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Section 249 (Engine - 6.8L): Disassembly: Engine: Material

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Material Specification Chart
G01537393Courtesy of FORD MOTOR CO.
  1. Remove the bolts and the flexplate.
    Fig 2: Removing Flexplate
    G01537394Courtesy of FORD MOTOR CO.
  2. Using the special tools, remove the crankshaft rear slinger.
    Fig 3: Removing Crankshaft Rear Slinger
    G01537395Courtesy of FORD MOTOR CO.
  3. Using the special tools, remove the crankshaft rear seal.
    Fig 4: Removing Crankshaft Rear Seal
    G01537396Courtesy of FORD MOTOR CO.
  4. Remove the bolts and the crankshaft rear seal retainer plate.
    Fig 5: Removing Crankshaft Rear Seal Retainer Plate
    G01537397Courtesy of FORD MOTOR CO.
  5. Mount the engine on an engine stand.
  6. Remove the Modular Engine Lift Bracket.
  7. With the engine on the engine stand, remove the engine wiring harness.
  8. Remove the bolts, the oil pan, and the oil pan gasket.
    Fig 6: Removing Oil Pan And Oil Pan Gasket
    G01537398Courtesy of FORD MOTOR CO.
  9. Remove the bolts, the oil pump screen cover and tube, and the spacer.
    Fig 7: Removing Oil Pump Screen Cover, Tube And Spacer
    G01537399Courtesy of FORD MOTOR CO.
    10. NOTE: The bolts are a part of the valve cover and are not to be removed.
    Fig 8: Removing Valve Covers And Valve Cover Gaskets
    G01537400Courtesy of FORD MOTOR CO.
  10. LH is shown, RH is similar.
    • Fully loosen the 32 bolts, and remove the valve covers and the valve cover gaskets.
  11. Remove the water pump pulley.
    1. Remove the bolts.
    2. Remove the water pump pulley.
    Fig 9: Removing Water Pump Pulley
    G01537401Courtesy of FORD MOTOR CO.
  12. Remove the bolts.
    Fig 10: Removing Water Pump Bolts
    G01537402Courtesy of FORD MOTOR CO.
  13. Remove the water pump from the cylinder block.
    Fig 11: Removing Water Pump From Cylinder Block
    G01537403Courtesy of FORD MOTOR CO.
  14. Remove the crankshaft pulley bolt and, using the special tool, remove the crankshaft pulley.
    Fig 12: Removing Crankshaft Pulley
    G01537404Courtesy of FORD MOTOR CO.
  15. Using the special tool, remove the crankshaft front seal.
    Fig 13: Removing Crankshaft Front Seal
    G01537405Courtesy of FORD MOTOR CO.
  16. Remove the engine front cover fasteners.
    Fig 14: Removing Engine Front Cover Fasteners
    G01537406Courtesy of FORD MOTOR CO.
  17. Remove the engine front cover from the front cover to cylinder block dowels.
    Fig 15: Removing Engine Front Cover
    G01537407Courtesy of FORD MOTOR CO.
  18. Remove the crankshaft sensor ring from the crankshaft.
    Fig 16: Removing Crankshaft Sensor Ring From Crankshaft
    G01537408Courtesy of FORD MOTOR CO.
  19. Position the piston of the cylinder being serviced at the bottom of the stroke and the camshaft lobe at base circle.
  20. Install the special tool between the valve spring coils to prevent valve stem seal damage.
    Fig 17: Installing Special Tool Between Valve Spring Coils For Preventing Valve Stem Seal Damage
    G01537409Courtesy of FORD MOTOR CO.
    21. NOTE: The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations.
    Fig 18: Removing Camshaft Roller Followers
    G01537410Courtesy of FORD MOTOR CO.
  21. Use the special tool to compress the valve springs, and remove the camshaft roller followers.
  22. Remove the special tool.
    Fig 19: Removing Special Tool
    G01537411Courtesy of FORD MOTOR CO.
    23. CAUTION: The bearing caps must be marked for installation in their original location or engine damage can occur.
    Fig 20: Removing Bearing Caps
    G01537412Courtesy of FORD MOTOR CO.
    Fig 21: Removing Balance Shaft
    G01537413Courtesy of FORD MOTOR CO.
  23. Remove the six bolts, the bearing caps and the balance shaft.
    24. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
    Fig 22: Rotating Crankshaft For Aligning Timing Mark On RH Camshaft Sprocket And LH Camshaft Sprocket
    G01537414Courtesy of FORD MOTOR CO.
  24. Rotate the crankshaft until the timing mark on the RH camshaft sprocket is approximately at the 11 o'clock position and the timing mark on the LH camshaft sprocket is approximately at the 12 o'clock position.
  25. Remove the bolts and the timing chain tensioners. Remove the timing chain tensioner arms from the dowel pins.
    Fig 23: Removing Timing Chain Tensioner and Timing Chain Tensioner Arms From Dowel Pins
    G01537415Courtesy of FORD MOTOR CO.
    26. CAUTION: Unless otherwise instructed, at no time when the timing chains are removed and the cylinder heads are installed is the crankshaft or camshaft to be rotated. Severe piston and valve damage will occur.
    Fig 24: Removing LH And RH Timing Chain And Crankshaft Sprocket
    G01537416Courtesy of FORD MOTOR CO.
  26. Remove the LH and RH timing chain 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 from the crankshaft sprocket.
  27. Remove the bolts and the timing chain guides.
    Fig 25: Removing Timing Chain Guides
    G01537417Courtesy of FORD MOTOR CO.
  28. Remove the 10 nuts and the RH exhaust manifold and exhaust manifold gaskets. Discard the exhaust manifold gaskets.
    Fig 26: Removing RH Exhaust Manifold And Exhaust Manifold Gaskets
    G01537418Courtesy of FORD MOTOR CO.
  29. Remove the 10 nuts, the LH exhaust manifold and the exhaust manifold gaskets. Discard the exhaust manifold gaskets.
    Fig 27: Removing LH Exhaust Manifold And Exhaust Manifold Gaskets
    G01537419Courtesy of FORD MOTOR CO.
  30. Remove the oil level indicator, the bolt and the oil level indicator tube.
    Fig 28: Removing Oil Level Indicator Tube
    G01537420Courtesy of FORD MOTOR CO.
  31. Install the special tools on both ends of the cylinder head.
    Fig 29: Installing Special Tools On Both Ends Of Cylinder Head
    G01537421Courtesy of FORD MOTOR CO.
    32. CAUTION: The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
    Fig 30: Removing Cylinder Head
    G01537422Courtesy of FORD MOTOR CO.
  32. Remove the bolts and the cylinder head.
    • Discard the head gasket and clean the engine block surface.
    • LH is shown, RH is similar.
    33. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the cylinder head. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of oil sealant.
  33. Clean and inspect the cylinder head surface.
  34. Remove the bolts and the engine mounts.
  35. Remove the bolts and nut retaining the oil filter adapter to the cylinder block. Remove the oil filter adapter and clean the gasket surface.
    Fig 31: Removing Oil Filter Adapter
    G01537423Courtesy of FORD MOTOR CO.
  36. Remove the bolts and the oil pump.
    Fig 32: Removing Oil Pump
    G01537424Courtesy of FORD MOTOR CO.
    37. CAUTION: Make sure connecting rods and rod caps are numbered, to keep in correct orientation.
    Fig 33: Removing Connecting Rod Caps
    G01537425Courtesy of FORD MOTOR CO.
  37. 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.
    38. CAUTION: Do not scratch the cylinder walls or the crankshaft journals with the connecting rod.
    Fig 34: Removing Piston And Rod Assembly
    G01537426Courtesy of FORD MOTOR CO.
  38. Remove the piston and rod assembly.
    • Using the special tool, guide the piston and rod assembly out of the cylinder.
  39. Repeat the previous steps until all 10 piston and rod assemblies have been removed from the cylinder block.
  40. Remove and discard the 12 cross-mounted bolts.
    Fig 35: Removing Cross-Mounted Bolts
    G01537427Courtesy of FORD MOTOR CO.
  41. Remove and discard the bolts.
    Fig 36: Removing Main Bearing Caps Bolts
    G01537428Courtesy of FORD MOTOR CO.
  42. Remove the main bearing cap dowel pins.
    Fig 37: Removing Main Bearing Cap Dowel Pins
    G01537429Courtesy of FORD MOTOR CO.
  43. Remove the main bearing caps, the lower crankshaft main bearings and the thrust washer.
    Fig 38: Removing Main Bearing Caps
    G01537430Courtesy of FORD MOTOR CO.
  44. Remove the crankshaft and the crankshaft main bearings from the cylinder block.
    Fig 39: Removing Crankshaft And Crankshaft Main Bearings From Cylinder Block
    G01537431Courtesy of FORD MOTOR CO.
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