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Home >> Ford >> 2012 >> Explorer Limited, 3.5 8, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 24 (Engine Mechanical - 6.7L Diesel) >> Disassembly >> Engine - Enhanced Long Block >> Disassembly

Engine - Enhanced Long Block: Disassembly

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
NOTE: This procedure assumes that the engine was removed using the recommended body off engine removal procedure. If it was necessary to remove the engine using the alternate body on engine removal procedure, some of the components in this procedure will have already been removed.
NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel opening to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.
NOTE: For EXPORT ONLY vehicles (outside US/Canada) an Export Supplement is provided and should be referenced to identify differences that can impact service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US EPA or CARB Regulations".
  1. Remove the engine. Refer to ENGINE - BODY OFF  or ENGINE - BODY ON .
  2. Position the engine on wood blocks as needed.
    • Verify that the engine is stable on the wooden blocks.
  3. Remove the 4 bolts and the Engine Removal Bracket.
    Fig 1: Locating Engine Removal Bracket And Bolts
    G08593554Courtesy of FORD MOTOR CO.
  4. NOTE: Discard the engine support insulator bracket bolts and install new bolts or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.
    NOTE: Left side shown, right side similar.

    Remove the 8 bolts and the LH and RH engine support insulator brackets.

    • Discard the bolts.
      Fig 2: Locating Engine Support Insulator Brackets Mounting Bolts
      G08593555Courtesy of FORD MOTOR CO.
  5. Disconnect the EGR cooler hose retainer.
    Fig 3: Locating EGR Cooler Hose Retainer
    G08593556Courtesy of FORD MOTOR CO.
  6. Remove the EGR cooler hose from the EGR cooler.
    Fig 4: Locating EGR Cooler Hose Clamp
    G08593557Courtesy of FORD MOTOR CO.
  7. Disconnect the coolant hose from the vacuum hose retainer.
    Fig 5: Locating Vacuum Hose Retainer
    G08593558Courtesy of FORD MOTOR CO.
  8. Disconnect and remove the EGR cooler hose and the vent hose.
    G08593559Courtesy of
  9. Disconnect the fan clutch electrical connector.
    G08593560
  10. Remove the fan clutch electrical connector bolt.
    G08593561
  11. Using the Fan Clutch Nut Wrench and Wrench, remove the fan clutch.
    G08593562Courtesy of
  12. NOTE: Single generator shown, dual generator similar.

    Remove the accessory drive belt.

    G08593563Courtesy of
  13. Disconnect the A/C compressor electrical connectors and the wire retainer.
    Fig 6: Locating A/C Compressor Electrical Connectors And Wire Retainers
    G08593564Courtesy of FORD MOTOR CO.
  14. Remove the 3 bolts and the A/C compressor.
    Fig 7: Locating A/C Compressor Mounting Bolts
    G08593565Courtesy of FORD MOTOR CO.
  15. Remove the bolt and the accessory drive belt tensioner.
    Fig 8: Locating Accessory Drive Belt Tensioner Mounting Bolts
    G08593566Courtesy of FORD MOTOR CO.
  16. Remove the 4 bolts and the secondary coolant pump assembly.
    Fig 9: Locating Secondary Coolant Pump Assembly Mounting Bolts
    G08593567Courtesy of FORD MOTOR CO.
  17. Remove the 4 bolts and the cooling fan drive assembly.
    Fig 10: Locating Cooling Fan Drive Assembly Mounting Bolts
    G08593568Courtesy of FORD MOTOR CO.
  18. Disconnect the engine vacuum hose connector at the tee. If equipped, disconnect and remove the brake booster vacuum hose.
    Fig 11: Locating Engine Vacuum Hose Connector And Brake Booster Vacuum Hose
    G08593569Courtesy of FORD MOTOR CO.
  19. Remove the 2 stator standoffs.
    Fig 12: Locating Stator Standoffs
    G08593570Courtesy of FORD MOTOR CO.
  20. NOTE: Hose retainer not shown.

    Disconnect the oil cooler outlet hose from the lower radiator hose and hose retainer.

    Fig 13: Locating Lower Radiator Hose Retainer
    G08593571Courtesy of FORD MOTOR CO.
  21. Remove the clip and the lower radiator hose.
    G08593572
  22. Remove the engine fill hose from the engine front cover.
    Fig 14: Locating Engine Fill Hose Clip
    G08593573Courtesy of FORD MOTOR CO.
  23. Remove the clip and the upper radiator hose.
    Fig 15: Locating Upper Radiator Hose Clip
    G08593574Courtesy of FORD MOTOR CO.
  24. NOTE: Boot positioned back for clarity.

    Disconnect the generator electrical connector, remove the terminal nut and B+ terminal.

    G08593575
  25. Disconnect the lower engine wire harness retainer from the power steering bracket.
    Fig 16: Locating Engine Wire Harness Retainer
    G08593576Courtesy of FORD MOTOR CO.
  26. NOTE: RH side shown, LH side similar.

    Remove the 2 lower engine wire harness ground bolts.

    G08593577
  27. Disconnect the power steering tube from the retainer.
    Fig 17: Locating Power Steering Tube Retainer
    G08593578Courtesy of FORD MOTOR CO.
  28. NOTE: Power steering pump mounting bracket removed for clarity.

    Remove the 2 lower engine wire harness bolts.

    Fig 18: Locating Lower Engine Wire Harness Bolts
    G08593579Courtesy of FORD MOTOR CO.
  29. Disconnect the Engine Oil Temperature (EOT) sensor and the Engine Oil Pressure (EOP) switch electrical connectors.
    Fig 19: Locating Engine Oil Temperature Sensor And Engine Oil Pressure Switch Electrical Connector
    G08593580Courtesy of FORD MOTOR CO.
  30. Remove the lower engine wire harness nut at the oil filter adapter.
    Fig 20: Locating Oil Filter Adapter Lower Engine Wire Harness Nut
    G08593581Courtesy of FORD MOTOR CO.
  31. Remove the lower engine wire harness nut.
    Fig 21: Locating Lower Engine Wire Harness Nut
    G08593582Courtesy of FORD MOTOR CO.
  32. Remove the 2 front retaining nuts and the lower engine wire harness from the engine.
    Fig 22: Locating Front Retaining Nuts
    G08593583Courtesy of FORD MOTOR CO.
  33. Remove the bolt and oil fill pipe.
    • Remove and discard the O-ring seal.
      Fig 23: Locating Oil Fill Pipe Mounting Bolt
      G08593584Courtesy of FORD MOTOR CO.
  34. Remove the oil level indicator tube.
    • Remove and discard the O-ring seals.
      G08593585
  35. Remove the 2 bolts and EGR valve inlet tube bracket.
    • Discard the bolts.
      Fig 24: Locating EGR Valve Inlet Tube Bracket Mounting Bolts
      G08593586Courtesy of FORD MOTOR CO.
  36. NOTE: Exhaust side shown, EGR cooler side similar.

    Remove the 4 bolts and the EGR valve inlet tube.

    • Discard the gaskets and bolts.
      G08593587
  37. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) electrical connector and 2 wire retainers.
    Fig 25: Locating Exhaust Gas Recirculation Temperature Electrical Connector And Wire Retainer
    G08593588Courtesy of FORD MOTOR CO.
  38. Remove the 4 bolts and the EGR bypass outlet tube.
    • Discard the gaskets and bolts.
      Fig 26: Locating EGR Bypass Outlet Tube Mounting Bolts
      G08593589Courtesy of FORD MOTOR CO.
  39. NOTE: LH side shown, RH side similar.

    Remove the 2 bolts and 2 ground straps from the back of the cylinder heads.

    G08593590
  40. Disconnect the 2 wire harness retainers.
    Fig 27: Locating Wire Harness Retainers
    G08593591Courtesy of FORD MOTOR CO.
  41. Disconnect the EGR valve, bypass solenoid and EGR Engine Coolant Temperature (ECT) sensor electrical connectors. Disconnect the vacuum hose and the wire retainer.
    G08593592
  42. Remove the 2 engine wire harness bolts at the EGR cooler.
    Fig 28: Locating EGR Cooler Engine Wire Harness Bolts
    G08593593Courtesy of FORD MOTOR CO.
  43. Remove the 7 bolts and the EGR cooler assembly.
    • Discard the gaskets.
      Fig 29: Locating EGR Cooler Assembly Mounting Bolts
      G08593594Courtesy of FORD MOTOR CO.
  44. Leak test the EGR cooler. Refer to ENGINE EMISSION CONTROL .
  45. Disconnect the Throttle Body (TB) electrical connector.
    G08593595
  46. NOTE: The oil separator hose contains a collar at the lower intake manifold fitting. Rotate the collar counterclockwise to release the hose.

    If equipped, disconnect the crankcase vent oil separator hose sensor electrical connector. Disconnect the crankcase vent oil separator hose from the lower intake manifold.

    G08593596
  47. Remove the 4 bolts and the throttle body.
    • Discard the gasket.
      G08593597
  48. Remove the 3 bolts and the lower intake manifold.
    Fig 30: Locating Lower Intake Manifold Mounting Bolts
    G08593598Courtesy of FORD MOTOR CO.
  49. Disconnect the Camshaft Position (CMP) sensor electrical connector and the 3 pin type retainers.
    Fig 31: Locating Camshaft Position Sensor Electrical Connector And Pin Type Retainers
    G08593599Courtesy of FORD MOTOR CO.
  50. Disconnect the fuel volume control valve electrical connector.
    Fig 32: Locating Fuel Volume Control Valve Electrical Connector
    G08593600Courtesy of FORD MOTOR CO.
  51. Disconnect the vacuum hose retainer from the secondary fuel filter stud.
    G08593601
  52. Disconnect the turbocharger wastegate control valve vacuum and electrical connector.
    Fig 33: Locating Turbocharger Wastegate Control Vacuum And Electrical Connector
    G08593602Courtesy of FORD MOTOR CO.
  53. Disconnect the ECT sensor electrical connector and wire retainer.
    Fig 34: Locating ECT Sensor Electrical Connector And Wire Retainer
    G08593603Courtesy of FORD MOTOR CO.
  54. Disconnect the fuel pressure switch and the fuel temperature sensor electrical connectors. Disconnect the wire retainer.
    G08593604
  55. Disconnect the Fuel Rail Pressure (FRP) sensor electrical connector and 2 wire harness retainers.
    Fig 35: Locating Fuel Rail Pressure Sensor Electrical Connector And Wire Harness Retainer
    G08593605Courtesy of FORD MOTOR CO.
  56. Disconnect the fuel pressure control valve electrical connector.
    Fig 36: Locating Fuel Pressure Control Valve Electrical Connector
    G08593606Courtesy of FORD MOTOR CO.
  57. Remove the cylinder block opening cover.
    G08593607
  58. NOTE: Only one wire retainer shown.

    Disconnect the Crankshaft Position (CKP) sensor electrical connector and the 3 wire retainers.

    Fig 37: Locating Crankshaft Position Sensor Electrical Connector And Wire Retainer
    G08593608Courtesy of FORD MOTOR CO.
  59. NOTE: Only one fuel injector and glow plug electrical connector shown.

    Disconnect the 8 fuel injector and 8 glow plug electrical connectors.

    Fig 38: Locating Fuel Injector And Glow Plug Electrical Connector
    G08593609Courtesy of FORD MOTOR CO.
  60. Disconnect the 3 wire retainers from the LH valve cover.
    Fig 39: Locating LH Valve Cover Wire Retainers
    G08593610Courtesy of FORD MOTOR CO.
  61. NOTE: Only one retainer shown.

    Disconnect the 6 retainers from the fuel supply manifolds.

    Fig 40: Locating Fuel Supply Manifold Retainer
    G08593611Courtesy of FORD MOTOR CO.
  62. Remove the bolt and disconnect the 2 engine wire harness retainers.
    • Pull forward to disconnect the engine wire harness retainer and then pull up to disconnect the other retainer. Remove the engine wire harness from the engine.
      Fig 41: Locating Engine Wire Harness And Mounting Bolt
      G08593612Courtesy of FORD MOTOR CO.
  63. Remove the 4 bolts and the power steering mounting bracket.
    Fig 42: Locating Power Steering Mounting Bracket Mounting Bolts
    G08593613Courtesy of FORD MOTOR CO.
  64. Disconnect the fuel injection pump hose from the fuel rail.
    G08593614
  65. Disconnect the fuel injector return hose and retainer from the secondary fuel filter. Disconnect the secondary outlet hose from the fuel injection pump supply tube.
    G08593615
  66. Remove the 2 fuel injection pump supply tube assembly bolts.
    Fig 43: Locating Fuel Injection Pump Supply Tube Assembly Bolts
    G08593616Courtesy of FORD MOTOR CO.
  67. Remove the fuel injection pump supply tube assembly stud bolt.
    Fig 44: Locating Fuel Injection Pump Supply Tube Assembly Stud Bolt
    G08593617Courtesy of FORD MOTOR CO.
  68. Remove the bolt and the fuel injection pump supply tube assembly.
    • Remove and discard the O-ring seals.
      Fig 45: Locating Fuel Injection Pump Supply Tube Assembly Mounting Bolt
      G08593618Courtesy of FORD MOTOR CO.
  69. NOTE: Only 2 bolts shown.

    Remove the 4 bolts and crankcase vent oil separator.

    • Remove and discard the gaskets.
      Fig 46: Locating Crankcase Vent Oil Separator Mounting Bolt
      G08593619Courtesy of FORD MOTOR CO.
  70. Remove the fuel filter-to-fuel injection pump supply tube. Refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
    G08593620
  71. NOTE: Early build fuel filter bracket shown.
    NOTE: On late build fuel filter brackets, rotate the fuel filter counter clockwise to remove.

    Loosen the bolt on the fuel filter bracket. Remove and discard the secondary fuel filter.

    G08593621
  72. Remove the 3 bolts and the secondary fuel filter bracket.
    G08593622
  73. Remove the turbocharger coolant tube.
    G08593623
  74. Remove the 2 bolts and the heater supply tube.
    • Remove and discard the O-ring seal.
      G08593624
  75. NOTE: The center lock of the fuel injector return hose connectors must be pulled completely out before the connector can be removed from the fuel injector or damage may occur to the connector.

    Push down on the tabs and pull up on the center of the fuel injector return hose fitting to unlock the fitting.

    • Disconnect the 8 fuel injector return hose fittings from the fuel injectors.
      Fig 47: Pulling Center Of Fuel Injector Return Hose Fitting
      G08593625Courtesy of FORD MOTOR CO.
  76. NOTE: RH valve cover shown, other connectors similar.

    Disconnect and remove the fuel injector return hose and vacuum hose assembly from the retaining clips.

    G08593626
  77. NOTE: Only one fuel injector supply tube shown.

    Remove and discard the 8 fuel injector supply tubes.

    Fig 48: Locating Fuel Injector Supply Tube Fittings
    G08593627Courtesy of FORD MOTOR CO.
  78. NOTE: LH side shown, RH side similar.

    Disconnect the 4 fuel rail supply tube assembly from the fuel rails.

    Fig 49: Locating Fuel Rail Supply Tube Assembly
    G08593628Courtesy of FORD MOTOR CO.
  79. Disconnect the 2 fuel rail supply tube assembly at the high-pressure fuel injection pump.
    G08593629
  80. Remove the 5 bolts and fuel rail supply tube assembly.
    • Discard the fuel rail supply tube assembly.
      G08593630
  81. Remove the 2 bolts and LH fuel rail.
    Fig 50: Locating LH Fuel Rail Mounting Bolts
    G08593631Courtesy of FORD MOTOR CO.
  82. Remove the 2 bolts and RH fuel rail.
    Fig 51: Locating RH Fuel Rail Mounting Bolts
    G08593632Courtesy of FORD MOTOR CO.
  83. Remove the 3 bolts, thermostat housing and thermostat.
    • Discard the thermostat.
      Fig 52: Locating Thermostat Housing Mounting Bolts
      G08593633Courtesy of FORD MOTOR CO.
  84. Remove the 5 bolts and the coolant crossover manifold assembly.
    • Discard the gaskets.
      Fig 53: Locating Coolant Crossover Manifold Assembly Mounting Bolts
      G08593634Courtesy of FORD MOTOR CO.
  85. 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 4 new bolts when installing the crankshaft pulley.

    Remove the 4 bolts and the crankshaft pulley.

    • Discard the bolts.
      G08593635
  86. Remove the 4 bolts and the vacuum pump.
    • Discard the gasket.
      Fig 54: Locating Vacuum Pump Mounting Bolts
      G08593636Courtesy of FORD MOTOR CO.
  87. Remove the 10 bolts and flexplate.
    • Discard the bolts.
      G08593637
  88. NOTE: Do not use magnetic screwdrivers or other magnetic tools around the Crankshaft Position (CKP) sensor and the crankshaft sensor pulse ring or damage to the components may occur.

    Remove the crankshaft sensor pulse ring.

    G08593638
  89. Remove the 4 bolts and the LH exhaust manifold heat shield.
    • Discard the bolts.
      Fig 55: Locating LH Exhaust Manifold Heat Shield Mounting Bolts
      G08593639Courtesy of FORD MOTOR CO.
  90. Remove the 5 bolts and the RH exhaust manifold heat shield.
    • Discard the bolts.
      Fig 56: Locating RH Exhaust Manifold Heat Shield Mounting Bolts
      G08593640Courtesy of FORD MOTOR CO.
  91. NOTE: RH side shown, LH side similar.

    Remove and discard the 6 exhaust manifold studs.

    G08593641
  92. Remove the 8 nuts, 8 spacers and the LH exhaust manifold.
    • Remove and discard the LH exhaust manifold gasket, spacers and nuts.
      G08593642
  93. Remove the 8 nuts, 8 spacers and the RH exhaust manifold.
    • Remove and discard the RH exhaust manifold gasket, spacers and nuts.
      G08593643
  94. NOTE: The fuel injector hold-down clamp bolts are torque-to-yield and cannot be reused.

    Remove the 8 fuel injector bolts and fuel injector hold-downs.

    • Discard the fuel injector bolts.
      G08593644
  95. Using the Fuel Injector Remover tool, remove the 8 fuel injectors.
    1. Install the Fuel Injector Remover tool to the fuel injector and fully hand-tighten the Fuel Injector Remover tool mounting bolt.
    2. Install the allen head push bolt and tighten to remove the fuel injector.
    3. Remove the Fuel Injector Remover tool mounting bolt and the lower portion of the Fuel Injector Remover tool.
    4. Remove and discard the O-ring seal and the copper combustion gasket from the fuel injector.
    5. Remove and discard the fuel injector return fuel O-ring.
      • Position the fuel injector in the Fuel Injector Holding Rack and Injector Cups.
        G08593645Courtesy of
  96. NOTE: Only one glow plug shown.

    Remove the 8 glow plugs.

    Fig 57: Locating Glow Plugs
    G08593646Courtesy of FORD MOTOR CO.
  97. NOTE: Engine front cover removed for clarity.

    Remove the high-pressure fuel injection pump drive gear nut.

    Fig 58: Locating High-Pressure Fuel Injection Pump Drive Gear Nut
    G08593647Courtesy of FORD MOTOR CO.
  98. Using a Universal Puller, remove the high-pressure fuel injection pump drive gear.
    Fig 59: Removing High-Pressure Fuel Injection Pump Drive Gear Using Universal Puller
    G08593648Courtesy of FORD MOTOR CO.
  99. Remove the 2 bolts and the fuel rail supply tube bracket.
    G08593649
  100. NOTE: Do not pry against the mating surface of the high-pressure fuel injection pump or damage to the high-pressure fuel injection pump may occur.

    Remove the 3 high-pressure fuel injection pump spacers and high-pressure fuel injection pump.

    • Discard the O-ring seal.
      G08593650
  101. If equipped, remove the block heater.
    G08593651
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