Section 1160 (Engine - 6.0L Diesel -- F250-F550 Super Duty): Disassembly: Engine: Disassembly
WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Remove the bolts and the flexplate/flywheel.
- Discard the bolts.
- Mount the engine on an engine stand.
- Remove the rear lifting eye.
- Remove the front lifting brackets.
- Remove the three bolts and the starter.
- Remove the cylinder block drain plugs.
- Remove the bolts and the LH and RH motor mounts.
- Remove the retaining nuts and the glow plug control module and mounting bracket.
- Disconnect the wire retainer. Remove the nut, oil level indicator and tube.
- Remove and discard the O-ring seal.
- Disconnect the exhaust pressure tube at the exhaust manifold.
- Remove the retaining nuts and the exhaust pressure bracket assembly.
- Remove the stud bolts and thermostat housing.
- Remove and discard the O-ring seal.
- Remove the bolt and the fuel lines and bracket.
- Remove the left cylinder head banjo fitting and fuel line.
- Discard the sealing washers.
- Remove the bolt and serpentine belt idlers.
- If equipped, remove the bolts and serpentine belt tensioner.
- Remove and discard the O-ring seals from the oil filter base.
- Remove the exhaust gas recirculation (EGR) cooler coolant supply port cover.
- Remove the bolts.
- Remove and discard the press-in-place gasket.
- Clean and inspect the sealing surfaces.
- Remove the oil filter base.
- Remove the bolts.
- Remove and discard the press-in-place gasket.
- Clean and inspect the sealing surfaces.
- Remove the oil cooler assembly.
- Remove the bolts.
- Remove and discard the press-in-place gasket.
- Clean and inspect the sealing surfaces.
- Remove the oil pump inlet strainer. Clean and inspect for tears and other damage.
- Unsnap and remove the heat shield.
- Remove the IPR valve.
- Remove the turbocharger heat shield.
- Remove the bolts from the high-pressure pump cover.
- Use a thin gasket scraper to separate the cover from the crankcase at the rear cover seam.
- Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
- Loosen the bolts on the high-pressure tube assembly.
- Remove the bolts and the high-pressure oil pump.
- Remove and discard the lower O-ring seals.
- Using the special tool, disconnect and remove the high-pressure tube assembly.
- Remove and discard the high-pressure oil pump O-ring seal.
- Using the special tool, remove the glow plug harness.
- Remove the eight glow plugs.
- Remove the injection control pressure (ICP) sensor.
- Remove the valve covers.
- Remove the stud bolts and bolts.
- Clean and inspect the gaskets. Install a new gasket if necessary.
- Clean and inspect the sealing surfaces.
- Remove the RH high-pressure oil rail to valve cover gasket.
- Remove the bolts and the coolant pump pulley.
- Remove the coolant pump.
- Remove the bolts.
- Remove and discard the O-ring seal.
- If equipped, remove the bolts and dual generator pulley.
- 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.
- 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.
NOTE: Pry the crankshaft forward at the same point to eliminate possible error caused by crankshaft end play. - Remove the bolts and the crankcase vibration damper.
- Discard the bolts.
- Punch two holes in the seal.
- Using the special tool, remove the crankshaft seal.
- If equipped, remove the crankshaft seal wear sleeve with the special tool.
- Remove the oil pump body.
- Remove the bolts.
- Remove and discard the O-ring seal.
- Remove the inner and outer oil pump drive rotors.
- Remove the bolts and engine front cover.
- Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove and discard the front cover gasket.
- Remove the flywheel adapter.
- Using the appropriate drill bit, drill a hole on the RH side of the seal and another directly across from it on the LH side of the seal, as shown.
- Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.
- If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
- Clean and inspect the crankshaft sealing surface.
- Remove the 11 bolts from the rear engine cover.
- Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.
- Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.
- Remove and discard the press-in-place gasket.
- Clean and inspect the sealing surfaces.
- Remove the crankcase-to-head tube assembly.
- Remove and discard the D-ring seals.
- Remove the bolts and the high-pressure oil rail.
- Remove the crankcase-to-head tube assembly.
- Remove and discard the D-ring seals.
- If the crankcase-to-head tube separated, using a pair of soft-jawed pliers, remove the lower crankcase-to-head tube.
- Remove and discard the D-ring seal.
- Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
- Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
- Remove the bolt, the fuel injector hold down and the fuel injector.
- Remove the shop towels.
- Remove and discard the 10 head bolts from each cylinder head.
- Remove the 16 bolts and the rocker arm assemblies.
- Remove the rocker arm carrier from the cylinder head.
- Remove the bolts.
- Remove and discard the press-in-place gasket.
- Clean and inspect the sealing surfaces.
- Remove the 16 valve bridges.
- Mark the location and remove the 16 push rods.
- Remove the five outer bolts from each cylinder head.
- Remove the cylinder heads.
- Install the special tool.
- Install the bolts.
- Remove and discard the cylinder head gasket.
- Remove and discard the four cylinder head dowel sleeves.
- Remove the bolts and the rear engine tube assembly.
- Remove the bolts and the roller follower guides. Remove the hydraulic cam followers.
- Remove the 16 bolts and oil pan.
- Remove and discard the press-in-place gasket.
- Clean and inspect the sealing surfaces.
- Remove the oil pick-up tube and the screen.
- Remove the bolts.
- Remove and discard the O-ring.
- Remove the bolts and upper oil pan.
- Remove and discard the press-in-place gasket.
- Clean and inspect the sealing surfaces.
- Check the piston protrusion above the crankcase as follows.
- Zero the dial indicator gauge on the crankcase deck surface.
- Position the dial indictor 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 crankshaft to measure the maximum piston protrusion and record. Average the two readings to see if the maximum piston protrusion is exceeded.
- Using a feeler gauge, check for connecting rod side clearance.
- Remove the bolts and the connecting rod caps.
- Use a razor knife or emery board to scrape the carbon ridge from the top of the cylinder bore.
- Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.
- Remove the piston rings.
- Remove the top compression ring.
- Remove the intermediate compression ring.
- Remove the oil control ring.
- Remove and discard the connecting rod bearings.
- Install the special tool and measure the camshaft gear backlash. Install a new gear if backlash is not within specification.
- Install the special tool and measure the camshaft end play. Install a new camshaft thrust plate if end play is not within specification.
- Install the special tool and measure the crankshaft end play. Record the end play.
- Remove the bolt and the crankshaft position (CKP) sensor.
- Remove the bolt and the camshaft position (CMP) sensor.
- Remove the block heater.
- Remove the 20 lower case bolts and the 8 outside lower crankcase bolts. Remove the lower crankcase assembly.
- Remove the lower crankcase seals and the lower bearings and discard.
- Using the appropriate lifting device, remove the crankshaft assembly.
- Remove and discard the crankshaft upper bearings and crankshaft upper thrust bearing.
- Remove the thrust plate mounting bolts and remove the camshaft and gear.
- Remove the bolts and the eight piston cooling tubes.
- Using the special tool, remove the camshaft bearings and discard.
All vehicles
NOTE:
LH shown, RH similar.
NOTE:
Left side shown, right side similar.
Early build vehicles
All vehicles
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.
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.
Early build vehicles
All vehicles
CAUTION:
To prevent engine damage, do not pry the high-pressure pump cover from the pump or damage to the cover can occur.
NOTE:
These are captured bolts and not removable.
CAUTION:
Do not pull on the wiring to remove the glow plug connector or damage may occur.
NOTE:
Only one glow plug connector shown.
NOTE:
RH side shown, LH side similar.
NOTE:
Mark the location of the stud bolts.
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.
NOTE:
The production engine will not have a wear sleeve.
NOTE:
Mark the front of each drive rotor for correct reassembly orientation.
CAUTION:
Sealant is used where the crankcase and lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the front cover gasket.
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 the engine vibration and premature transmission component wear.
NOTE:
The drill bit used must be the appropriate size for the body dent puller used in the following step.
NOTE:
It will be necessary to alternate between the two holes, drilled in the previous step, to walk the seal out of the engine rear cover.
NOTE:
Production engines will not have wear sleeve.
CAUTION:
To prevent engine damage, replace damaged or missing dowel pins before installing the rear engine cover.
CAUTION:
Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.
NOTE:
A 5-1/2-inch long thin-blade scraper is needed to correctly cut the sealant.
CAUTION:
Sealant is used where the crankcase and the lower crankcase meet. Failure to cut the sealant could result in pulling the lower crankcase seal out while removing the rear cover.
NOTE:
A 5-1/2-inch long thin-blade scraper is needed to correctly cut the sealant.
Late build vehicles
All vehicles
NOTE:
Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
Early build vehicles
NOTE:
The rings on the crankcase-to-head tube must be used to pry the tube assembly from the branch tube assembly or the oil rail assembly.
Late build vehicles
CAUTION:
Use care not to deform the lower crankcase-to-head tube during removal. If the tube is damaged, a new tube must be installed.
NOTE:
Use a shop towel and brake parts cleaner to remove the oil residue prior to removing.
All vehicles
CAUTION:
Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
CAUTION:
Failure to account for all snap rings or pieces of snap rings prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system causing severe engine damage.
CAUTION:
To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
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
.
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.
NOTE:
Mark the location of the valve bridges before removing.
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.
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.
NOTE:
The oil pan bolts must be installed in their original positions. Mark the locations of the longer bolts to aid in installation.
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.
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.
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.
CAUTION:
Do not knick or scratch the camshaft bearings with the camshaft lobes or engine damage will occur.
CAUTION:
This patch bolt is unique. Do not substitute or engine damage can occur.