaust manifold.
    37. Fig 34: Locating LH Exhaust Manifold Nuts And Studs
    GF0002792Courtesy of FORD MOTOR CO.
  37. Remove the 3 bolts and the LH engine support insulator.
    • Discard the bolts.
    38. Fig 35: Locating LH Engine Support Insulator Bolts
    GF0048376Courtesy of FORD MOTOR CO.
  38. Remove the nut, the 4 bolts and the oil filter adapter and gasket.
    • Discard the gasket.
    39. Fig 36: Locating Oil Filter Adapter, Gasket, Bolts & Nuts
    GF0048377Courtesy of FORD MOTOR CO.
  39. Remove the bolts, coolant pump pulley and accessory drive belt idler pulley.
    40. Fig 37: Identifying Coolant Pump Pulley Bolts And Idler Pulley Bolt
    G03920233Courtesy of FORD MOTOR CO.
  40. Remove the bolts and the accessory drive belt tensioner.
    41. Fig 38: Identifying Accessory Drive Belt Tensioner Bolts
    G03920234Courtesy of FORD MOTOR CO.
  41. Remove the bolts.
    42. Fig 39: Coolant Pump Bolts
    GF0000354Courtesy of FORD MOTOR CO.
  42. Remove the coolant pump from the cylinder block.
    • Discard the O-ring seal.
    43. Fig 40: Identifying Coolant Pump
    G03885759Courtesy of FORD MOTOR CO.
  43. Remove and discard the crankshaft pulley bolt. Using the special tool, remove the crankshaft pulley.
    44. Fig 41: Removing Crankshaft Pulley Using Special Tool (303-009)
    G03919906Courtesy of FORD MOTOR CO.
  44. Using the special tool, remove and discard the crankshaft front seal.
    45. Fig 42: Removing Crankshaft Front Seal Using Special Tool (303-107)
    G03919889Courtesy of FORD MOTOR CO.
  45. 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.
    • Clean and inspect the sealing surfaces.
    46. Fig 43: Locating Oil Pan And Oil Pan Gasket Bolts
    GF0000321Courtesy of FORD MOTOR CO.
    NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
  46. Remove the fasteners.
    47. Fig 44: Locating Bolts And Studs
    GF0005525Courtesy of FORD MOTOR CO.
  47. Remove the engine front cover from the cylinder block.
    48. Fig 45: Removing Engine Front Cover From Cylinder Block
    GF0000349Courtesy of FORD MOTOR CO.
  48. Remove the crankshaft sensor ring from the crankshaft.
    49. Fig 46: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
  49. Position the crankshaft keyway at the 12 o'clock position.
    50. Fig 47: Positioning Crankshaft Keyway At 12 O'Clock Position
    G03919943Courtesy of FORD MOTOR CO.
    NOTE: If the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.
  50. 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.
    51. Fig 48: Identifying Camshaft Lobe Position
    G03919944Courtesy of FORD MOTOR CO.
    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. Failure to follow these instructions may result in engine damage.
  51. Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.
    52. Fig 49: Identifying RH Cylinder Head Camshaft Roller Followers And Bolts
    G03919945Courtesy of FORD MOTOR CO.
    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.
  52. Using the special tool, remove the 3 camshaft roller followers designated in the previous step from the RH cylinder head.
    53. Fig 50: Identifying Special Tool (303-1039) For Removing/Installing Camshaft Roller Followers
    G03919946Courtesy of FORD MOTOR CO.
    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. Failure to follow these instructions may result in engine damage.
  53. Remove only the 3 camshaft roller followers shown in the illustration from the LH cylinder head.
    54. Fig 51: Locating LH Cylinder Head Camshaft Roller Followers And Bolts
    G03919947Courtesy of FORD MOTOR CO.
    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.
  54. Using the special tool, remove the 3 camshaft roller followers designated in the previous step from the LH cylinder head.
    55. Fig 52: Compressing Spring Using Special Tool (303-1039)
    G03919948Courtesy of FORD MOTOR CO.
    CAUTION: The crankshaft cannot be moved past the 6 o'clock position once set or engine damage may occur.
  55. Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
    56. Fig 53: Crankshaft Positioned With Keyway At 6 O'clock Position
    G03919949Courtesy of FORD MOTOR CO.
    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 or engine damage may occur.
  56. Remove the bolts, the LH timing chain tensioner and tensioner arm.
    57. Fig 54: Identifying LH Timing Chain Tensioner & Tensioner Arm
    G03919950Courtesy of FORD MOTOR CO.
    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 or engine damage may occur.
  57. Remove the bolts, the RH timing chain tensioner and tensioner arm.
    58. Fig 55: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts
    G03919951Courtesy of FORD MOTOR CO.
  58. 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.
    59. Fig 56: Identifying RH/LH Timing Chains
    G03919952Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  59. Remove the LH and RH timing chain guides.
    • Remove the bolts.
    • Remove both timing chain guides.
    60. Fig 57: Identifying Timing Chain Guide And Mounting Bolts
    G03919953Courtesy of FORD MOTOR CO.
    CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the variable camshaft timing (VCT) phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
  60. Using the special tool, remove the bolt and the RH VCT phaser sprocket assembly.
    • Discard the VCT phaser sprocket bolt.
    61. Fig 58: Identifying VCT Phaser Sprocket Bolt And Holder Tool
    G03919954Courtesy of FORD MOTOR CO.
    CAUTION: Damage to the variable camshaft timing (VCT) phaser sprocket assembly will occur if mishandled or used as a lifting or leveraging device.
    CAUTION: Only use hand tools to remove the variable camshaft timing (VCT) phaser sprocket assembly or damage may occur to the camshaft or VCT phaser sprocket.
  61. Using the special tool, remove the bolt and the LH VCT phaser sprocket assembly.
    • Discard the VCT phaser sprocket bolt.
    62. Fig 59: Identifying Special Sprocket Phaser Tool
    G03919955Courtesy of FORD MOTOR CO.
  62. Install the special tool onto the LH cylinder head.
    63. Fig 60: Identifying Special Tool (303-572) Onto Cylinder Head
    G03920258Courtesy of FORD MOTOR CO.
  63. Install the special tool onto the RH cylinder head.
    64. Fig 61: Identifying Special Tool (303-572) On Cylinder Head
    G03920261Courtesy of FORD MOTOR CO.
    CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.
  64. Remove the 2 bolts and the RH cylinder head camshaft front bearing cap.
    65. Fig 62: Removing Camshaft Front Bearing Cap Bolts
    GF0005526Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  65. Remove the remaining bolts in the sequence shown and remove the RH cylinder head camshaft bearing caps.
    66. Fig 63: Removing Camshaft Bearing Caps Bolts In Sequence
    GF0005527Courtesy of FORD MOTOR CO.
  66. 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.
    67. Fig 64: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
    G03919957Courtesy of FORD MOTOR CO.
  67. Remove the RH camshaft.
    68. 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. Failure to follow these instructions may result in engine damage.
  68. Remove the remaining camshaft roller followers from the RH 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. Failure to follow these instructions may result in engine damage.
  69. Remove the hydraulic lash adjusters from the RH cylinder head.
    70. CAUTION: Remove the front thrust camshaft bearing cap straight upward from the bearing towers or the bearing cap may be damaged from side loading.
  70. Remove the 2 bolts and the LH cylinder head camshaft bearing cap.
    71. Fig 65: Removing Camshaft Front Bearing Cap Bolts
    GF0005526Courtesy of FORD MOTOR CO.
    CAUTION: 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.
  71. Remove the remaining bolts in the sequence shown and remove the LH cylinder head camshaft bearing caps.
    72. Fig 66: Removing Camshaft Bearing Caps Bolts In Sequence
    GF0005527Courtesy of FORD MOTOR CO.
  72. 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.
    73. Fig 67: Identifying Camshaft Front Thrust Bearing Cap Oil Metering Groove
    G03919957Courtesy of FORD MOTOR CO.
  73. Remove the LH camshaft.
    74. 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. Failure to follow these instructions may result in engine damage.
  74. Remove the remaining camshaft roller followers from the LH cylinder head.
    75. 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. Failure to follow these instructions may result in engine damage.
  75. Remove the hydraulic lash adjusters from the LH cylinder head.
    76. CAUTION: 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.
    CAUTION: 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.
    CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design 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, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    CAUTION: 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, LH similar.
  76. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    77. Fig 68: Cylinder Head Bolts
    GF0022046Courtesy of FORD MOTOR CO.
    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: Observe all warnings or cautions and follow all application directions contained on the packaging of the Silicone Gasket Remover and the Motorcraft Metal Surface Prep. Failure to follow this procedure may cause engine damage.
    NOTE: If there is no residual gasket material present, Motorcraft Metal Surface Prep can be used to clean and prepare the surfaces.
  77. 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 Motorcraft 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.
    78. 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, such as Snap-On® GA438A or equivalent. 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.
  78. 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).
    79. Fig 69: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
    G03885653Courtesy of FORD MOTOR CO.
  79. Remove the bolts, the oil pump screen and pickup tube and the spacer.
    80. Fig 70: Locating Oil Pump Screen Bolts, Pickup Tube & Spacer
    GF0002695Courtesy of FORD MOTOR CO.
  80. Remove the 3 bolts and the oil pump.
    81. Fig 71: Locating Oil Pump Bolts
    G04638972Courtesy of FORD MOTOR CO.
  81. 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.
    82. 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. Failure to follow these instructions may result in engine damage.
  82. Remove the bolts and the connecting rod caps. Discard the bolts.
    83. Fig 72: Locating Connecting Rod Caps
    GF0000355Courtesy of FORD MOTOR CO.
    CAUTION: Do not scratch the cylinder walls or crankshaft journals with the connecting rod. Failure to follow these instructions may result in engine damage.
  83. Use the special tool to push the piston through the top of the cylinder block.
    84. Fig 73: Pushing Piston Through Top Of Cylinder Block
    G03920342Courtesy of FORD MOTOR CO.
  84. Disassemble the 8 pistons. For additional information, refer to Piston .
  85. 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.
    86. Fig 74: Identifying Main Bearing Cap Bolts
    GF0002796Courtesy of FORD MOTOR CO.
  86. Remove the 5 main bearing caps, the lower crankshaft main bearings and the lower thrust washer.
    87. Fig 75: Locating Main Bearing Caps, Lower Crankshaft Main Bearings And Lower Thrust Washer
    GF0000356Courtesy of FORD MOTOR CO.
  87. Remove the crankshaft, the upper crankshaft main bearings and the upper thrust washers from the cylinder block.
    88. Fig 76: Removing Crankshaft, Upper Crankshaft Main Bearings And Upper Thrust Washers From Cylinder Block
    GF0000357Courtesy of FORD MOTOR CO.
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