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Home >> Ford >> 2002 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2911 (Engine Mechanical - 6.7L Diesel -- F250-F550 Super Duty) >> Removal >> Engine - Body Off >> Removal

Engine - Body Off: Removal

WARNING: This page is about a different car, the 2011 Ford Pickup, 2011 Ford F550 Super Duty, 2011 Ford F450 Super Duty, and 2011 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: Change the engine oil any time the turbocharger is removed from the engine. The passages in the block, located underneath the turbocharger, are direct passages to the lubrication system. Debris and/or coolant may enter the lubrication system and engine damage may occur.
NOTE: It is recommended that this component be serviced with the vehicle body removed. Refer to BODY -- DIESEL . If the body cannot be removed, refer to ENGINE - BODY ON  in this service information.
NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel openings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.
  1. Remove the body. For additional information, refer to FULL FRAME & BODY MOUNTING -- F250-F550 SUPER DUTY article .
    2. WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.
  2. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  3. Mark the location of the tires on the floor prior to rolling out the chassis. Roll the chassis out from under the body.
    4. NOTE: Failure to replace the transmission support insulator nuts may result in transmission support insulator damage.
    NOTE: If the transmission support insulator stud loosens when the transmission support insulator nut is removed, the stud must be discarded and a new stud installed.
    Fig 1: Locating Transmission Support Insulator Nuts
    G07480979Courtesy of FORD MOTOR CO.
  4. Remove and discard the 2 transmission support insulator nuts.
    5. NOTE: The engine oil drain plug is a quarter turn design.
    Fig 2: Locating Engine Oil Drain Plug
    G07480980Courtesy of FORD MOTOR CO.
  5. Remove the engine oil drain plug and drain the engine oil.
    6. NOTE: The engine oil drain plug is a quarter turn design.
    Fig 3: Locating Engine Oil Drain Plug
    G07480981Courtesy of FORD MOTOR CO.
  6. Install the engine oil drain plug.
  7. Remove and discard the engine oil filter.
  8. Remove the turbocharger downpipe bracket bolt.
    Fig 4: Locating Turbocharger Downpipe Bracket Bolt
    G07480982Courtesy of FORD MOTOR CO.
  9. Remove the 2 turbocharger downpipe flange bolts.
    Fig 5: Remove/Install Turbocharger Downpipe Flange Bolts
    G07480983Courtesy of FORD MOTOR CO.
  10. Remove the turbocharger downpipe.
    • Remove and discard the turbocharger downpipe clamp.
    Fig 6: Locating Turbocharger Downpipe Clamp
    G07480984Courtesy of FORD MOTOR CO.
  11. If equipped, disconnect the block heater cord.
    Fig 7: Locating Block Heater Cord
    G07480985Courtesy of FORD MOTOR CO.
  12. Remove the starter motor. For additional information, refer to STARTING SYSTEM - DIESEL ENGINE article.
    13. NOTE: The flexplate access cover retainers are plastic, use care when removing.
    Fig 8: Locating Flexplate Access Cover Retainers
    G07480986Courtesy of FORD MOTOR CO.
  13. Unscrew the 2 flexplate access cover retainers and remove the flexplate access cover.
  14. Remove and discard the 8 torque converter nuts.
    Fig 9: Locating Torque Converter Nuts
    G07480987Courtesy of FORD MOTOR CO.
  15. Remove the engine wiring harness bracket bolt and the ground wire bolt.
    Fig 10: Locating Engine Wiring Harness Bracket Bolt And Ground Wire Bolt
    G07480988Courtesy of FORD MOTOR CO.
  16. Remove the 4 nuts and the cooling fan stator.
    Fig 11: Locating Cooling Fan Stator Nuts
    G07480989Courtesy of FORD MOTOR CO.
  17. Remove the transmission cooler line bracket nut from the RH side of the engine and position the transmission cooler lines aside.
    Fig 12: Locating Transmission Cooler Tube Bracket Nut
    G07480990Courtesy of FORD MOTOR CO.
    18. NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components.
    Fig 13: Locating Fuel Return Tube Quick Connect Coupling
    G07480991Courtesy of FORD MOTOR CO.
  18. Disconnect the fuel supply tube quick connect coupling from the secondary fuel filter and position aside. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  19. Remove the 2 fuel line bracket bolts from the transmission bellhousing.
    Fig 14: Remove/Install Fuel Line Bracket Bolts
    G07480992Courtesy of FORD MOTOR CO.
  20. Remove the 2 fuel line bracket bolts from the left side of the transmission and position the fuel lines aside.
    Fig 15: Remove/Install Fuel Line Bracket Bolts
    G07480993Courtesy of FORD MOTOR CO.
    21. NOTE: Only one retainer shown in illustration, 3 other retainers similar.
    Fig 16: Locating Power Steering Pressure Line Retainers
    G07480994Courtesy of FORD MOTOR CO.
  21. Disconnect the power steering pressure line from the 4 retainers and secure the power steering pressure line to the engine.
  22. Disconnect the Manifold Absolute Pressure (MAP) sensor and the turbocharger actuator electrical connectors.
    • Disconnect the 2 wiring harness retainers.
    Fig 17: Locating Manifold Absolute Pressure Sensor, Turbocharger Actuator Electrical Connectors And Wiring Harness Retainers
    G07480995Courtesy of FORD MOTOR CO.
  23. Remove the engine and transmission oil level indicator tube bolts.
    • Disconnect the wastegate vacuum line from the wastegate actuator.
    Fig 18: Locating Engine And Transmission Oil Level Indicator Tube Bolts
    G07480996Courtesy of FORD MOTOR CO.
    24. NOTE: Cover or tape the openings on the rocker covers and lower intake.
    Fig 19: Locating Upper Intake Manifold Bolts
    G07480997Courtesy of FORD MOTOR CO.
  24. Remove the 15 bolts and the upper intake manifold.
    • Remove and discard the intake manifold gaskets.
    25. NOTE: Left side shown in illustration, right side similar.
    Fig 20: View Of Turbocharger Inlet Pipe Nuts
    G07480998Courtesy of FORD MOTOR CO.
  25. Remove and discard the 3 nuts from each turbocharger inlet pipe.
    26. NOTE: The Exhaust Pressure (EP) sensor and tube are attached to the RH turbocharger inlet pipe.
    Fig 21: Locating EP Sensor Electrical Connector And Heat Shield
    G07480999Courtesy of FORD MOTOR CO.
  26. Position the EP sensor electrical connector heat shield aside.
    • Disconnect the EP  sensor electrical connector.
    27. NOTE: Left side shown in illustration, right side similar.
    Fig 22: Locating Turbocharger Inlet Pipe Clamps
    G07481000Courtesy of FORD MOTOR CO.
  27. Loosen the 2 turbocharger inlet pipe clamps and remove the 2 turbocharger inlet pipes.
    • Remove and discard the turbocharger inlet pipe gaskets and clamps.
  28. Release the clip and remove the Charge Air Cooler (CAC) tube from the turbocharger.
    Fig 23: Locating Charge Air Cooler Tube Clip
    G07481001Courtesy of FORD MOTOR CO.
    29. NOTE: Use a 3/8 inch Jiffy-tite quick line disconnect tool, such as Snap-on® LDTSP4 or equivalent, to disconnect the turbocharger coolant outlet tube.
    Fig 24: Locating Coolant Return Tube
    G07481002Courtesy of FORD MOTOR CO.
  29. Disconnect the coolant return tube from the turbocharger.
  30. Loosen the 4 turbocharger inlet boot clamps.
    Fig 25: Locating Turbocharger Inlet Boot Clamps
    G07481003Courtesy of FORD MOTOR CO.
    31. NOTE: Left side shown in illustration, right side similar.
    NOTE: The turbocharger mounting bolts are torque-to-yield design and cannot be reused.
    Fig 26: Locating Turbocharger Mounting Bolts
    G07481004Courtesy of FORD MOTOR CO.
  31. Remove and discard the 4 turbocharger mounting bolts.
    32. NOTE: Lift the turbocharger off of the locating dowels before positioning rearward for removal.
  32. Remove the turbocharger and the 2 turbocharger inlet boots from the engine.
    • Remove and discard the turbocharger mounting gasket.
  33. Install the Engine Removal Bracket and the 4 bolts.
    • Tighten to 55 Nm (41 lb-ft).
    Fig 27: Identifying Engine Removal Bracket And Bolts
    G07481005Courtesy of FORD MOTOR CO.
  34. Remove the upper Front End Accessory Drive (FEAD) bracket mounting bolt.
    Fig 28: Locating Upper Front End Accessory Drive Bracket Mounting Bolt
    G07481006Courtesy of FORD MOTOR CO.
  35. Install the Lifting Eye and the upper FEAD bracket mounting bolt.
    • Tighten to 24 Nm (18 lb-ft).
    Fig 29: Locating Lifting Eye And Upper FEAD Bracket Mounting Bolt
    G07481007Courtesy of FORD MOTOR CO.
  36. Position a Floor Crane and connect to the Engine Removal Bracket.
    • Install a suitable ratchet strap from the arm of the Floor Crane to the Engine Lifting Bracket to adjust the angle of the engine.
    Fig 30: Identifying Suitable Ratchet Strap From Arm Of Floor Crane To Engine Lifting Bracket
    G07481008Courtesy of FORD MOTOR CO.
    37. NOTE: Failure to replace the engine support insulator cross bolts may result in engine support insulator damage.
    NOTE: If it is necessary to loosen the engine support insulator nuts, they must be discarded. For additional information, refer to ENGINE SUPPORT INSULATORS  in this service information.
    Fig 31: Locating Engine Support Insulator Cross Bolts
    G07481009Courtesy of FORD MOTOR CO.
  37. Remove and discard the 2 engine support insulator cross bolts.
  38. Lift the engine and transmission assembly high enough to clear the engine support insulators and support the transmission using a suitable transmission jack.
  39. Remove the 4 lower transmission-to-engine mounting bolts.
    Fig 32: Remove/Install Lower Transmission-To-Engine Mounting Bolts
    G07481010Courtesy of FORD MOTOR CO.
  40. Remove the 5 upper transmission-to-engine mounting bolts.
    Fig 33: Remove/Install Upper Transmission-To-Engine Mounting Bolts
    G07481011Courtesy of FORD MOTOR CO.
    41. NOTE: After the engine is removed, position the engine close to the floor in case of lifting crane failure. Failure to lower the engine may result in engine damage.
  41. Remove the engine from the vehicle.
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