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Section 1260 (Engine - 6.8L): Disassembly: Engine

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0000262
 Compressor, Valve Spring 303-567 (T97P-6565-AH)
GF0000434
 Compressor Spacer, Valve Spring 303-382 (T91P-6565-AH)
GF0011693
 Engine Lift Bracket Set 303-DS086 (D93P-6001-A)
GF0000351
 Installer, Connecting Rod 303-442 (T93P-6136-A)
GF0000339
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
GF0000344
 Remover, Crankshaft Front Oil Seal 303-107 (T74P-6700-A)
GF0000317
 Remover, Crankshaft Rear Oil Seal 303-519 (T95P-6701-EH)
GF0000319
 Remover, Crankshaft Rear Oil Slinger 303-514 (T95P-6701-AH)
GF0000385
 Remover, Crankshaft Vibration Damper 303-009 (T58P-6316-D)
GF0000345
 Remover/Installer, Cylinder Head 303-572 (T97T-6565-AH)
GF0000218
 Slide Hammer 100-001 (T50T-100-A)
Material

Item Specification
Motorcraft Metal Surface Prep
ZC-31		 -
Silicone Gasket Remover
ZC-30		 -
  1. Remove the engine. For additional information, refer to Engine  under the Removal portion of this part.
  2. Remove the 8 bolts and the flexplate.
    3. Fig 1: Flexplate Bolts
    GF0011780Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove and discard the crankshaft oil slinger.
    4. Fig 2: Removing Crankshaft Rear Oil Seal Slinger
    G03920149Courtesy of FORD MOTOR CO.
  4. Using the special tools, remove and discard the crankshaft rear seal.
    5. Fig 3: Removing Crankshaft Rear Seal
    G03920150Courtesy of FORD MOTOR CO.
  5. Remove the 2 rear oil pan bolts and the 6 crankshaft rear seal retainer plate bolts and the crankshaft rear seal retainer plate.
    6. Fig 4: Identifying Crankshaft Rear Seal Retainer Plate Bolts
    GF0000352Courtesy of FORD MOTOR CO.
    CAUTION: Use care when lowering the engine, to prevent damage to the oil pan.
  6. Lower the engine onto wooden blocks.
  7. Remove the special tool.
    8. Fig 5: Identifying Special Tool (303-F047)
    G03962845Courtesy of FORD MOTOR CO.
  8. Install the special tool.
    9. Fig 6: Special Tool (303-D087)
    G04612457Courtesy of FORD MOTOR CO.
  9. Install the special tool.
    10. Fig 7: Special Tool (303-D088)
    G04612458Courtesy of FORD MOTOR CO.
  10. Mount the engine on a suitable work stand.
  11. Remove the 4 bolts and the RH engine support insulator.
    12. Fig 8: Right Engine Support Insulator Bolts
    GF0011786Courtesy of FORD MOTOR CO.
  12. Remove the 4 bolts and the LH engine support insulator.
    13. Fig 9: Left Engine Support Insulator Bolts
    GF0011791Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  13. Remove the cylinder block drain plugs and drain the coolant into a suitable container.
    14. Fig 10: Locating Cylinder Block Drain Plug
    G03885619Courtesy of FORD MOTOR CO.
  14. Disconnect the LH radio frequency interference capacitor and cylinder head temperature (CHT) sensor electrical connectors.
    15. Fig 11: Locating LH Radio Ignition Interference Capacitor & Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    G03962635Courtesy of FORD MOTOR CO.
  15. Disconnect the camshaft position (CMP) sensor electrical connector.
    16. Fig 12: Locating Camshaft Position (CMP) Sensor Electrical Connector
    G03885221Courtesy of FORD MOTOR CO.
  16. Disconnect the RH radio frequency interference capacitor electrical connector.
    17. Fig 13: Locating RH Radio Ignition Interference Capacitor Electrical Connector
    G03885622Courtesy of FORD MOTOR CO.
  17. Disconnect the knock sensor (KS) electrical connector.
    18. Fig 14: Knock Sensor (KS) Electrical Connector
    G03886734Courtesy of FORD MOTOR CO.
  18. Disconnect the crankshaft position (CKP) sensor electrical connector.
    19. Fig 15: Locating CKP Sensor Electrical Connector And Harness Retainer
    GF0002667Courtesy of FORD MOTOR CO.
  19. Disconnect the engine oil pressure (EOP) switch electrical connector.
    20. Fig 16: Locating Oil Pressure Switch Electrical Connector
    G03886309Courtesy of FORD MOTOR CO.
  20. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
    21. NOTE: RH shown, LH similar.
  21. Remove the 2 nuts and the 2 radio frequency interference capacitors.
    22. Fig 17: Radio Interference Capacitor And Retaining Nut
    G04612142Courtesy of FORD MOTOR CO.
  22. Remove the crankcase ventilation tube from the LH valve cover.
    23. Fig 18: Crankcase Ventilation Tube
    GF0011792Courtesy of FORD MOTOR CO.
  23. Remove the nut attaching the oil level indicator tube to the front of the engine.
    24. Fig 19: Oil Level Indicator Tube Nut
    GF0011787Courtesy of FORD MOTOR CO.
  24. Remove the bolt attaching the oil level indicator tube to the LH cylinder head.
    25. Fig 20: Oil Level Indicator Tube Bolt
    G03886681Courtesy of FORD MOTOR CO.
  25. Position the oil level indicator tube aside.
    26. Fig 21: Oil Level Indicator Tube
    GF0011788Courtesy 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.
    NOTE: The fasteners are part of the valve cover and should not be removed.
  26. Remove the LH valve cover.
    • 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.
    • Discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
    27. Fig 22: Identifying Valve Cover Fasteners
    G03886378Courtesy 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.
    NOTE: The fasteners are part of the valve cover and should not be removed.
  27. Remove the RH valve cover.
    • 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.
    • Discard the gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
    28. Fig 23: Identifying Valve Cover Bolts
    G03886406Courtesy of FORD MOTOR CO.
  28. Remove the bolt and the accessory drive belt idler pulley.
    29. Fig 24: Accessory Drive Belt Idler Pulley And Retaining Bolt
    G04613548Courtesy of FORD MOTOR CO.
  29. Remove the 4 bolts and the coolant pump pulley.
    30. Fig 25: Identifying Coolant Pump Pulley Bolts
    G04612515Courtesy of FORD MOTOR CO.
  30. Using the special tool, remove the crankshaft pulley.
    31. Fig 26: Removing Crankshaft Pulley Using Special Tool
    G03919906Courtesy of FORD MOTOR CO.
  31. Using the special tool, remove and discard the crankshaft front seal.
    32. Fig 27: Removing Crankshaft Front Seal Using Special Tool
    G03919889Courtesy of FORD MOTOR CO.
  32. Remove the 3 bolts and the power steering pump.
    33. Fig 28: Power Steering Pump Bolts
    GF0011694Courtesy of FORD MOTOR CO.
  33. Remove the 4 front oil pan bolts.
    34. Fig 29: Front Oil Pan Bolts
    GF0000348Courtesy of FORD MOTOR CO.
    NOTE: Correct fastener location is essential for assembly procedure. Record fastener location.
  34. Remove the fasteners.
    35. Fig 30: Front Cover Bolts
    GF0011640Courtesy of FORD MOTOR CO.
  35. Remove the engine front cover from the cylinder block.
    36. Fig 31: Removing Engine Front Cover From Cylinder Block
    GF0000349Courtesy of FORD MOTOR CO.
  36. Remove the crankshaft sensor ring from the crankshaft.
    37. Fig 32: View Of Crankshaft Sensor Ring At Crankshaft
    G04583449Courtesy of FORD MOTOR CO.
    CAUTION: The balance shaft bearing caps must be installed in their original locations. Record the balance shaft bearing cap locations. Failure to follow these instructions may result in engine damage.
  37. Remove the 6 bolts and remove the balance shaft bearing caps.
    38. Fig 33: Balance Shaft Caps & Bolts
    GF0011760Courtesy of FORD MOTOR CO.
  38. Remove the balance shaft.
    39. Fig 34: Balance Shaft
    GF0011761Courtesy of FORD MOTOR CO.
  39. Remove the 10 spark plugs. For additional information, refer to ENGINE IGNITION - 4.6L (2V) AND 5.4L (2V) article or ENGINE IGNITION - 6.8L article.
    40. NOTE: Camshaft roller follower is removed for clarity.
  40. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    41. Fig 35: Installing Special Tool Between Valve Spring Coils
    G03962476Courtesy of FORD MOTOR CO.
    CAUTION: The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in engine damage.
    NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head .
    NOTE: It may be necessary to push the valve down while compressing the spring.
    NOTE: Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.
  41. Use the special tool to compress the valve springs, and remove the all of the camshaft roller followers.
    42. Fig 36: Compressing Valve Springs Using Special Tool (303-567)
    G04612479Courtesy of FORD MOTOR CO.
  42. Position the crankshaft with the keyway at the 12 o'clock position.
    43. Fig 37: Crankshaft With Keyway At 12 O'clock Position
    GF0002691Courtesy 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. Failure to follow these instructions may result in engine damage.
  43. Remove the timing chain tensioning system from both timing chains.
    1. Remove the bolts.
    2. Remove the timing chain tensioners.
    3. Remove the timing chain tensioner arms.
    44. Fig 38: Identifying Timing Chain Tensioning System
    G03962450Courtesy of FORD MOTOR CO.
  44. Remove the timing chains and crankshaft sprocket.
    45. Fig 39: View Of Left And Right Timing Chains, Sprockets And Crankshaft Gear
    G03885313Courtesy of FORD MOTOR CO.
  45. Remove the timing chain guides.
    1. Remove the 2 bolts.
    2. Remove the LH timing chain guide.
    3. Remove the 2 bolts.
    4. Remove the RH timing chain guide.
    46. Fig 40: Identifying Timing Chain Guides
    G03962452Courtesy of FORD MOTOR CO.
  46. Remove the RH exhaust manifold.
    • Remove and discard the 10 nuts.
    • Remove the RH exhaust manifold.
    • Remove and discard the RH exhaust manifold gaskets.
    47. Fig 41: Removing RH Exhaust Manifold
    GF0005616Courtesy of FORD MOTOR CO.
  47. Remove the LH exhaust manifold.
    • Remove and discard the 10 nuts.
    • Remove the LH exhaust manifold.
    • Remove and discard the LH exhaust manifold gaskets.
    48. Fig 42: Removing LH Exhaust Manifold
    GF0005615Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  48. Remove and discard the 20 exhaust manifold studs.
    49. Fig 43: Exhaust Manifold Studs
    GF0011771Courtesy of FORD MOTOR CO.
  49. Clean and inspect the exhaust manifolds. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
  50. Install the special tools on both ends of the cylinder head.
    51. Fig 44: Identifying Special Tool (303-572)
    G04671899Courtesy of FORD MOTOR CO.
    CAUTION: The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations. Failure to follow these instructions may result in engine damage.
  51. Remove the hydraulic lash adjusters.
    52. Fig 45: Locating Hydraulic Lash Adjusters
    GF0000287Courtesy of FORD MOTOR CO.
    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. Failure to follow these instructions may result in engine damage.
    CAUTION: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused. Failure to follow these instructions may result in engine damage.
    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: LH shown, RH similar.
  52. Remove the bolts and the cylinder head.
    • Discard the cylinder head gasket.
    • Discard the cylinder head bolts.
    53. Fig 46: Removing Head
    GF0011790Courtesy 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 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. Failure to follow these instructions may result in engine damage.
    NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the surfaces.
  53. 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.
    54. 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 with 0.005 mm (0.0002 in) per running foot length. For example, if the straightedge is 61 cm (24 in) long, the machine edge must be flat with 0.010 mm (0.0004 in) from end to end.
    NOTE: LH shown, RH similar.
  54. 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 more than 0.0254 mm (0.001 in).
    55. Fig 47: Identifying Cylinder Head/Cylinder Block Oil Pressure Feed Areas
    G03885653Courtesy of FORD MOTOR CO.
  55. Remove the 4 bolts, the nut, the oil filter adapter and discard the gasket.
    56. Fig 48: Oil Filter Adapter
    GF0011793Courtesy of FORD MOTOR CO.
  56. Clean the oil filter adapter gasket surface at the cylinder block.
    57. Fig 49: Cleaning Gasket Surfaces At Cylinder Block And Oil Filter Adapter
    GF0002694Courtesy of FORD MOTOR CO.
  57. Remove the 4 coolant pump bolts and the coolant pump.
    • Discard the O-ring seal.
    58. Fig 50: Coolant Pump Bolts
    GF0000354Courtesy of FORD MOTOR CO.
  58. 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.
  59. Remove the bolts, the oil pan and the oil pan gasket.
    • Discard the oil pan gasket.
    60. Fig 51: Locating Oil Pan Gasket
    GF0005619Courtesy of FORD MOTOR CO.
  60. Remove the 3 bolts, the oil pump screen cover and tube and the spacer.
    61. Fig 52: Identifying Oil Pump Screen, Pickup Tube And Spacer
    GF0005620Courtesy of FORD MOTOR CO.
  61. Remove the 3 bolts and the oil pump.
    62. Fig 53: Locating Oil Pump Bolts
    G03962525Courtesy of FORD MOTOR CO.
    CAUTION: Make sure connecting rods and rod caps are numbered to keep them in the correct orientation. Failure to follow these instructions may result in engine damage.
  62. 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.
    63. Fig 54: Removing Bolts
    GF0044548Courtesy of FORD MOTOR CO.
    CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod. Failure to follow these instructions may result in cylinder block damage.
  63. Remove the piston and rod assembly.
    • Using the special tools, guide the piston and rod assembly out of the cylinder.
    64. Fig 55: Removing Piston And Rod Assembly
    GF0005623Courtesy of FORD MOTOR CO.
  64. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
  65. Disassemble the 10 pistons. For additional information, refer to Piston .
  66. Remove and discard the 12 cross-mounted bolts.
    67. Fig 56: Removing Cross-Mounted Bolts
    GF0044549Courtesy of FORD MOTOR CO.
  67. Remove and discard the bolts.
    68. Fig 57: Removing Bolts
    GF0005625Courtesy of FORD MOTOR CO.
  68. Remove the main bearing cap dowel pins.
    69. Fig 58: Removing Main Bearing Cap Dowel Pins
    GF0005626Courtesy of FORD MOTOR CO.
  69. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
    70. Fig 59: Removing Main Bearing Caps, Lower Crankshaft Main Bearings And Thrust Washer
    GF0005627Courtesy of FORD MOTOR CO.
  70. Remove the crankshaft and the crankshaft main bearings from the cylinder block.
    71. Fig 60: Removing Crankshaft And Crankshaft Main Bearings
    GF0005628Courtesy of FORD MOTOR CO.
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