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Engine - Late Build: Disassembly

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    All vehicles 

  1. Remove the bolts and the flexplate/flywheel.
    Fig 1: Identifying Flexplate/Flywheel Bolts
    G03887287Courtesy of FORD MOTOR CO.
    2. NOTE: Left side shown, right side similar.
    Fig 2: Removing Bolts LH And RH Motor Mounts
    G03899869Courtesy of FORD MOTOR CO.
  2. Remove the bolts and the LH and RH motor mounts.
  3. Mount the engine on an engine stand.
  4. Remove the front lifting brackets.
    Fig 3: Identifying Special Tool
    G03887258Courtesy of FORD MOTOR CO.
  5. Remove the oil level indicator and tube.
    • Remove the nut.
    • Remove and discard the O-ring.
    Fig 4: Removing Oil Level Indicator And Tube
    G03899871Courtesy of FORD MOTOR CO.
  6. Remove the bolt and the fuel lines and bracket.
    Fig 5: Removing Bolt Fuel Lines And Bracket
    G03899872Courtesy of FORD MOTOR CO.
  7. Disconnect the exhaust backpressure tube at the exhaust manifold.
    Fig 6: Disconnecting Exhaust Backpressure Tube
    G03899873Courtesy of FORD MOTOR CO.
  8. Remove the retaining nuts and the exhaust backpressure bracket assembly.
    Fig 7: Removing Retaining Nuts Exhaust Backpressure Bracket Assembly
    G03899874Courtesy of FORD MOTOR CO.
  9. Remove the stud bolts and thermostat housing
    • Remove and discard the O-ring.
    Fig 8: Identifying Thermostat Housing Stud Bolts
    G03887297Courtesy of FORD MOTOR CO.
  10. Remove the left cylinder head banjo fitting and fuel line. Discard the sealing washers.
    Fig 9: Identifying Fuel Line Banjo Bolt
    G03887486Courtesy of FORD MOTOR CO.
  11. Remove the bolt and serpentine belt idler.
    Fig 10: Locating Accessory Drive Idler Pulley Bolt
    G03887524Courtesy of FORD MOTOR CO.
  12. Remove the bolts and serpentine belt tensioner.
    Fig 11: Identifying Accessory Drive Belt Tensioner Bolts
    G03887304Courtesy of FORD MOTOR CO.
  13. Remove and discard the O-rings from the oil filter base.
    Fig 12: Identifying O-Ring Seals On Oil Filter Base
    G03887527Courtesy of FORD MOTOR CO.
  14. 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 13: Identifying EGR Cooler Coolant Supply Port Cover Bolts
    G03887229Courtesy of FORD MOTOR CO.
    15. 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.
    Fig 14: Identifying Oil Filter Base Bolts
    G03887230Courtesy of FORD MOTOR CO.
  15. Remove the oil filter base.
    • Remove the bolts.
    • Clean and inspect the gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
    16. 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 15: Identifying Oil Cooler Assembly Bolts
    G03887231Courtesy of FORD MOTOR CO.
  16. 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.
  17. Remove the oil pump inlet strainer. Clean and inspect for tears and other damage.
    Fig 16: Identifying Oil Pump Inlet Strainer
    G03887232Courtesy of FORD MOTOR CO.
  18. Remove bolts and the turbocharger heat shield.
    Fig 17: Locating Turbocharger Heat Shield And Bolts
    G03887333Courtesy of FORD MOTOR CO.
  19. 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 18: Removing High-Pressure Oil Pump Cover
    G03899885Courtesy of FORD MOTOR CO.
  20. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
    Fig 19: Positioning Dial Indicator With Bracketry
    G03899886Courtesy of FORD MOTOR CO.
  21. Remove the bolts from the high-pressure oil pump discharge pipe. Position the high-pressure discharge pipe aside.
    Fig 20: Removing High-Pressure Discharge Pipe Bolts
    G03899887Courtesy of FORD MOTOR CO.
  22. Remove and discard the high-pressure pump O-ring seal.
    Fig 21: Removing High-Pressure Pump O-Ring Seal
    G03899888Courtesy of FORD MOTOR CO.
  23. Remove the bolts and the high-pressure oil pump.
    Fig 22: Removing High-Pressure Oil Pump Bolts
    G03899889Courtesy of FORD MOTOR CO.
  24. Remove and discard the lower O-ring seal.
    Fig 23: Removing O-Ring
    G03899890Courtesy of FORD MOTOR CO.
    25. 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 24: View Of Glow Plug Harness And Special Tool
    G03887483Courtesy of FORD MOTOR CO.
  25. Using the special tool, remove the glow plug harness.
  26. Remove the eight glow plugs.
    Fig 25: Identifying Glow Plug
    G03887484Courtesy of FORD MOTOR CO.
  27. Remove the injection control pressure (ICP) sensor.
    Fig 26: Locating Injection Control Pressure Sensor
    G03906932Courtesy of FORD MOTOR CO.
    28. NOTE: RH side shown, LH side similar.
    NOTE: Mark the location of the stud bolts.
    Fig 27: Removing Valve Covers
    G03899894Courtesy of FORD MOTOR CO.
  28. 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.
  29. Remove the RH high-pressure oil rail to valve cover gasket.
    Fig 28: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    G03887197Courtesy of FORD MOTOR CO.
  30. Remove the bolts and the coolant pump pulley.
    Fig 29: Removing Coolant Pump Pulley Bolts
    G03899896Courtesy of FORD MOTOR CO.
  31. Remove the coolant pump.
    • Remove the bolts.
    • Remove and discard the O-ring.
    Fig 30: Locating Coolant Pump Bolts
    G03887306Courtesy of FORD MOTOR CO.
  32. If equipped, remove the bolts and dual generator pulley.
    Fig 31: Locating Dual Generator Pulley Bolts
    G03887210Courtesy of FORD MOTOR CO.
  33. 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.
      Fig 32: Checking Crankshaft Vibration Damper Runout
      G03899899Courtesy of FORD MOTOR CO.
    • Rotate the crankshaft 90 degrees. Pry the crankshaft forward. Record the measurement. Repeat at each unpainted surface.
      1. If the runout exceeds specification, install a new crankshaft vibration damper.
    34. 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 33: Locating Crankcase Vibration Damper Bolts
    G03887213Courtesy of FORD MOTOR CO.
  34. Remove the bolts and the crankcase vibration damper.
    • Discard the bolts.
  35. Punch two holes in the seal.
    Fig 34: Identifying Crankshaft Seal
    G03887244Courtesy of FORD MOTOR CO.
  36. Using the special tool, remove the crankshaft seal.
    Fig 35: Removing Crankshaft Seal
    G03899902Courtesy of FORD MOTOR CO.
    37. NOTE: The production engine will not have a wear sleeve.
    Fig 36: Removing Crankshaft Damper Wear Sleeve
    G03899903Courtesy of FORD MOTOR CO.
  37. If equipped, remove the crankshaft damper wear sleeve with the special tool.
  38. Remove the oil pump body.
    • Remove the bolts.
    • Remove and discard the O-ring seal.
    Fig 37: Locating Oil Pump Body Bolts
    G03887280Courtesy of FORD MOTOR CO.
    39. NOTE: Mark the front of each drive rotor for correct reassembly orientation.
    Fig 38: Identifying Inner And Outer Oil Pump Drive Rotors With Alignment Marks
    G03887281Courtesy of FORD MOTOR CO.
  39. Remove the inner and outer oil pump drive rotors.
  40. 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 39: Locating Engine Front Cover Bolts
    G03887307Courtesy of FORD MOTOR CO.
  41. Remove the flywheel adapter.
    Fig 40: Identifying Flywheel Adapter
    G03887288Courtesy of FORD MOTOR CO.
    42. 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.
    Fig 41: View Of Holes On RH and LH Side of Seal
    G03887289Courtesy of FORD MOTOR CO.
  42. 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.
    43. 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.
    Fig 42: Removing Rear Main Seal Using Special Tool
    G03887290Courtesy of FORD MOTOR CO.
  43. Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.
    44. NOTE: Production engines will not have wear sleeve.
    Fig 43: Removing Crankshaft Rear Wear Sleeve
    G03899910Courtesy of FORD MOTOR CO.
  44. If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
  45. Clean and inspect the crankshaft sealing surface.
    Fig 44: Identifying Crankshaft Sealing Surface
    G03887292Courtesy of FORD MOTOR CO.
  46. 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 45: Locating Rear Engine Cover Bolts
    G03887334Courtesy of FORD MOTOR CO.

    47. Two-piece head tube 

    NOTE: Some engines may have been updated with a new two-piece crankcase-to-head tube. If the crankcase-to-head tube has been updated it will have a hex head.
  47. If the high-pressure oil rail has a hex head, remove the crankcase-to-head tube assembly.
    • Remove and discard the O-ring seals.
      Fig 46: Locating D-Ring Seals
      G03887376Courtesy of FORD MOTOR CO.

    48. 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.
    Fig 47: Identifying Bolts And High-Pressure Oil Rail
    G03887377Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the high-pressure oil rail.

    49. One-piece head tube 

    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: Identifying Crankcase-To-Head Tube Assembly
    G03887400Courtesy of FORD MOTOR CO.
  49. Remove the crankcase-to-head tube assembly.
    • Remove and discard the O-rings.

    50. Two-piece head tube 

    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 metal brake parts cleaner to remove the oil residue prior to removing.
    Fig 49: Removing Lower Crankcase-To-Head Tube
    G03899916Courtesy of FORD MOTOR CO.
  50. If the updated crankcase-to-head tube separated, using a pair of soft jawed pliers, remove the lower crankcase-to-head tube.

    51. All vehicles 

    CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
    Fig 50: Removing Fuel Injector Electrical Connector
    G03887380Courtesy of FORD MOTOR CO.
  51. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
  52. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    53. 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 not any need to drain the fuel rail.
    NOTE: If engine coolant is found in the combustion chamber, it may be necessary to install a new injector sleeve. For additional information, refer to FUEL CHARGING & CONTROLS - 6.0L DIESEL .
    Fig 51: Identifying Fuel Injector Hold-Down Bolt
    G03887381Courtesy of FORD MOTOR CO.
  53. Remove the bolt, the fuel injector hold down and the fuel injector.
    54. 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.
  54. Remove the shop towels.
  55. Remove and discard the 20 head bolts from both cylinder heads.
    Fig 52: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
  56. Remove the 16 bolts and the rocker arm assemblies.
    Fig 53: Identifying Rocker Arm Assembly Bolts
    G03887497Courtesy of FORD MOTOR CO.
    57. NOTE: Mark the location of the valve bridges before removing.
    Fig 54: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
  57. Remove the 16 valve bridges.
    58. 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 55: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
  58. Mark the location and remove the 16 push rods.
  59. Remove the 10 outer head bolts.
    Fig 56: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
  60. Remove the cylinder heads.
    1. Install the special tool.
    2. Install the bolts.
    Fig 57: Identifying Special Tool And Cylinder Head
    G03887502Courtesy of FORD MOTOR CO.
  61. Remove and discard the cylinder head gasket.
    Fig 58: Identifying Gasket Sealing Surfaces Area
    G03887503Courtesy of FORD MOTOR CO.
  62. Remove and discard the four cylinder head dowel sleeves.
    Fig 59: Locating Cylinder Head Dowels
    G03887582Courtesy of FORD MOTOR CO.
  63. Remove the bolts from the rear engine tube assembly.
    Fig 60: Identifying Rear Engine Tube Assembly
    G03887583Courtesy of FORD MOTOR CO.
  64. Remove the bolt and the rear engine tube assembly.
    Fig 61: Removing Bolt Rear Engine Tube Assembly
    G03899928Courtesy of FORD MOTOR CO.
    65. 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 62: Identifying Roller Follower Guide Bolt
    G03887584Courtesy of FORD MOTOR CO.
  65. Remove the bolts and the roller follower guides. Remove the hydraulic cam followers.
  66. Remove the oil pan.
    • Remove the 16 bolts.
    • Remove the oil pan.
    • Clean and inspect the gaskets. Install new gaskets if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 63: Removing Oil Pan
    G03899930Courtesy of FORD MOTOR CO.
  67. Remove the oil pick-up tube and the screen.
    • Remove the bolts.
    • Remove and discard the O-ring.
    Fig 64: Removing Oil Pick-Up Tube And Screen
    G03899931Courtesy of FORD MOTOR CO.
  68. 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 65: Identifying Upper Oil Pan Bolts
    G03887278Courtesy of FORD MOTOR CO.
    69. 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 66: Measuring Maximum Piston Protrusion
    G03899933Courtesy of FORD MOTOR CO.
  69. 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 crankcase 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.
  70. Using a feeler gauge, check for connecting rod side clearance.
    Fig 67: Checking Connecting Rod Side Clearance
    G04519326Courtesy of FORD MOTOR CO.
  71. Remove the bolts and the connecting rod caps.
    Fig 68: Identifying Connecting Rod Cap Bolts
    G03887588Courtesy of FORD MOTOR CO.
    72. 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.
  72. Use a razor knife or emery board to scrape the carbon ridge from the top of the cylinder bore.
  73. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.
    Fig 69: Pushing Connecting Rod And Piston Assembly Out
    G03899936Courtesy of FORD MOTOR CO.
  74. Remove the piston rings.
    1. Remove the top compression ring.
    2. Remove the intermediate compression ring.
    3. Remove the oil control ring.
    Fig 70: Identifying Piston Rings
    G03887590Courtesy of FORD MOTOR CO.
  75. Remove and discard the connecting rod bearings.
    Fig 71: View Of Upper And Lower Connecting Rod Bearings
    G03887591Courtesy of FORD MOTOR CO.
  76. Install the special tool and measure the camshaft gear backlash. Install a new gear if backlash is not within specification.
    Fig 72: Measuring Camshaft Gear Backlash
    G03887592Courtesy of FORD MOTOR CO.
  77. Install the special tool and measure the camshaft end play. Install a new camshaft thrust plate if end play is not within specification.
    Fig 73: Measuring Camshaft End Play
    G03887593Courtesy of FORD MOTOR CO.
    78. 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 74: Measuring Crankshaft End Play
    G03899941Courtesy of FORD MOTOR CO.
  78. Install the special tool and measure the crankshaft end play. Record the end play.
  79. Remove the bolt and the crankshaft position (CKP) sensor.
    Fig 75: Identifying Crankshaft Position (CKP) Sensor
    G03887595Courtesy of FORD MOTOR CO.
  80. Remove the bolt and the camshaft position (CMP) sensor.
    Fig 76: Identifying Camshaft Position (CMP) Sensor
    G03887596Courtesy of FORD MOTOR CO.
  81. Remove the block heater.
    Fig 77: Identifying Block Heater
    G03887597Courtesy of FORD MOTOR CO.
  82. Remove the 20 lower case bolts and the 8 outside lower crankcase bolts. Remove the lower crankcase assembly.
    Fig 78: Locating Lower Crankcase Bolts
    G03887598Courtesy of FORD MOTOR CO.
  83. Remove the lower crankcase seals and the lower bearings and discard.
    Fig 79: Locating Lower Crankcase Seals
    G03887599Courtesy of FORD MOTOR CO.
  84. Using the appropriate lifting device, remove the crankshaft assembly.
    Fig 80: Removing Crankshaft Assembly
    G03899947Courtesy of FORD MOTOR CO.
  85. Remove and discard the crankshaft upper bearings and crankshaft upper thrust bearing.
    Fig 81: View Of Crankshaft Upper Bearing Seats
    G03887601Courtesy of FORD MOTOR CO.
    86. CAUTION: Do not knick or scratch the camshaft bearings with the camshaft lobes or engine damage will occur.
    Fig 82: Locating Thrust Plate Mounting Bolts
    G03887602Courtesy of FORD MOTOR CO.
  86. Remove the thrust plate mounting bolts and remove the camshaft and gear.
    87. CAUTION: This patch bolt is unique - do not substitute or engine damage can occur.
    Fig 83: Identifying Piston Cooling Tube Bolt
    G03887603Courtesy of FORD MOTOR CO.
  87. Remove the bolts and the eight piston cooling tubes.
  88. Using the special tool, remove the camshaft bearings and discard.
    Fig 84: Removing Camshaft Bearings
    G03899951Courtesy of FORD MOTOR CO.
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