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Section 726 (Engine 6.0L Diesel (99P E-Series & 99P F450/550)): Disassembly: Engine: Disassembly

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the bolts and the flexplate.
    Fig 1: Removing Bolts And Flexplate
    G02764691Courtesy of FORD MOTOR CO.
  2. Mount the engine on an engine stand.
  3. Remove the rear lifting eye.
  4. Remove the special tools.
    Fig 2: Removing Special Tools
    G02764692Courtesy of FORD MOTOR CO.
  5. Remove the bolts and RH motor mount plate.
    Fig 3: Removing Bolts And RH Motor Mount Plate
    G02764693Courtesy of FORD MOTOR CO.
  6. Remove the retaining nut and position the fuel line bracket aside.
    Fig 4: Removing Retaining Nut
    G02764694Courtesy of FORD MOTOR CO.
  7. Remove the stud bolts and thermostat housing.
    • Remove and discard the O-ring seal.
    Fig 5: Removing O-Ring Seal
    G02764695Courtesy of FORD MOTOR CO.
  8. Remove the left cylinder head banjo fitting and fuel line. Discard the sealing washers.
    Fig 6: Removing Left Cylinder Head Banjo Fitting And Fuel Line
    G02764696Courtesy of FORD MOTOR CO.
  9. Remove the bolt and serpentine belt idler.
    Fig 7: Removing Bolt And Serpentine Belt Idler
    G02764697Courtesy of FORD MOTOR CO.
  10. If equipped, remove the bolts and serpentine belt tensioner.
    Fig 8: Removing Bolts And Serpentine Belt Tensioner
    G02764698Courtesy of FORD MOTOR CO.
  11. Remove the bolts and oil filter adapter.
    Fig 9: Removing Bolts And Oil Filter Adapter
    G02764699Courtesy of FORD MOTOR CO.
  12. Remove and discard the O-ring seals from the oil filter base.
    Fig 10: Removing O-Ring Seals From Oil Filter Base
    G02764700Courtesy of FORD MOTOR CO.
  13. Remove the exhaust gas recirculation (EGR) cooler coolant supply port cover.
    • Remove the bolts.
    • Clean and inspect the gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 11: Inspecting Sealing Surfaces
    G02764701Courtesy of FORD MOTOR CO.
  14. Remove the oil filter base.
    • Remove the bolts.
    • Clean and inspect the gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 12: Inspecting Sealing Surfaces
    G02764702Courtesy of FORD MOTOR CO.
    15. CAUTION: In the event of a catastrophic engine failure, always install a new oil cooler cover assembly (with oil cooler). Foreign material cannot be removed from the oil cooler.
    NOTE: The oil cooler is replaced as an assembly.
    Fig 13: Inspecting Sealing Surfaces
    G02764703Courtesy of FORD MOTOR CO.
  15. Remove the oil cooler assembly.
    • Remove the bolts.
    • Clean and inspect the gaskets. Install a new gasket, if necessary.
    • Clean and inspect the sealing surfaces.
  16. Remove the oil pump inlet strainer. Clean and inspect for tears and other damage.
    Fig 14: Removing Oil Pump Inlet Strainer
    G02764704Courtesy of FORD MOTOR CO.
  17. Remove the bolts and the turbocharger heat shield.
    Fig 15: Removing Turbocharger Heat Shield
    G02764705Courtesy of FORD MOTOR CO.
  18. Remove the high-pressure oil pump cover.
    • Remove the bolts.
    • Use a thin gasket scraper to separate the cover from the crankcase.
    • Clean and inspect the gaskets. Install a new gasket if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 16: Inspecting Sealing Surfaces
    G02764706Courtesy of FORD MOTOR CO.
  19. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
    Fig 17: Positioning Dial Indicator With Bracketry Onto Oil Pump Drive
    G02764707Courtesy of FORD MOTOR CO.
  20. Remove the bolts from the high-pressure oil pump discharge pipe. Position the high-pressure discharge pipe aside.
    Fig 18: Removing Bolts From High-Pressure Oil Pump Discharge Pipe
    G02764708Courtesy of FORD MOTOR CO.
  21. Remove and discard the high-pressure pump O-ring seal.
    Fig 19: Removing High-Pressure Pump O-Ring Seal
    G02764709Courtesy of FORD MOTOR CO.
  22. Remove the bolts and the high-pressure oil pump.
    Fig 20: Removing Bolts And High-Pressure Oil Pump
    G02764710Courtesy of FORD MOTOR CO.
  23. Remove and discard the lower O-ring seal.
    Fig 21: Removing Lower O-Ring Seal
    G02764711Courtesy of FORD MOTOR CO.
    24. CAUTION: Do not pull on the wiring to remove the glow plug connector or damage may occur.
    NOTE: Only one glow plug connector shown.
    Fig 22: Removing Glow Plug Harness
    G02764712Courtesy of FORD MOTOR CO.
  24. Remove the glow plug harness.
  25. Remove the eight glow plugs.
    Fig 23: Removing Eight Glow Plugs
    G02764713Courtesy of FORD MOTOR CO.
  26. Remove the protective covering from the LH cylinder head.
    27. NOTE: Mark the location of the stud bolts.
    Fig 24: Inspecting Sealing Surfaces
    G02764714Courtesy of FORD MOTOR CO.
  27. Remove the RH valve cover.
    • Remove the stud bolts, bolts and valve cover.
    • Clean and inspect the gaskets. Install a new gasket, if necessary.
    • Clean and inspect the sealing surfaces.
  28. Remove the RH high pressure oil rail-to-valve cover gasket.
    Fig 25: Removing RH High Pressure Oil Rail-To-Valve Cover Gasket
    G02764715Courtesy of FORD MOTOR CO.
  29. Remove the bolts and the coolant pump pulley.
    Fig 26: Removing Bolts And Coolant Pump Pulley
    G02764716Courtesy of FORD MOTOR CO.
  30. Remove the coolant pump.
    • Remove the bolts.
    • Remove and discard the O-ring seal.
    Fig 27: Removing O-Ring Seal
    G02764717Courtesy of FORD MOTOR CO.
  31. If equipped, remove the bolts and the dual generator pulley.
    Fig 28: Removing Bolts And Dual Generator Pulley
    G02764718Courtesy of FORD MOTOR CO.
  32. Check the crankshaft vibration damper runout.
    • Remove the paint from the face of the crankshaft vibration damper at four points 90 degrees apart.
    • Attach the special tool to the cylinder block. Position the special tool on one of the unpainted surfaces.
    • Using a suitable tool, pry the crankshaft forward. Zero the dial indicator.
      • NOTE: Pry the crankshaft forward at the same point to eliminate possible error caused by crankshaft end play.
    • Rotate the crankshaft 90 degrees. Pry the crankshaft forward. Record the measurement. Repeat at each unpainted surface.
      • If the runout exceeds specification, install a new crankshaft vibration damper.
    Fig 29: Installing Crankshaft Vibration Damper
    G02764719Courtesy of FORD MOTOR CO.
    33. CAUTION: To prevent engine damage, you must always install four new bolts when installing the vibration damper.
    WARNING: To avoid personal injury, support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft very easily.
    Fig 30: Removing Bolts And Crankcase Vibration Damper
    G02764720Courtesy of FORD MOTOR CO.
  33. Remove the bolts and the crankcase vibration damper.
    • Discard the bolts.
  34. Punch two holes in the seal.
    Fig 31: Punching Two Holes In Seal
    G02764721Courtesy of FORD MOTOR CO.
  35. Using the special tool, remove the crankshaft seal.
    Fig 32: Removing Crankshaft Seal
    G02764722Courtesy of FORD MOTOR CO.
    36. NOTE: The production engine will not have a wear sleeve.
    Fig 33: Removing Crankshaft Damper Wear Sleeve With Special Tool
    G02764723Courtesy of FORD MOTOR CO.
  36. If equipped, remove the crankshaft damper wear sleeve with the special tool.
  37. Remove the oil pump body.
    • Remove the bolts.
    • Remove and discard the O-ring seal.
    Fig 34: Removing O-Ring Seal
    G02764724Courtesy of FORD MOTOR CO.
    38. NOTE: Mark the front of each drive rotor for correct reassembly orientation.
    Fig 35: Removing Inner And Outer Oil Pump Drive Rotors
    G02764725Courtesy of FORD MOTOR CO.
  38. Remove the inner and outer oil pump drive rotors.
  39. Remove the engine front cover.
    • Remove the bolts.
    • Clean and inspect the gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 36: Inspecting Sealing Surfaces
    G02764726Courtesy of FORD MOTOR CO.
  40. Remove the flywheel adapter.
    Fig 37: Removing Flywheel Adapter
    G02764727Courtesy of FORD MOTOR CO.
    41. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.
    Fig 38: Punching Two Holes Across From Each Other In Rear Main Seal
    G02764728Courtesy of FORD MOTOR CO.
  41. Punch two holes across from each other in the rear main seal.
  42. Using the special tool, remove the rear main seal.
    Fig 39: Removing Rear Main Seal
    G02764729Courtesy of FORD MOTOR CO.
    43. NOTE: Production engines will not have wear sleeve.
    Fig 40: Removing Crankshaft Rear Wear Sleeve
    G02764730Courtesy of FORD MOTOR CO.
  43. If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
  44. Clean and inspect the crankshaft sealing surface.
    Fig 41: Inspecting Crankshaft Sealing Surface
    G02764731Courtesy of FORD MOTOR CO.
  45. Remove the rear engine cover.
    • Remove the bolts.
    • Clean and inspect the gaskets. Install a new gasket if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 42: Inspecting Sealing Surfaces
    G02764732Courtesy of FORD MOTOR CO.
  46. Prior to removing the exhaust manifolds, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and cylinder head. Record the measurement and compare with the specifications.
  47. Remove the bolts and the RH exhaust manifold.
    Fig 43: Removing Bolts And RH Exhaust Manifold
    G02764733Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the LH exhaust manifold.
    Fig 44: Removing Bolts And LH Exhaust Manifold
    G02764734Courtesy of FORD MOTOR CO.
    49. NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
    Fig 45: Removing Bolts And High Pressure Oil Rail
    G02764735Courtesy of FORD MOTOR CO.
  49. Remove the bolts and the high pressure oil rail.
    50. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
    Fig 46: Pushing Fuel Injector Electrical Connector Out Of Rocker Arm Carrier
    G02764736Courtesy of FORD MOTOR CO.
  50. Using a 19 mm (0.74 in) socket, push the fuel injector electrical connector out of the rocker arm carrier.
  51. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    52. CAUTION: To prevent engine damage, do not use air tools when removing and installing the fuel injectors. The snap ring that extracts the fuel injector can dislodge and fall off.
    CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be injested into the lube oil system causing severe engine damage.
    NOTE: If engine oil is found in the engine coolant or engine coolant is found in the combustion chambers, new injector sleeves may need to be installed.
    Fig 47: Removing Bolt, Fuel Injector Hold Down And Fuel Injector
    G02764737Courtesy of FORD MOTOR CO.
  52. Remove the bolt, the fuel injector hold down and the fuel injector.
    53. NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.
  53. Remove the shop towels.
    54. NOTE: The rings on the crankcase-to-head tube are to be used to pry the tube assembly from the branch tube assembly or the oil rail assembly.
    Fig 48: Removing O-Ring Seals
    G02764738Courtesy of FORD MOTOR CO.
  54. Remove the crankcase-to-head tube assembly.
    • Remove and discard the O-ring seals.
  55. Remove and discard the 20 head bolts from both cylinder heads.
    Fig 49: Removing 20 Head Bolts From Both Cylinder Heads
    G02764739Courtesy of FORD MOTOR CO.
  56. Remove the 16 bolts and the rocker arm assemblies.
    Fig 50: Removing 16 Bolts And Rocker Arm Assemblies
    G02764740Courtesy of FORD MOTOR CO.
  57. Remove the rocker arm carrier from the cylinder head.
    • Remove the bolts.
    • Clean and inspect the gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 51: Inspecting Sealing Surfaces
    G02764741Courtesy of FORD MOTOR CO.
    58. NOTE: Mark the location of the valve bridges before removing.
    Fig 52: Removing 16 Valve Bridges
    G02764742Courtesy of FORD MOTOR CO.
  58. Remove the 16 valve bridges.
    59. CAUTION: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
    Fig 53: Removing 16 Push Rods
    G02764743Courtesy of FORD MOTOR CO.
  59. Mark and remove the 16 push rods.
  60. Remove the 10 outer head bolts.
    Fig 54: Removing 10 Outer Head Bolts
    G02764744Courtesy of FORD MOTOR CO.
  61. Remove the cylinder heads.
    1. Install the special tool.
    2. Install the bolts.
      • Remove the cylinder heads.
    Fig 55: Removing Cylinder Heads
    G02764745Courtesy of FORD MOTOR CO.
  62. Remove and discard the cylinder head gaskets.
    Fig 56: Removing Cylinder Head Gaskets
    G02764746Courtesy of FORD MOTOR CO.
  63. Remove and discard the four cylinder head dowel sleeves.
    Fig 57: Removing Four Cylinder Head Dowel Sleeves
    G02764747Courtesy of FORD MOTOR CO.
  64. Remove the bolts from the rear engine tube assembly.
    Fig 58: Removing Bolts From Rear Engine Tube Assembly
    G02764748Courtesy of FORD MOTOR CO.
  65. Remove the bolt and the rear engine tube assembly.
    Fig 59: Removing Rear Engine Tube Assembly
    G02764749Courtesy of FORD MOTOR CO.
    66. CAUTION: To prevent engine damage, keep the cam followers in the order in which they were removed. Install all cam followers back in their original positions.
    Fig 60: Removing Bolts And Roller Follower Guides
    G02764750Courtesy of FORD MOTOR CO.
  66. Remove the bolts and the roller follower guides. Remove the hydraulic cam followers.
  67. Remove the upper oil pan.
    • Remove the bolts.
    • Clean and inspect the gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 61: Inspecting Sealing Surfaces
    G02764751Courtesy of FORD MOTOR CO.
    68. NOTE: Prior to removing any piston and connecting rod assemblies, it is recommended that piston protrusion be evaluated. This will help identify bent or twisted connecting rods.
    Fig 62: Measuring Maximum Piston Protrusion
    G02764752Courtesy of FORD MOTOR CO.
  68. Check the piston protrusion above the crankcase as follows.
    • Zero the dial indicator gauge on the crankcase deck surface.
    • Position the dial indicator tip on the piston head at the 3 or 9 o'clock position.
    • Rotate the crankshaft to measure the maximum piston protrusion and record.
    • Reposition the dial indicator tip onto the piston head at the opposite position.
    • Rotate the crank shaft to measure the maximum piston protrusion and record. Average the two readings to see if the maximum piston protrusion is exceeded.
  69. Using a feeler gauge, check for the minimum connecting rod side clearance.
    Fig 63: Checking Minimum Connecting Rod Side Clearance
    G02764753Courtesy of FORD MOTOR CO.
  70. Remove the bolts and the connecting rod caps.
    Fig 64: Removing Bolts And Connecting Rod Caps
    G02764754Courtesy of FORD MOTOR CO.
    71. CAUTION: To prevent engine damage, remove the ridge prior to removing the rod and piston assemblies if evident from the top of the cylinder bore. This reduces the chance of piston ring land damage during removal.
  71. Use a razor knife or emery board to scrape the carbon ridge from the top of the cylinder bore.
  72. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.
    Fig 65: Pushing Connecting Rod And Piston Assembly Out Of Cylinder Bore
    G02764755Courtesy of FORD MOTOR CO.
  73. Remove the piston rings.
    1. Remove the top compression ring.
    2. Remove the intermediate compression ring.
    3. Remove the oil control ring.
    Fig 66: Removing Oil Control Ring
    G02764756Courtesy of FORD MOTOR CO.
  74. Remove and discard the connecting rod bearings.
    Fig 67: Removing Connecting Rod Bearings
    G02764757Courtesy of FORD MOTOR CO.
  75. Install the special tool and measure the camshaft gear backlash. Install a new gear if backlash is not within specification.
    Fig 68: Measuring Camshaft Gear Backlash
    G02764758Courtesy of FORD MOTOR CO.
  76. Install the special tool and measure the camshaft end play. Install a new camshaft thrust plate if end play is not within specification.
    Fig 69: Measuring Camshaft End Play
    G02764759Courtesy of FORD MOTOR CO.
    77. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.
    Fig 70: Measuring Crankshaft End Play
    G02764760Courtesy of FORD MOTOR CO.
  77. Install the special tool and measure the crankshaft end play. Record the end play.
  78. Remove the bolt and the crankshaft position (CKP) sensor.
    Fig 71: Removing Bolt And Crankshaft Position (CKP) Sensor
    G02764761Courtesy of FORD MOTOR CO.
  79. Remove the bolt and the camshaft position (CMP) sensor.
    Fig 72: Removing Bolt And Camshaft Position (CMP) Sensor
    G02764762Courtesy of FORD MOTOR CO.
  80. Remove the block heater.
    Fig 73: Removing Block Heater
    G02764763Courtesy of FORD MOTOR CO.
  81. Remove the 20 lower case bolts and the 8 outside lower crankcase bolts. Remove the lower crankcase assembly.
    Fig 74: Removing 20 Lower Case Bolts And 8 Outside Lower Crankcase Bolts
    G02764764Courtesy of FORD MOTOR CO.
  82. Remove the lower crankcase seals and the lower bearings and discard.
    Fig 75: Removing Lower Crankcase Seals And Lower Bearings
    G02764765Courtesy of FORD MOTOR CO.
  83. Using the appropriate lifting device, remove the crankshaft assembly.
    Fig 76: Removing Crankshaft Assembly
    G02764766Courtesy of FORD MOTOR CO.
  84. Remove and discard the crankshaft upper bearings and crankshaft upper thrust bearing.
    Fig 77: Removing Crankshaft Upper Bearings And Crankshaft Upper Thrust Bearing
    G02764767Courtesy of FORD MOTOR CO.
    85. CAUTION: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage will occur.
    Fig 78: Removing Thrust Plate Mounting Bolts
    G02764768Courtesy of FORD MOTOR CO.
  85. Remove the thrust plate mounting bolts and remove the camshaft and gear.
    86. CAUTION: This patch bolt is unique - do not substitute or engine damage can occur.
    Fig 79: Removing Bolts And Eight Piston Cooling Tubes
    G02764769Courtesy of FORD MOTOR CO.
  86. Remove the bolts and the eight piston cooling tubes.
  87. Using the special tool, remove the camshaft bearings and discard.
    Fig 80: Removing Camshaft Bearings
    G02764770Courtesy of FORD MOTOR CO.
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