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Section 1791 (Engine - 6.0L Diesel -- F250-F550 Super Duty 6.0L (99P F450/550)): Disassembly: Engine: Disassembly

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying Flexplate/Flywheel Bolts
G03887287Courtesy of FORD MOTOR CO.
  1. Remove the bolts and the flexplate/flywheel.
    • Discard the bolts.
  2. Mount the engine on an engine stand.
  3. Remove the rear lifting eye.
    4. Fig 2: Locating Engine Lift Adapters (303-D043-01)
    G04614140Courtesy of FORD MOTOR CO.
  4. Remove the front lifting brackets.
    5. Fig 3: Starter & Bolt
    GF0005817Courtesy of FORD MOTOR CO.
  5. Remove the 3 bolts and the starter.
    6. Fig 4: Locating Cylinder Block Coolant Drain Plug
    G03887451Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  6. Remove the cylinder block coolant drain plugs.
    7. Fig 5: Motor Mount Bolts
    GF0005818Courtesy of FORD MOTOR CO.
    NOTE: Left side shown, right side similar.
  7. Remove the bolts and the LH and RH motor mounts.
    8. Fig 6: Glow Plug Module Mounting Bracket Nuts
    GF0005701Courtesy of FORD MOTOR CO.
  8. Remove the 4 nuts and the glow plug control module and mounting bracket.
    9. Fig 7: Locating Wire Harness Retainer
    G03907047Courtesy of FORD MOTOR CO.
  9. Disconnect the wire harness retainer, the nut and the oil level indicator and tube.
    • Discard the oil level indicator tube O-ring seal.
    10. Fig 8: Thermostat Housing Bolts
    GF0005712Courtesy of FORD MOTOR CO.
  10. Remove the 2 bolts and the thermostat housing.
    • Discard the O-ring seal.
    11. Fig 9: Fuel Tube Bracket Bolt
    GF0005752Courtesy of FORD MOTOR CO.
  11. Remove the bolt, the fuel tubes and the bracket.
    12. Fig 10: Identifying Fuel Line Banjo Bolt
    G03887486Courtesy of FORD MOTOR CO.
  12. Remove the LH cylinder head banjo fitting and fuel tube.
    • Discard the sealing washers.
    13. Fig 11: Locating Accessory Drive Idler Pulley Bolt
    G03887524Courtesy of FORD MOTOR CO.
  13. Remove the bolt and accessory drive belt idlers.
    14. Fig 12: Identifying Accessory Drive Belt Tensioner Bolts
    G03887304Courtesy of FORD MOTOR CO.
  14. If equipped, remove the bolts and accessory drive belt tensioner.
    15. Fig 13: Identifying O-Ring Seals On Oil Filter Base
    G03887527Courtesy of FORD MOTOR CO.
  15. Remove and discard the O-ring seals from the oil filter base.
    16. Fig 14: Identifying EGR Cooler Coolant Supply Port Cover Bolts
    G03887229Courtesy of FORD MOTOR CO.
  16. 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.
    17. Fig 15: Identifying Oil Filter Base Bolts
    G03887230Courtesy 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.
  17. Remove the oil filter base.
    • Remove the bolts.
    • Remove and discard the press-in-place gasket.
    • Clean and inspect the sealing surfaces.
    18. Fig 16: Identifying Oil Cooler Assembly Bolts
    G03887231Courtesy of FORD MOTOR CO.
    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.
  18. Remove the oil cooler assembly.
    • Remove the bolts.
    • Remove and discard the press-in-place gasket.
    • Clean and inspect the sealing surfaces.
    19. Fig 17: Identifying Oil Pump Inlet Strainer
    G03887232Courtesy of FORD MOTOR CO.
  19. Remove the oil pump inlet strainer. Clean and inspect for tears and other damage.
    20. Fig 18: Locating Heat Insulating Wrap
    G03887533Courtesy of FORD MOTOR CO.
  20. If equipped, unsnap and remove the heat shield.
    21. Fig 19: Identifying Special Tool (303-1112)
    G04614381Courtesy of FORD MOTOR CO.
  21. Using the special tool, remove the injection pressure regulator (IPR) valve.
    22. Fig 20: High-Pressure Oil Pump Cover Bolts
    GF0005819Courtesy of FORD MOTOR CO.
  22. Remove the bolts from the high-pressure pump cover.
    23. Fig 21: Identifying Crankcase Rear Cover
    GF0005820Courtesy of FORD MOTOR CO.
    CAUTION: To prevent engine damage, do not pry the high-pressure pump cover from the pump or damage to the cover can occur.
  23. Use a thin gasket scraper to separate the cover from the crankcase at the rear cover seam.
    24. Fig 22: Checking Oil Pump Drive Gear Backlash
    GF0005821Courtesy of FORD MOTOR CO.
  24. Position the special tool and check the oil pump drive gear backlash.
    25. Fig 23: Locating High-Pressure Tube Assembly Bolts
    GF0005822Courtesy of FORD MOTOR CO.
  25. Loosen the bolts on the high-pressure tube assembly.
    26. Fig 24: Locating High-Pressure Oil Pump Bolts
    G03887539Courtesy of FORD MOTOR CO.
  26. Remove the bolts and the high-pressure oil pump.
    27. Fig 25: Identifying Lower O-Ring Seals
    G03887540Courtesy of FORD MOTOR CO.
  27. Remove and discard the lower O-ring seals.
    28. Fig 26: Disconnecting High-Pressure Tube Assembly
    GF0005823Courtesy of FORD MOTOR CO.
  28. Using the special tool, disconnect and remove the high-pressure tube assembly.
    29. Fig 27: Locating High-Pressure Oil Pump O-Ring Seal
    G03887542Courtesy of FORD MOTOR CO.
  29. Remove and discard the high-pressure oil pump O-ring seal.
    30. Fig 28: Identifying Glow Plug Harness Special Tool (303-1114)
    G04614327Courtesy of FORD MOTOR CO.
    CAUTION: Do not pull on the wiring to remove the glow plug connector or damage may occur.
    NOTE: Only one glow plug connector shown.
  30. Using the special tool, remove the glow plug harness.
    31. Fig 29: Identifying Glow Plug
    G03887484Courtesy of FORD MOTOR CO.
  31. Remove the 8 glow plugs.
    32. Fig 30: Locating Injection Control Pressure Sensor
    G03906932Courtesy of FORD MOTOR CO.
  32. Remove the injection control pressure (ICP) sensor.
    33. Fig 31: Valve Cover Fastener
    GF0005744Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
    NOTE: Mark the location of the stud bolts.
  33. 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.
    34. Fig 32: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    G03887197Courtesy of FORD MOTOR CO.
  34. Remove the RH high-pressure oil rail-to-valve cover gasket.
    35. Fig 33: Identifying Coolant Pump Pulley Bolts
    G04614086Courtesy of FORD MOTOR CO.
  35. Remove the 4 bolts and the coolant pump pulley.
    36. Fig 34: Locating Coolant Pump Bolts
    G03887306Courtesy of FORD MOTOR CO.
  36. Remove the bolts and the coolant pump.
    • Discard the O-ring seal.
    37. Fig 35: Locating Dual Generator Pulley Bolts
    G03887210Courtesy of FORD MOTOR CO.
  37. If equipped, remove the bolts and dual generator pulley.
    38. Fig 36: Checking Crankshaft Vibration Damper Runout
    GF0005703Courtesy of FORD MOTOR CO.
  38. 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 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.
    39. Fig 37: Locating Crankcase Vibration Damper Bolts
    G03887213Courtesy of FORD MOTOR CO.
    CAUTION: To prevent engine damage, you must always install 4 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.
  39. Remove the 4 bolts and the crankcase vibration damper.
    • Discard the bolts.
    40. Fig 38: Identifying Crankshaft Seal
    G03887244Courtesy of FORD MOTOR CO.
  40. Punch 2 holes in the crankshaft seal.
    41. Fig 39: Removing Crankshaft Front Seal
    GF0005709Courtesy of FORD MOTOR CO.
  41. Using the special tool, remove and discard the crankshaft seal.
    42. Fig 40: Removing Crankshaft Pulley Wear Sleeve
    GF0005710Courtesy of FORD MOTOR CO.
    NOTE: The production engine will not have a wear sleeve.
  42. If equipped, remove the crankshaft seal wear sleeve with the special tool.
    • Discard the crankshaft seal wear sleeve.
    43. Fig 41: Locating Oil Pump Body Bolts
    G03887280Courtesy of FORD MOTOR CO.
  43. Remove the bolts and the oil pump body.
    • Remove and discard the O-ring seal.
    44. Fig 42: Identifying Inner And Outer Oil Pump Drive Rotors With Alignment Marks
    G03887281Courtesy of FORD MOTOR CO.
    NOTE: Mark the front of each drive rotor for correct reassembly orientation.
  44. Remove the inner and outer oil pump drive rotors.
    45. Fig 43: Front Cover Bolts
    GF0005715Courtesy of FORD MOTOR CO.
  45. Remove the bolts and engine front cover.
    46. 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.
  46. Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove and discard the front cover gasket.
    47. Fig 44: Identifying Flywheel Adapter
    G03887288Courtesy of FORD MOTOR CO.
  47. Remove the flywheel adapter.
    48. Fig 45: View Of Holes On RH and LH Side of Seal
    G03887289Courtesy of FORD MOTOR CO.
    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.
    NOTE: The drill bit used must be the appropriate size for the body dent puller used in the following step.
  48. 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.
    49. Fig 46: Removing Crankshaft Rear Oil Seal
    GF0005722Courtesy of FORD MOTOR CO.
    NOTE: It will be necessary to alternate between the 2 holes, drilled in the previous step, to walk the seal out of the engine rear cover.
  49. Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.
    50. Fig 47: Removing Crankshaft Rear Seal Wear Sleeve
    GF0005723Courtesy of FORD MOTOR CO.
    NOTE: Production engines will not have wear sleeve.
  50. If equipped with a crankshaft wear sleeve, use the special tool to remove and discard the crankshaft rear wear sleeve.
    51. Fig 48: Identifying Crankshaft Sealing Surface
    G03887292Courtesy of FORD MOTOR CO.
  51. Clean and inspect the crankshaft sealing surface.
    52. Fig 49: Locating Rear Engine Cover Bolts
    G03887334Courtesy of FORD MOTOR CO.
    CAUTION: To prevent engine damage, replace damaged or missing dowel pins before installing the rear engine cover.
  52. Remove the 11 bolts from the rear engine cover.
    53. Fig 50: Cutting Sealant At Crankcase And Lower Crankcase Seam
    GF0005725Courtesy of FORD MOTOR CO.
    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.
  53. Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet.
    54. Fig 51: Cutting Sealant At Crankcase And Lower Crankcase Seam
    GF0005726Courtesy of FORD MOTOR CO.
    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 139.7 mm (5.5 in) long thin-blade scraper is needed to correctly cut the sealant.
  54. 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.
    55. Fig 52: Locating D-Ring Seals
    G03887376Courtesy of FORD MOTOR CO.
  55. Remove the crankcase-to-head tube assembly.
    56. Fig 53: Identifying Bolts And High-Pressure Oil Rail
    G03887377Courtesy of FORD MOTOR CO.
    NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
  56. Remove the bolts and the high-pressure oil rail.
    57. Fig 54: Identifying Special Tool (303-1164)
    G04519461Courtesy of FORD MOTOR CO.
    NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.
  57. If the crankcase-to-head tube separated, using the special tool, remove the lower crankcase-to-head tube.
    • Remove and discard the D-ring seal.
    58. Fig 55: Identifying D-Ring Seals
    G03899308Courtesy of FORD MOTOR CO.
  58. Remove and discard the D-ring seals.
    59. Fig 56: Locating Fuel Injector Electrical Connector
    GF0005745Courtesy of FORD MOTOR CO.
    CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
  59. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
  60. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    61. Fig 57: Identifying Fuel Injector Hold-Down Bolt
    G03887381Courtesy of FORD MOTOR CO.
    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 article.
  61. Remove the bolt, the fuel injector hold down and the fuel injector.
    62. 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.
  62. Remove the shop towels.
    63. Fig 58: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
    NOTE: Left cylinder head shown, right cylinder head similar.
  63. Remove and discard the 10 head bolts from each cylinder head.
    64. Fig 59: Identifying Rocker Arm Assembly Bolts
    G03887497Courtesy of FORD MOTOR CO.
  64. Remove the 16 bolts and the rocker arm assemblies.
    65. Fig 60: Identifying Rocker Arm Carrier Bolts
    GF0005824Courtesy of FORD MOTOR CO.
  65. 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.
    66. Fig 61: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
    NOTE: Mark the location of the valve bridges before removing.
  66. Remove the 16 valve bridges.
    67. Fig 62: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
    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.
  67. Mark the location and remove the 16 push rods.
    68. Fig 63: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
  68. Remove the 5 outer bolts from each cylinder head.
    69. Fig 64: Special Tool
    GF0005825Courtesy of FORD MOTOR CO.
  69. Using the special tool, remove the cylinder heads.
    • Install the special tool.
    • Install the bolts.
  70. Check for cylinder head distortion. For additional information, refer to Cylinder Head Distortion .
    71. Fig 65: Identifying Gasket Sealing Surfaces Area
    G03887503Courtesy of FORD MOTOR CO.
  71. Remove and discard the cylinder head gasket.
    72. Fig 66: Locating Cylinder Head Dowels
    G03887582Courtesy of FORD MOTOR CO.
  72. Remove and discard the 4 cylinder head dowel sleeves.
    73. Fig 67: Identifying Rear Engine Tube Assembly
    G03887583Courtesy of FORD MOTOR CO.
  73. Remove the bolts and the rear engine tube assembly.
    74. Fig 68: Identifying Roller Follower Guide Bolt
    G03887584Courtesy of FORD MOTOR CO.
    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.
  74. Remove the bolts and the roller follower guides. Remove the hydraulic cam followers.
    75. Fig 69: Oil Pan Bolt
    GF0005826Courtesy of FORD MOTOR CO.
    NOTE: The oil pan bolts must be installed in their original positions. Mark the locations of the longer bolts to aid in installation.
  75. Remove the 16 bolts and oil pan.
    • Remove and discard the press-in-place gasket.
    • Clean and inspect the sealing surfaces.
    76. Fig 70: Oil Pick-Up Tube & Screen Bolts
    GF0005827Courtesy of FORD MOTOR CO.
  76. Remove the oil pick-up tube and the screen.
    • Remove the bolts.
    • Remove and discard the O-ring.
    77. Fig 71: Identifying Upper Oil Pan Bolts
    G03887278Courtesy of FORD MOTOR CO.
  77. Remove the bolts and upper oil pan.
    • Remove and discard the press-in-place gasket.
    • Clean and inspect the sealing surfaces.
    78. Fig 72: Checking Piston Protrusion (With Specifications)
    GF0005828Courtesy 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.
  78. 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 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.
    79. Fig 73: Checking Connecting Rod Side Clearance (With Specifications)
    GF0005829Courtesy of FORD MOTOR CO.
  79. Using a feeler gauge, check for connecting rod side clearance.
    80. Fig 74: Identifying Connecting Rod Cap Bolts
    G03887588Courtesy of FORD MOTOR CO.
  80. Remove the bolts and the connecting rod caps.
    81. 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.
  81. Use a razor knife or emery board to scrape the carbon ridge from the top of the cylinder bore.
    82. Fig 75: Pushing Connecting Rod And Piston Assembly Out Of The Cylinder Bore
    GF0005830Courtesy of FORD MOTOR CO.
  82. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.
    83. Fig 76: Piston Rings
    GF0005831Courtesy of FORD MOTOR CO.
  83. Remove the piston rings.
    • Remove the keystone ring.
    • Remove the intermediate compression ring.
    • Remove the oil control ring.
    84. Fig 77: View Of Upper And Lower Connecting Rod Bearings
    G03887591Courtesy of FORD MOTOR CO.
  84. Remove and discard the connecting rod bearings.
    85. Fig 78: Checking Camshaft Gear Backlash (With Specifications)
    GF0005832Courtesy of FORD MOTOR CO.
  85. Install the special tool and measure the camshaft gear backlash. Install a new gear if backlash is not within specification.
    86. Fig 79: Checking Camshaft End Play (With Specifications)
    GF0005833Courtesy of FORD MOTOR CO.
  86. Install the special tool and measure the camshaft end play. Install a new camshaft thrust plate if end play is not within specification.
    87. Fig 80: Checking Crankshaft End Play (With Specifications)
    GF0005834Courtesy of FORD MOTOR CO.
    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.
  87. Install the special tool and measure the crankshaft end play. Record the end play.
    88. Fig 81: Identifying Crankshaft Position (CKP) Sensor
    G03887595Courtesy of FORD MOTOR CO.
  88. Remove the bolt and the crankshaft position (CKP) sensor.
    89. Fig 82: Identifying Camshaft Position (CMP) Sensor
    G03887596Courtesy of FORD MOTOR CO.
  89. Remove the bolt and the camshaft position (CMP) sensor.
    90. Fig 83: Identifying Block Heater
    G03887597Courtesy of FORD MOTOR CO.
  90. Remove the block heater.
    91. Fig 84: Lower Crankcase Bolts
    GF0005835Courtesy of FORD MOTOR CO.
  91. Remove the 20 lower case bolts. Remove the lower crankcase assembly.
    92. Fig 85: Locating Lower Crankcase Seals
    G03887599Courtesy of FORD MOTOR CO.
  92. Remove the lower crankcase seals and the lower bearings and discard.
    93. Fig 86: Crankshaft Assembly
    GF0005836Courtesy of FORD MOTOR CO.
  93. Using the appropriate lifting device, remove the crankshaft assembly.
    94. Fig 87: View Of Crankshaft Upper Bearing Seats
    G03887601Courtesy of FORD MOTOR CO.
  94. Remove and discard the crankshaft upper bearings and crankshaft upper thrust bearing.
    95. Fig 88: Locating Thrust Plate Mounting Bolts
    G03887602Courtesy of FORD MOTOR CO.
    CAUTION: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage will occur.
  95. Remove the thrust plate mounting bolts and remove the camshaft and gear.
    96. Fig 89: Identifying Piston Cooling Tube Bolt
    G03887603Courtesy of FORD MOTOR CO.
    CAUTION: This patch bolt is unique. Do not substitute or engine damage can occur.
  96. Remove the bolts and the 8 piston cooling tubes.
    97. Fig 90: Removing Camshaft Bearings
    GF0005837Courtesy of FORD MOTOR CO.
  97. Using the special tool, remove the camshaft bearings and discard.
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