Section 1296 (Engine - 6.0L (99P E-Series) Diesel): Disassembly: Engine: Disassembly

All vehicles 

1. Remove the 10 bolts and the flexplate.
   • Discard the bolts.
Fig 1: Identifying Flexplate/Flywheel Bolts
Courtesy of FORD MOTOR CO.
2. Mount the engine on an engine stand.
3. Remove the 4 bolts and RH motor mount plate.
Fig 2: Right Motor Mount Plate Bolts
Courtesy of FORD MOTOR CO.
4. Remove the nut and position the fuel tube support bracket aside.
Fig 3: Fuel Tube Support Bracket Nut
Courtesy of FORD MOTOR CO.
5. Remove the 2 stud bolts and thermostat housing.
   • Remove and discard the O-ring seal.
Fig 4: Identifying Thermostat Housing Stud Bolts
Courtesy of FORD MOTOR CO.
6. Remove the LH cylinder head banjo fitting and fuel tube.
   • Discard the sealing washers.
Fig 5: Identifying Fuel Line Banjo Bolt
Courtesy of FORD MOTOR CO.
7. Remove the bolt and the accessory drive belt idler pulley.
Fig 6: Locating Accessory Drive Idler Pulley Bolt
Courtesy of FORD MOTOR CO.
8. If equipped, remove the 2 bolts and serpentine belt tensioner.
Fig 7: Identifying Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
9. Remove the 4 bolts and oil filter adapter.
Fig 8: Identifying Oil Filter Adapter Bolts
Courtesy of FORD MOTOR CO.
10. Remove and discard the O-ring seals from the oil filter base.
Fig 9: Identifying O-Ring Seals On Oil Filter Base
Courtesy of FORD MOTOR CO.
11. Remove the 2 bolts and the EGR cooler coolant supply port cover.
    • Remove and discard the press-in-place gasket.
    • Clean and inspect the sealing surfaces.
Fig 10: Identifying EGR Cooler Coolant Supply Port Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: Do not discard the oil cooler cover bolts. They are self-tapping bolts and will be needed to cut the threads in the new oil cooler cover.
12. Remove 8 bolts and the oil cooler cover.
    • Remove and discard the press-in-place gaskets.
    • Clean and inspect the sealing surfaces.
Fig 11: Identifying Oil Filter Base Bolts
Courtesy of FORD MOTOR CO.
NOTE: 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 and engine damage may occur.
NOTE: The oil cooler is installed as an assembly.
13. Remove the 10 bolts and the oil cooler assembly.
    • Remove and discard the press-in-place gasket.
    • Clean and inspect the sealing surfaces.
Fig 12: Identifying Oil Cooler Assembly Bolts
Courtesy of FORD MOTOR CO.
14. Remove the oil pump inlet strainer.
    • Clean and inspect for tears and other damage.
Fig 13: Identifying Oil Pump Inlet Strainer
Courtesy of FORD MOTOR CO.
15. Remove the 3 bolts and the turbocharger heat shield.
Fig 14: Locating Turbocharger Heat Shield And Bolts
Courtesy of FORD MOTOR CO.
16. Using the Injection Pressure Regulator Socket, remove the Injection Pressure Regulator (IPR) valve.
Fig 15: Identifying Special Tool (303-1112)
Courtesy of FORD MOTOR CO.
17. Remove the 8 bolts from the high-pressure oil pump cover.
Fig 16: High-Pressure Oil Pump Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, do not pry the high-pressure pump cover from the pump or damage to the cover can occur.
18. Use a thin gasket scraper to separate the cover from the crankcase at the rear cover seam. Remove the high-pressure oil pump cover.
    • Remove and discard the press-in-place gasket.
Fig 17: Separating Cover From Crankcase
Courtesy of FORD MOTOR CO.
19. Position the Dial Indicator Gauge with Holding Fixture and check the oil pump drive gear backlash.
Fig 18: Checking Oil Pump Drive Gear Backlash Using Special Tool (100-002)
Courtesy of FORD MOTOR CO.
20. Remove the 2 bolts on the high-pressure tube assembly.
Fig 19: Locating High-Pressure Tube Assembly Bolts
Courtesy of FORD MOTOR CO.
21. Remove the 3 bolts and the high-pressure oil pump.
Fig 20: Locating High-Pressure Oil Pump Bolts
Courtesy of FORD MOTOR CO.
22. Remove and discard the lower O-ring seals.
Fig 21: Identifying Lower O-Ring Seals
Courtesy of FORD MOTOR CO.
23. Remove and discard the high-pressure oil pump O-ring seal.
Fig 22: Locating High-Pressure Oil Pump O-Ring Seal
Courtesy of FORD MOTOR CO.
NOTE: Do not pull on the wiring to remove the glow plug connector or damage may occur.
24. Using the Glow Plug Connector Remover/Installer, remove the glow plug harness.
Fig 23: Identifying Glow Plug Harness Special Tool (303-1114)
Courtesy of FORD MOTOR CO.
25. Remove the 8 glow plugs.
Fig 24: Identifying Glow Plug
Courtesy of FORD MOTOR CO.
26. Remove the protective covering from the LH cylinder head.
NOTE: Mark the location of the stud bolts.
27. Remove the 6 stud bolts, 5 bolts and the RH valve cover.
    • Clean and inspect the gaskets. Install a new gasket, if necessary.
    • Clean and inspect the sealing surfaces.
Fig 25: Identifying RH Stud Bolts, Bolts & Valve Cover
Courtesy of FORD MOTOR CO.
28. Remove the high-pressure oil rail-to-valve cover gasket.
Fig 26: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
Courtesy of FORD MOTOR CO.
29. Remove the 4 bolts and the coolant pump pulley.
Fig 27: Identifying Coolant Pump Pulley Bolts
Courtesy of FORD MOTOR CO.
30. Remove the 4 bolts and the coolant pump.
    • Discard the O-ring seal.
Fig 28: Locating Coolant Pump Bolts
Courtesy of FORD MOTOR CO.
31. If equipped, remove the 3 bolts and the dual generator pulley.
Fig 29: Locating Dual Generator Pulley Bolts
Courtesy of FORD MOTOR CO.
32. Check the crankshaft vibration damper runout.
    • Remove the paint from the face of the crankshaft vibration damper at 4 points, 90 degrees apart.
    • Attach the Dial Indicator Gauge with Holding Fixture to the cylinder block. Position the Dial Indicator Gauge with Holding Fixture 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 30: Checking Crankshaft Vibration Damper Runout
Courtesy of FORD MOTOR CO.
WARNING: Support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft. Failure to follow this instruction may result in serious personal injury.
NOTE: To prevent engine damage, always install new bolts when installing the vibration damper.
33. Remove the 4 bolts and the crankcase vibration damper.
    • Discard the bolts.
Fig 31: Locating Crankcase Vibration Damper Bolts
Courtesy of FORD MOTOR CO.
34. Punch 2 holes in the crankshaft front seal.
Fig 32: Identifying Crankshaft Seal
Courtesy of FORD MOTOR CO.
35. Using the Oil Seal Remover, remove the crankshaft front seal.
    • Discard the seal.
Fig 33: Removing Crankshaft Front Oil Seal
Courtesy of FORD MOTOR CO.
NOTE: Production seals will not have a wear sleeve. If a service part has been installed, it will have a wear sleeve.
36. If equipped, remove and discard the crankshaft seal wear sleeve with the Crankshaft Front Wear Ring Remover.
Fig 34: Removing Crankshaft Pulley Wear Sleeve
Courtesy of FORD MOTOR CO.
37. Remove the 5 bolts and the oil pump body.
    • Discard the O-ring seal.
Fig 35: Locating Oil Pump Body Bolts
Courtesy of FORD MOTOR CO.
NOTE: Mark the front of each drive rotor for correct reassembly orientation.
38. Remove the inner and outer oil pump drive rotors.
Fig 36: Identifying Inner And Outer Oil Pump Drive Rotors With Alignment Marks
Courtesy of FORD MOTOR CO.
39. Remove the 17 bolts and engine front cover.
Fig 37: Locating Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: Sealant is used where the crankcase and lower crankcase meet. Failure to cut the sealant may result in pulling the lower crankcase seal out and damaging it while removing the front cover gasket.
40. Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove and discard the front cover gasket.
41. Remove the flywheel adapter.
Fig 38: Identifying Flywheel Adapter
Courtesy of FORD MOTOR CO.
NOTE: 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.
NOTE: Drill only deep enough to penetrate the seal. Engine damage will occur if the seal is drilled too deep.
NOTE: On original seals, if equipped, the wear sleeve will be removed separately.
42. Using a center punch, mark a location for 2 holes 180 degrees apart, 9.53 mm (0.37 in) from the outer diameter of the crankshaft flange. Using a drill bit of the appropriate size for the Slide Hammer being used, drill a hole on each side of the crankshaft rear seal as shown. Drill the holes to a depth of 8.76 mm (0.34 in) to capture the metal case of the crankshaft seal as well as the wear sleeve.
Fig 39: View Of Holes On RH and LH Side of Seal
Courtesy of FORD MOTOR CO.
43. Using the 2 drilled holes, the Slide Hammer and a commercially available body dent puller attachment, walk the seal out of the rear cover by alternating from side to side to remove the crankshaft rear seal.
    • Discard the crankshaft rear seal.
Fig 40: Removing Crankshaft Rear Seal
Courtesy of FORD MOTOR CO.

Original seal 

NOTE: Original seals will not have a wear sleeve. If a service part has previously been installed, it will have a wear sleeve. If the service part was a redesigned seal, the wear sleeve will have been removed with the seal in the previous step. If the service part was an original seal, the wear sleeve will remain in the engine after the seal has been removed.
44. If the wear sleeve remained in the engine after removing the seal, use the Crankshaft Rear Wear Ring Remover to remove and discard the crankshaft rear seal wear sleeve.
Fig 41: Removing Crankshaft Rear Seal Wear Sleeve
Courtesy of FORD MOTOR CO.

All vehicles 

45. Clean and inspect the crankshaft sealing surface.
Fig 42: Identifying Crankshaft Sealing Surface
Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.
46. Remove the 8 bolts from the engine rear cover.
Fig 43: Locating Rear Engine Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant may result in pulling the lower crankcase seal out and damaging it while removing the rear cover.
NOTE: A 139.7 mm (5.5 in) long thin-blade scraper is needed to properly cut the sealant.
47. Using a thin-blade scraper, cut the sealant where the crankcase and the lower crankcase meet.
Fig 44: Using Thin-Blade Scraper To Cut Sealant Where Crankcase And Lower Crankcase Meet
Courtesy of FORD MOTOR CO.
NOTE: Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant may result in pulling the lower crankcase seal out and damaging it while removing the rear cover.
NOTE: A 139.7 mm (5.5 in) long thin-blade scraper is needed to properly cut the sealant.
48. Using a thin-blade scraper, cut the sealant where the crankcase and the lower crankcase meet. Remove the engine rear cover.
    • Remove and discard the press-in-place gasket.
    • Clean and inspect the sealing surfaces.
Fig 45: Using Thin-Blade Scraper To Cut Sealant Where Crankcase And Lower Crankcase Meet
Courtesy of FORD MOTOR CO.
49. Prior to removing the exhaust manifolds, inspect the exhaust manifolds for warpage with a feeler gauge between the manifold and cylinder head. Record the measurement and compare with the specification.
50. Remove the 8 bolts, 8 spacers and the RH exhaust manifold.
    • Discard the bolts.
Fig 46: Identifying Exhaust Manifolds Bolts
Courtesy of FORD MOTOR CO.
51. Remove the 8 bolts, 8 spacers and the LH exhaust manifold.
    • Discard the bolts.
Fig 47: Exhaust Manifold Bolts
Courtesy of FORD MOTOR CO.
52. Disconnect the fuel injector electrical connectors.
Fig 48: Identifying Fuel Injector Electrical Connector & Retainer Clip
Courtesy of FORD MOTOR CO.
53. Remove the crankcase-to-head tubes.
Fig 49: Locating D-Ring Seals
Courtesy of FORD MOTOR CO.
NOTE: Left cylinder head shown, right cylinder head similar.
NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support these components.
54. Remove the 18 bolts and the high-pressure oil rails.
Fig 50: Identifying Bolts And High-Pressure Oil Rail
Courtesy of FORD MOTOR CO.
NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.
55. If the crankcase-to-head tube separated, using the High Pressure Supply Tube Remover, remove the lower crankcase-to-head tube.
    • Remove and discard the D-ring seal.
Fig 51: Identifying Special Tool (303-1164)
Courtesy of FORD MOTOR CO.
56. Remove and discard the D-ring seals.
Fig 52: Identifying D-Ring Seals
Courtesy of FORD MOTOR CO.
NOTE: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector may occur.
57. Using the Injector Connector Release Tool, push the fuel injector electrical connectors out of the rocker arm carrier.
Fig 53: Pushing Fuel Injector Electrical Connector Out Of The Rocker Arm Carrier
Courtesy of FORD MOTOR CO.
58. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
NOTE: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.
NOTE: There is no need to drain the fuel rail.
NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve. For additional information, refer to FUEL CHARGING AND CONTROLS - 6.0L DIESEL article.
59. Remove the bolt, the fuel injector hold down and the fuel injectors.
    • Remove and discard the O-ring seals and copper washer.
Fig 54: Identifying Fuel Injector Hold-Down Bolt
Courtesy of FORD MOTOR CO.
60. Remove the shop towels.
NOTE: Left cylinder head shown, right cylinder head similar.
61. Remove and discard the 20 head bolts from both cylinder heads.
Fig 55: Identifying Cylinder Head Retaining Bolts
Courtesy of FORD MOTOR CO.
62. Remove the 16 bolts and the rocker arm assemblies.
Fig 56: Identifying Rocker Arm Assembly Bolts
Courtesy of FORD MOTOR CO.
NOTE: Left cylinder head shown, right cylinder head similar.
63. Remove the 4 bolts and the rocker arm carriers.
    • Remove and discard the press-in-place gaskets.
    • Clean and inspect the sealing surfaces.
Fig 57: Rocker Arm Carrier Bolts
Courtesy of FORD MOTOR CO.
NOTE: Mark the location of the valve bridges before removing.
64. Remove the 16 valve bridges.
Fig 58: Identifying Valve Bridges
Courtesy of FORD MOTOR CO.
NOTE: 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.
65. Mark and remove the 16 push rods.
Fig 59: Identifying Push Rods
Courtesy of FORD MOTOR CO.
66. Remove the 10 outer head bolts.
Fig 60: Identifying Outer Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
67. Using the Cylinder Head Lifting Bracket, remove the cylinder heads.
Fig 61: Identifying Cylinder Head Lifting Bracket On Cylinder Head
Courtesy of FORD MOTOR CO.
68. Check for cylinder head distortion. For additional information, refer to Cylinder Head Distortion .
69. Remove and discard the cylinder head gaskets.
Fig 62: Identifying Gasket Sealing Surfaces Area
Courtesy of FORD MOTOR CO.
70. Remove and discard the 4 cylinder head dowel sleeves.
Fig 63: Locating Cylinder Head Dowels
Courtesy of FORD MOTOR CO.
71. Check the cylinder block distortion. For additional information, refer to Cylinder Block Distortion .
72. Remove the 2 bolts and the rear engine tube assembly.
Fig 64: Identifying Rear Engine Tube Assembly
Courtesy of FORD MOTOR CO.
NOTE: 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.
73. Remove the 2 bolts, the roller follower guides and the hydraulic cam followers.
Fig 65: Identifying Roller Follower Guide Bolt
Courtesy of FORD MOTOR CO.
74. Remove the 9 bolts and the upper oil pan.
    • Remove and discard the press-in-place gasket.
    • Clean and inspect the sealing surfaces.
Fig 66: Identifying Upper Oil Pan Bolts
Courtesy of FORD MOTOR CO.
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.
75. Check the piston protrusion above the crankcase as follows:
    • Position the Dial Indicator Gauge with Holding Fixture.
    • Zero the Dial Indicator Gauge on the crankcase deck surface.
    • Position the Dial Indicator Gauge tip on the piston head at the 3 o'clock or 9 o'clock position.
    • Rotate the crankshaft to measure the maximum piston protrusion and record.
    • Reposition the Dial Indicator Gauge tip onto the piston head at the opposite position.
    • Rotate the crankshaft to measure the maximum piston protrusion and record.
    • Average the 2 readings. If the average reading is lower than the specification, the piston is lower in the bore than it should be. This indicates a bent or twisted connecting rod.
Fig 67: Checking Piston Protrusion With Specification
Courtesy of FORD MOTOR CO.
76. Using a Feeler Gauge Set, check for the minimum connecting rod side clearance.
Fig 68: Checking For Minimum Connecting Rod Side Clearance Using A Feeler Gauge Set With Specification
Courtesy of FORD MOTOR CO.
NOTE: Only one connecting rod cap shown.
77. Remove the 16 bolts and the connecting rod caps.
Fig 69: Identifying Connecting Rod Cap Bolts
Courtesy of FORD MOTOR CO.
NOTE: 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.
78. Use a razor knife or emery board to scrape the carbon ridge from the top of the cylinder bore.
79. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.
Fig 70: Pushing Connecting Rod And Piston Assembly
Courtesy of FORD MOTOR CO.
80. Remove and discard the piston rings.
    1. Remove the keystone ring.
    2. Remove the intermediate compression ring.
    3. Remove the oil control ring.
Fig 71: Piston Rings
Courtesy of FORD MOTOR CO.
81. Remove and discard the connecting rod bearings.
Fig 72: View Of Upper And Lower Connecting Rod Bearings
Courtesy of FORD MOTOR CO.
82. Install the Dial Indicator Gauge with Holding Fixture and measure the camshaft gear backlash. Install a new gear if backlash is not within specification.
Fig 73: Checking Camshaft Gear Backlash With Specifications
Courtesy of FORD MOTOR CO.
83. Install the Dial Indicator Gauge with Holding Fixture and measure the camshaft end play. Install a new camshaft thrust plate if end play is not within specification.
Fig 74: Checking Camshaft End Play With Specifications
Courtesy of FORD MOTOR CO.
NOTE: 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.
84. Install the Dial Indicator Gauge with Holding Fixture and measure the crankshaft end play. Record the end play.
Fig 75: Checking Crankshaft End Play With Specifications
Courtesy of FORD MOTOR CO.
85. Remove the bolt and the Crankshaft Position (CKP) sensor.
Fig 76: Identifying Crankshaft Position (CKP) Sensor
Courtesy of FORD MOTOR CO.
86. Remove the bolt and the Camshaft Position (CMP) sensor.
Fig 77: Identifying Camshaft Position (CMP) Sensor
Courtesy of FORD MOTOR CO.
87. Remove the block heater.
Fig 78: Identifying Block Heater
Courtesy of FORD MOTOR CO.
88. Remove the 20 lower case bolts and the lower crankcase assembly.
Fig 79: Lower Crankcase Bolts
Courtesy of FORD MOTOR CO.
89. Remove the lower crankcase seals and the lower bearings and discard.
Fig 80: Locating Lower Crankcase Seals
Courtesy of FORD MOTOR CO.
90. Using the appropriate lifting device, remove the crankshaft assembly.
Fig 81: Crankshaft Assembly
Courtesy of FORD MOTOR CO.
91. Remove and discard the crankshaft upper bearings and crankshaft upper thrust bearing.
Fig 82: View Of Crankshaft Upper Bearing Seats
Courtesy of FORD MOTOR CO.
NOTE: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage may occur.
92. Remove the 2 thrust plate mounting bolts and remove the camshaft and gear.
Fig 83: Locating Thrust Plate Mounting Bolts
Courtesy of FORD MOTOR CO.
NOTE: This patch bolt is unique. Do not substitute or engine damage can occur.
93. Remove the 8 bolts and the 8 piston cooling tubes.
Fig 84: Identifying Piston Cooling Tube Bolt
Courtesy of FORD MOTOR CO.
94. Using the Camshaft Service Set, remove the camshaft bearings and discard.
Fig 85: Removing Camshaft Bearings
Courtesy of FORD MOTOR CO.