Engine - Enhanced Long Block
WARNING: This page is about a different car, the 2018 Ford F-550 Super Duty, 2018 Ford F-450 Super Duty, 2018 Ford F-350 Super Duty, and 2018 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
For information on Ford Color Coded Illustrations refer to OEM Color Coding .
Special Tool(s) / General Equipment
| 205-036 (T70P-4067-A) Wrench | |
|---|---|
| 303-050 (T70P-6000) Lifting Bracket, Engine | |
| 303-1518 Bracket, Engine Removal TKIT-2009C-F TKIT-2009C-ROW | |
| 303-214 (T83T-6312-B) Wrench, Fan Clutch Nut | |
| 310-230 Remover, Fuel Injector TKIT-2010FT-F TKIT-2010FT-ROW | |
| Floor Crane | |
| Hose Clamp Remover/Installer |
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".
NOTE:
Refer to the exploded view under Engine Component View .
- Remove the engine. Refer to: Engine - Body Off . Refer to: Engine - Body On .
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- Position the engine on wood blocks as needed. Remove the ratchet strap and the floor crane. Use the General Equipment: Floor Crane
- Verify that the engine is stable on the wooden blocks.
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NOTE: Discard the engine mount bracket bolts and install new bolts or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.
- Remove the bolts and the LH engine mount bracket.
- Discard the bolts.
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NOTE: Discard the engine mount bracket bolts and install new bolts or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.
- Remove the bolts and the RH engine mount bracket.
- Discard the bolts.
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- Disconnect the coolant hose assembly. Use the General Equipment: Hose Clamp Remover/Installer
- If equipped, disconnect the vacuum hose connector. Remove the coolant hose assembly.
- Loosen the clamp and remove the air cleaner outlet pipe.
- Remove the clip and the CAC pipe.
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- Disconnect the fan clutch electrical connector.
- Remove the fan clutch electrical connector bolt.
- Using the special tools, remove the fan clutch. Use Special Service Tool: 205-036 (T70P-4067-A) Wrench., 303-214 (T83T-6312-B) Wrench, Fan Clutch Nut.
- Remove the clip and disconnect the coolant hose.
- Remove the clip and the lower radiator hose.
- Remove the coolant engine fill hose. Use the General Equipment: Hose Clamp Remover/Installer
- If equipped with dual generators, remove the accessory drive belt.
- If equipped with single generator, remove the accessory drive belt.
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- Position back the boot and remove the nut.
- Disconnect the generator electrical connector.
- Disconnect the battery wire harness retainer from the bracket.
- Remove the bolts from the battery wire harness.
- Remove the LH ground bolt.
- Remove the clip and disconnect the heater hose.
- Disconnect the oil pressure switch and the oil temperature sensor electrical connectors.
- Remove the nut for the battery wire harness.
- Remove the RH ground bolt.
- Disconnect the A/C pressure switch electrical connector.
- Disconnect the A/C clutch electrical connector and the wire retainers.
- Remove the nut for the battery wire harness.
- Remove the nuts and the battery wire harness.
- Remove the bolts and the A/C compressor.
- Remove the bolt and the accessory drive belt tensioner.
- If equipped with dual generators, disconnect the wire harness retainer.
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NOTE: Dual generator shown, single generator similar.
Remove the bolts and the secondary coolant pump.
- Remove the bolts, lifting eye and the cooling fan drive assembly. Use Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.
- If equipped with dual generators, remove the idler pulley.
- Remove the bolts and the power steering pump mounting bracket.
- Disconnect the engine vacuum hose at the tee.
- Remove the nut, bolt and the transmission oil cooler coolant tube.
- Remove the stud bolt and the transmission oil cooler coolant tube.
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NOTE: Only one tube shown.
Remove and discard the transmission oil cooler coolant tube O-rings.
- Remove the stator standoffs.
- Remove the push pins and the RH sound shield.
- Remove the push pins and the LH sound shield.
- Remove the bolt and oil fill pipe.
- Remove and discard the O-ring seal.
- Remove the oil level indicator tube.
- Remove and discard the oil level indicator tube O-rings.
- Disconnect the retainer for the PCM wire harness.
- Disconnect the EGR valve electrical connector and the wire retainer.
- Disconnect the electrical connector and the vacuum hoses from the bypass valve solenoid. Detach the wire harness retainer.
- Remove the bolts and EGR cooler inlet pipe bracket. Discard the bolts.
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- Remove the bolts and the EGR cooler inlet pipe.
- Remove and discard the gaskets.
- Disconnect the EGRT electrical connector and wire retainers.
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- Remove the bolts and the EGR cooler outlet pipe.
- Remove and discard the gaskets.
- Remove the bolts and position aside the engine wire harness.
- Remove the bolts and the EGR cooler assembly.
- Remove and discard the EGR cooler gaskets.
- Leak test the EGR cooler. Refer to: Exhaust Gas Recirculation (EGR) Cooler Leak Test .
- Disconnect the TB (throttle body) electrical connector.
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NOTE: The crankcase vent oil separator must be replaced whenever the crankcase vent oil separator hose is disconnected from the lower intake.
Cut the rubber sleeve cover and peel it back out of the way.
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- Release the crankcase vent oil separator outlet hose retainers, break the tabs as needed.
- Disconnect the crankcase vent oil separator outlet hose from the lower intake manifold.
- Remove the throttle body.
- Remove and discard throttle body gasket.
- Remove the bolts and the lower intake manifold.
- Remove the CKP sensor cover.
- Disconnect the CKP sensor electrical connector and the wire retainer.
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- Remove the bolt and the ground strap.
- Disconnect the wire retainers.
- Disconnect the LH valve cover wiring.
- Disconnect the fuel pressure and temperature sensor electrical connector and the wire retainer.
- Disconnect the ECT sensor electrical connector and the wire retainer.
- Disconnect the CMP sensor electrical connector and the retainers.
- Disconnect the fuel volume control valve electrical connector.
- Disconnect the RH valve cover wiring.
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- Remove the bolt and disconnect the 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.
- Disconnect the fuel injection pump hose from the fuel rail. Refer to: Spring Lock Couplings
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- Disconnect the fuel injector return hose and retainer from the fuel line. Remove the fuel injection pump supply tube. Refer to: Quick Release Coupling
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- Remove and discard the fuel injection pump supply tube assembly bolts.
- Remove and discard the fuel injection pump supply tube assembly bolt.
- Remove the bolt and the fuel injection pump supply tube assembly. Discard the bolt.
- Remove and discard the O-ring seals.
- Remove the bolts and crankcase vent oil separator. Discard the crankcase vent oil separator.
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NOTE: Rotate the fuel filter counter clockwise to remove.
Remove and discard the secondary fuel filter.
- Remove the bolts and the secondary fuel filter bracket.
- Remove the turbocharger coolant tube. Use the General Equipment: Hose Clamp Remover/Installer
- Remove and discard the O-ring seal.
- Remove the bolts and heater supply tube.
- Remove and discard the O-ring seal.
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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 fuel injector return hose fittings from the fuel injectors.
- Disconnect and remove the fuel injector return hose and vacuum hose assembly from the retaining clips.
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NOTE: Only one shown.
Remove and discard the fuel injector supply tubes.
- Disconnect the fuel rail supply tube assembly from the LH fuel rail.
- Disconnect the fuel rail supply tube assembly from the RH fuel rail.
- Disconnect the fuel rail supply tube assembly at the high-pressure fuel injection pump.
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- Remove the bolts for the fuel rail supply tube assembly.
- Remove and discard the fuel rail supply tube assembly.
- Remove the bolts and the LH fuel rail.
- Remove the bolts and the RH fuel rail.
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- Remove the bolts and the thermostat housing.
- Remove and discard the thermostat.
- Remove the bolts and the coolant crossover manifold.
- Remove and discard the coolant crossover manifold gaskets.
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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 new bolts when installing the crankshaft pulley.
- Remove the bolts and the crankshaft pulley.
- Discard the bolts.
- Remove the bolts and the vacuum pump.
- Remove and discard the vacuum pump gasket.
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- Remove the bolts and the flexplate.
- Discard the bolts.
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NOTE: Do not use magnetic screwdrivers or other magnetic tools around the CKP sensor and the crankshaft sensor pulse ring or damage to the components may occur.
Remove the crankshaft sensor pulse ring.
- Remove the bolts and the LH exhaust manifold heat shield.
- Remove the bolts and the RH exhaust manifold heat shield.
- Remove and discard the exhaust manifold studs.
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NOTE: Mark the location of the spacers before removal.
- Remove the nuts, spacers and the LH exhaust manifold.
- Discard the nuts.
- Remove and discard the exhaust manifold gasket.
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NOTE: Mark the location of the spacers before removal.
- Remove the nuts, spacers and the RH exhaust manifold.
- Discard the nuts.
- Remove and discard the exhaust manifold gasket.
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NOTE: The fuel injector hold-down clamp bolts are torque-to-yield and cannot be reused.
- Remove and discard the fuel injector bolts.
- Remove the fuel injector hold-downs.
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NOTE: Mark the location of the fuel injector prior to removal.
- Install the special tool to the fuel injector and fully hand-tighten the special tool mounting bolt. Use Special Service Tool: 310-230 Remover, Fuel Injector.
- Install the push bolt and tighten to remove the fuel injector.
- Remove the special tool mounting bolt and the lower portion of the special tool. Remove the fuel injector.
- Remove and discard the O-rings and the copper combustion gasket.
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NOTE: Only one glow plug shown.
Remove the glow plugs.
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NOTE: Engine front cover removed for clarity.
Remove the high-pressure fuel injection pump drive gear nut.
- Remove the bolts and the fuel rail supply tube bracket.
- Remove the high-pressure fuel injection pump spacers.
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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.
Position the high-pressure fuel injection pump rearward until the gear contacts the cylinder block. Using a mallet, tap the high-pressure fuel injection pump shaft to free the gear from the pump. Remove the high-pressure fuel injection pump and drive gear.
- Remove and discard the O-ring seal
- If equipped, remove the block heater.
- Using the floor crane, remove the engine from the wooden blocks. Use the General Equipment: Floor Crane
- Remove Special Service Tool: 303-1518 Bracket, Engine Removal.