Section 322 (Engine - 7.3L Diesel): Removal: Engine: Removal

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.

ALL VEHICLES

Disconnect both battery ground cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the turbocharger. For additional information, refer to TURBOCHARGER .
Disconnect the intake air warmer, map hose and electrical harness.

Fig 1: Disconnecting Intake Air Warmer, Map Hose And Electrical Harness
Courtesy of FORD MOTOR CO.
Remove the turbocharger compressor manifold.
Remove the bolts and the turbocharger exhaust inlet Y-pipe.

Fig 2: Removing Turbocharger Exhaust Inlet Y-Pipe
Courtesy of FORD MOTOR CO.
Remove the air inlet duct tube mounting bracket.
1. Remove the nuts.
2. Remove the bracket.
Fig 3: Removing Air Inlet Duct Tube Mounting Bracket
Courtesy of FORD MOTOR CO.
Remove the radiator. For additional information, refer to ENGINE COOLING .
Remove the parking lamp and the headlamp assemblies. For additional information, refer to EXTERIOR LIGHTING .
Remove the A/C condenser assembly, if so equipped. For additional information, refer to AIR CONDITIONING .
Remove the radiator grille support. For additional information, refer to FRONT END BODY PANELS .
Remove the power steering reservoir. For additional information, refer to POWER STEERING .
Detach the retainers and remove the headlamp wiring harness.
Remove the screws and the valance panel.

Fig 4: Removing Valance Panel
Courtesy of FORD MOTOR CO.
Remove the hood latch and radiator core supports.
Remove the front bumper. For additional information, refer to BUMPERS .
Remove the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
E-550 ONLY
Disconnect the vacuum hose and detach from the oil filler tube.

Fig 5: Disconnecting Vacuum Hose And Detaching From Oil Filler Tube
Courtesy of FORD MOTOR CO.

ALL VEHICLES
Remove the oil filler tube.

Fig 6: Removing Oil Filler Tube
Courtesy of FORD MOTOR CO.

VEHICLES EQUIPPED WITH A/C
Disconnect the A/C compressor electrical connector.

Fig 7: Disconnecting A/C Compressor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the air conditioning manifold.

Fig 8: Disconnecting Air Conditioning Manifold
Courtesy of FORD MOTOR CO.
Disconnect the A/C manifold tube from the tee block.

Fig 9: Disconnecting A/C Manifold Tube From Tee Block
Courtesy of FORD MOTOR CO.

E-250 - E-450 ONLY
Disconnect the vacuum pump hose.

Fig 10: Disconnecting Vacuum Pump Hose
Courtesy of FORD MOTOR CO.

ALL VEHICLES

NOTE: E-250 - E-450 shown, E-550 similar.

Fig 11: Disconnecting Power Steering Hoses

Courtesy of FORD MOTOR CO.

Disconnect the power steering hoses.
Remove the A/C compressor or idler pulley mounting bracket retaining bolts, and the mounting bracket.

Fig 12: Removing A/C Compressor Or Idler Pulley Mounting Bracket Retaining Bolts
Courtesy of FORD MOTOR CO.

VEHICLES EQUIPPED WITH A SINGLE GENERATOR
Disconnect the generator electrical connectors.

Fig 13: Disconnecting Generator Electrical Connectors
Courtesy of FORD MOTOR CO.
Remove the accessory drive belt tensioner assembly.

Fig 14: Removing Accessory Drive Belt Tensioner Assembly
Courtesy of FORD MOTOR CO.
Remove the generator bracket retaining bolts and the generator mounting bracket.

Fig 15: Removing Generator Mounting Bracket
Courtesy of FORD MOTOR CO.

VEHICLES EQUIPPED WITH A DUAL GENERATOR
Disconnect the lower generator quick connector and push pins.

Fig 16: Disconnecting Lower Generator Quick Connector And Push Pins
Courtesy of FORD MOTOR CO.
Disconnect the lower generator electrical connector and push pin.

Fig 17: Disconnecting Lower Generator Electrical Connector And Push Pin
Courtesy of FORD MOTOR CO.
Remove the engine ground cables.
1. Remove the nut.
2. Remove the starter wire retaining bracket.
3. Remove the engine ground cable.
Fig 18: Removing Engine Ground Cables
Courtesy of FORD MOTOR CO.
Remove the lower generator mounting bracket retaining bolts and the mounting bracket.

Fig 19: Removing Lower Generator Mounting Bracket
Courtesy of FORD MOTOR CO.
Disconnect the upper generator electrical connector. Remove the upper generator mounting bracket retaining bolts and the mounting bracket.

Fig 20: Removing Upper Generator Mounting Bracket
Courtesy of FORD MOTOR CO.

ALL VEHICLES
Label and disconnect the electrical leads.

Fig 21: Disconnecting Electrical Leads
Courtesy of FORD MOTOR CO.
Loosen the nuts and position the bracket out of the way.

Fig 22: Removing Bracket
Courtesy of FORD MOTOR CO.
Disconnect the engine control sensor wiring.

Fig 23: Disconnecting Engine Control Sensor Wiring
Courtesy of FORD MOTOR CO.
Remove the retaining nuts and position the bracket out of the way.

Fig 24: Removing Bracket
Courtesy of FORD MOTOR CO.
Disconnect the lower radiator hose at the water pump and the fill hose.

Fig 25: Removing Lower Radiator Hose From Water Pump And Fill Hose
Courtesy of FORD MOTOR CO.
Disconnect the heater supply hose.

Fig 26: Disconnecting Heater Supply Hose
Courtesy of FORD MOTOR CO.

NOTE: If equipped with an auxiliary heater, disconnect the heater hose on the rear of the LH cylinder head.

Fig 27: Disconnecting Auxiliary Heater Hose

Courtesy of FORD MOTOR CO.

Disconnect the auxiliary heater hose.

NOTE: The water pump pulley is removed for clarity.

Fig 28: Disconnecting Heater Hose

Courtesy of FORD MOTOR CO.

Disconnect the heater hose.
Disconnect the maxifuse.
1. Remove the nuts.
2. Remove the wire.
Fig 29: Disconnecting Maxifuse
Courtesy of FORD MOTOR CO.
Disconnect the fuel tubes.

Fig 30: Disconnecting Fuel Tubes
Courtesy of FORD MOTOR CO.
Disconnect the transmission sensor harness inline electrical connector.

Fig 31: Disconnecting Transmission Sensor Harness Inline Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the transmission sensor harness retaining bolt, and the harness.

Fig 32: Removing Transmission Sensor Harness Retaining Bolt
Courtesy of FORD MOTOR CO.

NOTE: The fuel tube retaining bolt must be removed before the engine lift adapters can be installed.

Fig 33: Removing Fuel Tube Retaining Bolt

Courtesy of FORD MOTOR CO.

Remove the fuel tube retaining bolt.
Install the two engine lift adapters.

Fig 34: Installing Engine Lift Adapters
Courtesy of FORD MOTOR CO.
Install special tool 303-D099 (D94T-6000-C) on the right cylinder head, if required.
Raise and support the vehicle.
Remove the starter motor. For additional information, refer to STARTERS - DIESEL .

NOTE: E-250 - E-450 shown, E-550 similar

Fig 35: Removing Engine Mount Nuts

Courtesy of FORD MOTOR CO.

Remove the engine mount nuts.
Remove the flywheel housing cover.

Fig 36: Removing Flywheel Housing Cover
Courtesy of FORD MOTOR CO.
Remove the torque converter-to-flywheel retaining nuts.

Fig 37: Removing Torque Converter-To-Flywheel Retaining Nuts
Courtesy of FORD MOTOR CO.
Remove the oil filter.
Disconnect the block heater.

Fig 38: Disconnecting Block Heater
Courtesy of FORD MOTOR CO.

NOTE: Left side shown, right side similar.

Fig 39: Removing Lower Transmission-To Engine Bolts

Courtesy of FORD MOTOR CO.

Remove the lower transmission-to engine bolts.
Lower the vehicle.
Remove the transmission fluid indicator and remove the retaining nut.

Fig 40: Removing Transmission Fluid Indicator
Courtesy of FORD MOTOR CO.
Remove the bolt and the transmission fluid indicator tube.

Fig 41: Removing Transmission Fluid Indicator Tube
Courtesy of FORD MOTOR CO.
Remove the transmission-to-engine bolts.

Fig 42: Removing Transmission-To-Engine Bolts
Courtesy of FORD MOTOR CO.
Position a suitable jack under the transmission.
Install special tool 014-00071 and a lifting fixture on the engine.
Raise the engine high enough to clear the No. 1 crossmember, and pull the engine forward.
Install the plugs from special tool set 303-493 (T94T-9395-AH) where necessary.

Fig 43: Removing Engine From Vehicle
Courtesy of FORD MOTOR CO.