The procedure is similar for both ford and Lincoln car models:-----
Cylinder Head
REMOVAL & INSTALLATION
F150 1/2 ton P/U 2WD/ 4WD
F250 Super Duty P/U 2WD/4WD
F350 Super Duty P/U 2WD/4WD
F450 Super Duty P/U 2WD/4WD
F550 Super Duty P/U 2WD/4WD
AND Lincoln Mark LT Models
Removal & Installation
6.8L Engine
- Before servicing the vehicle, refer to the Precautions Section.
- Remove the engine.
- Remove the bolts and the flexplate or the flywheel.
CAUTIONDo not use the oil pan to support the engine. - Lower and support the engine assembly on wood blocks.
- Using the special tools, remove and discard the crankshaft rear oil slinger.
- Using the special tools, remove and discard the crankshaft rear seal.
- Remove the bolts and the crankshaft rear seal retainer plate.
- Mount the engine on a suitable work stand.
- Remove the right engine mount.
- Remove the cylinder block drain plugs and drain the coolant into a suitable container.
- Disconnect the camshaft position (CMP) electrical connector.
- Disconnect the right radio frequency interference capacitor electrical connector and the capacitor.
- Disconnect the electrical connector retainer from the coolant tube support bracket.
- Disconnect the 10 ignition coil electrical connectors.
- Remove the 10 bolts and the 10 ignition coils.
- Disconnect the cylinder head temperature (CHT) sensor electrical connector.
- Disconnect the engine oil pressure (EOP) sensor electrical connector.
- Remove the nut and the LH radio ignition interference capacitor.
- Disconnect the crankshaft position (CKP) sensor electrical connector.
- Remove the nuts and position the wiring harness aside.
- Remove the rear oil indicator tube and bracket.
- Disconnect and remove the CMP sensor.
- Remove the CKP sensor.
NOTEThe bolts are part of the valve cover and should not be removed. - Loosen the 16 fasteners in an alternating sequence and remove the valve cover and gasket.
- 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 valve cover gasket. Clean the valve cover gasket groove with soap and water or a suitable solvent.
- 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.
- Clean the valve cover mating surfaces 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 bolt and the idler pulley.
- Remove the coolant pump pulley.
- Remove the bolts and the accessory drive belt tensioner.
- Using a suitable tool, remove and discard the crankshaft pulley bolt. Remove the crankshaft pulley.
- Using a suitable tool, remove the crankshaft front seal.
- Remove the front four oil pan bolts.
NOTECorrect engine front cover fastener location is essential for assembly procedure. Record fastener location. - Remove the engine front cover fasteners.
- Remove the engine front cover from the cylinder block.
CAUTIONOnly use hand tools to loosen the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket. - Loosen and back off the RH camshaft sprocket bolt 1 full turn.
- Loosen the LH camshaft sprocket bolt.
NOTEThe balance shaft caps must be marked for installation in their original locations or damage to the engine may occur. - Remove the six bolts, in the sequence shown, and remove the balance shaft bearing caps.
- Remove the balance shaft.
- Remove the crankshaft sensor ring from the crankshaft.
- Position the crankshaft with the keyway at the 12 o'clock position.
NOTEIf the camshaft lobes are not exactly positioned as shown, the crankshaft will require one full additional rotation to 12 o'clock.
NOTEThe 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.
CAUTIONIf the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
- Remove only the 3 camshaft roller followers shown in the illustration from the RH cylinder head.
CAUTIONDo not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.
NOTEIt may be necessary to push the valve down while compressing the spring.
- Using the special tool, remove the 3 designated camshaft roller followers in the previous step from the RH cylinder head.
CAUTIONIf the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into the original locations.
- Remove only the 4 camshaft roller followers shown in the illustration from the LH cylinder head.
CAUTIONDo not allow the valve keepers to fall off the valve or the valve may drop into the cylinder.
NOTEIt may be necessary to push the valve down while compressing the spring.
- Using the special tool, remove the 4 designated camshaft roller followers in the previous step from the LH cylinder head.
CAUTIONThe crankshaft cannot be moved past the 6 o'clock position once set.
- Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
CAUTIONIf 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.
- Remove the bolts, the LH and RH timing chain tensioner and tensioner arm.
- Remove the timing chains. Where necessary, remove the crankshaft sprocket with the chain.
- Remove the 4 bolts and the timing chain guides.
- Remove the bolts and the RH and LH camshaft sprockets.
- Remove the balance shaft drive gear from the LH camshaft.
CAUTIONRemove the front thrust camshaft bearing cap straight upward from the bearing towers, or the bearing cap may be damaged from sideloading.
NOTEThe camshaft bearing caps must be installed in their original locations. Record camshaft bearing cap locations. - Remove the bolts in the sequence shown and remove the RH cylinder head front camshaft bearing cap and then the remaining 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.
- Repeat the above steps for the LH camshaft.
- Remove all of the remaining roller followers from the cylinder heads.
CAUTIONIf the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations. - Remove the hydraulic lash adjusters from the cylinder head.
- Install the special tool onto the cylinder head.
- Remove the nuts and the exhaust manifold. Discard the gasket.
- Remove the stud bolt and the coolant tube.
- Discard the O-ring seals.
- 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.
NOTEMake 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.
NOTEUse a straightedge that is calibrated by the manufacturer to be flat within 0.0002 inch (0.005 mm) per running foot length. For example, if the straightedge is 24 inch (61 cm) long, the machined edge must be flat within 0.0004 inch (0.010 mm) from end to end. - 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 0.001 inch (0.0254 mm) across a 1.5 inch (38.1 mm) square area, or scratches longer than 0.001 inch (0.0254 mm).
To install:
CAUTION
The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry.
CAUTION
The cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
NOTE
Do not turn the crankshaft until instructed to do so.
- Using the special tools, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
NOTEBe sure to tighten the bolts in 3 stages. - Tighten the bolts in the sequence shown.
- Install the cylinder block drain plugs. Tighten to 18 ft. lbs. (24 Nm).
- Install the RH engine mount and the bolts. Tighten to 46 ft. lbs. (63 Nm).
LH Cylinder Head
- Remove the special lifting tool from the LH cylinder head.
- Install the hydraulic lash adjusters into the LH cylinder head. Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
- Position a new gasket, the LH exhaust manifold and tighten the 10 nuts in the sequence shown. Tighten to 18 ft. lbs. (25 Nm).
RH Cylinder Head
- Remove the special lifting tool from the RH cylinder head.
- Install the hydraulic lash adjusters into the RH cylinder head. Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.
- Position a new gasket, the RH exhaust manifold and tighten the 10 nuts in the sequence shown. Tighten to 18 ft. lbs. (25 Nm).
- Install the coolant tube and the stud bolt. Tighten to 89 inch lbs. (10 Nm).
All Cylinder Heads
CAUTION
If the components are to be reinstalled, they must be installed into their original locations.
NOTE
Lubricate the camshaft roller followers with clean engine oil prior to installation.
6.8L Engine
- Install only the identified camshaft roller followers onto the RH cylinder head.
CAUTIONIf the components are to be reinstalled, they must be installed into their original locations.
NOTELubricate the camshaft roller followers with clean engine oil prior to installation.
- Install only the identified camshaft roller followers onto the LH cylinder head.
- Install the LH and RH camshafts. Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
- Install the LH and RH camshaft bearing caps in their original locations. Lubricate the camshaft bearing caps with clean engine oil.
- Position the front camshaft bearing cap. Position the remaining camshaft bearing caps. Install the bolts loosely.
- Tighten the LH camshaft bearing cap bolts in 2 stages:
- Install the balance shaft drive gear onto the LH camshaft.
- Install both camshaft sprockets and camshaft sprocket bolts finger tight.
CAUTIONTiming chain procedures must be followed exactly or damage to valves and pistons will result.
CAUTIONPrior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner. - Compress the tensioner plunger, using a vise.
- Install a retaining clip on the tensioner to hold the plunger in during installation.
NOTEThere are 61 links in each timing chain. - If copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.
- Install the timing chain guides and the 4 bolts. Tighten to 89 inch lbs. (10 Nm).
- Preposition the camshafts:
- Position the crankshaft with the special tool, then remove the tool.
- Install the crankshaft sprocket, marking sure the flange faces forward.
- Install the lower end of the LH timing chain, aligning the timing marks.
NOTEBe sure the upper half of the timing chain is below the tensioner guide dowel.
- Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.
NOTEThe LH timing chain tensioner arm has a bump near the dowel hole for identification. - Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and bolts. Tighten to 18 ft. lbs. (25 Nm).
NOTEBe sure the chain link and crankshaft sprocket timing marks are aligned. The lower half of the timing chain must be positioned above the dowel. - Install the RH (outer) timing chain on the crankshaft sprocket.
- Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.
- Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and bolts. Tighten to 18 ft. lbs. (25 Nm).
- Remove the retaining clips from the RH and LH timing chain tensioners.
- Check for correct alignment of all timing marks.
- Install the crankshaft sensor ring on the crankshaft.
CAUTIONOnly use hand tools to tighten the camshaft sprocket bolt or damage may occur to the camshaft or camshaft sprocket. - Tighten the RH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 30 ft. lbs. (40 Nm).
- Stage 2: Tighten an additional 90 degrees.
- Tighten the LH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 30 ft. lbs. (40 Nm).
- Stage 2: Tighten an additional 90 degrees.
- Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.
- Remove the 2 bolts and the camshaft bearing cap.
CAUTIONIf the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.
- Using the special tool, install the roller follower. Lubricate the camshaft roller follower with clean engine oil prior to installation.
- Position the camshaft bearing cap and install the bolts in 2 stages:
- Stage 1: Tighten to 71 inch lbs. (8 Nm).
- Stage 2: Tighten an additional 45 degrees.
- Repeat for the remaining roller followers with similar bearing cap.
- Using the special tool, install all of the remaining camshaft roller followers. Lubricate the camshaft roller followers with clean engine oil prior to installation.
- Rotate the crankshaft counterclockwise and position the crankshaft keyway at the 11 o'clock position.
- Lubricate the balance shaft journals with clean engine oil.
- Using the index mark on the balance shaft, mark the corresponding gear tooth with chalk.
- Position the balance shaft on the journals.
NOTEIt may be necessary to use an inspection mirror to see the marks. - Position the balance shaft on the journals and align the chalk mark on the balance shaft with the camshaft timing mark as shown.
NOTEInstall the balance shaft bearing caps in their original locations
- Install the bolts and tighten in the sequence shown. Tighten to 89 inch lbs. (10 Nm).
CAUTIONDo 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.
NOTEIf the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
NOTEMake sure that the engine front cover gasket is in place on the engine front cover before installation.
- Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.
- Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the fasteners finger-tight.
- Tighten the engine front cover fasteners, in sequence, in 2 stages.
- Install the front 4 oil pan bolts in an alternating sequence, in 2 stages:
- Stage 1: Tighten to 15 ft. lbs. (20 Nm).
- Stage 2: Tighten an additional 60 degrees.
- Install the camshaft position (CMP) sensor and the bolt. Lubricate the new O-ring seal with clean engine oil prior to installation. Tighten the sensor to 89 inch lbs. (10 Nm).
- Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.
- Using the special tools, install a new crankshaft seal into the engine front cover.
NOTEIf not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. - Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.
- Use the special tool to install the crankshaft pulley.
- Tighten the new crankshaft pulley bolt in 4 stages.
- Stage 1: Tighten to 66 ft. lbs. (90 Nm).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 37 ft. lbs. (50 Nm).
- Stage 4: Tighten an additional 90 degrees.
- Position the crankshaft position (CKP) sensor and the bolt. Tighten to 89 inch lbs. (10 Nm).
- Position the accessory drive belt tensioner and install the 3 bolts. Tighten to 18 ft. lbs. (25 Nm).
- Install the accessory drive belt idler pulley bolt and the coolant pump pulley bolts. Tighten to 18 ft. lbs. (25 Nm).
CAUTIONDo not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean 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 the valve cover mating surface with silicone gasket remover and metal surface prep.
NOTEIf the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and metal surface prep. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage. - Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.
- Position the RH valve cover and new gasket on the cylinder head and tighten the 16 fasteners in the sequence shown. Tighten to 89 inch lbs. (10 Nm).
- Repeat for the LH valve cover.
- Position the oil level indicator and tube and install the bolt. Install a new O-ring seal and lubricate with clean engine oil prior to installation. Tighten to 89 inch lbs. (10 Nm).
- Install the oil level indicator and tube front bolt. Tighten to 18 ft. lbs. (25 Nm).
- Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
- Connect the CKP sensor electrical connector.
- Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs.
- Install the 10 ignition coils and the 10 bolts.
- Connect the 10 ignition coil electrical connectors.
- Install the LH radio ignition interference capacitor and the stud bolt. Tighten to 18 ft. lbs. (25 Nm).
- Connect the engine oil pressure (EOP) sensor electrical connector.
- Connect the cylinder head temperature (CHT) sensor electrical connector.
- Connect the electrical connector retainer to the coolant tube.
- Install the RH radio ignition interference capacitor and the stud bolt. Tighten to 18 ft. lbs. (25 Nm).
- Connect the CMP sensor electrical connector.
- Using a suitable floor crane, remove the engine from the engine stand.
- Lower and support the engine assembly on wood blocks.
- Install the special engine lifting tool.
- Using a suitable floor crane raise the engine.
- Install the flexplate or flywheel and the 8 bolts in the sequence shown. Tighten to 59 ft. lbs. (80 Nm).
- Install the engine.
These details will help.
Thanks.
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