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Home >> Ford >> 2022 >> Transit Connect Titanium, Gas/Ethanol >> Repair and Diagnosis >> External Pages >> Different car >> Section 37 (Engine - 6.7L Power Stroke Diesel) >> Disassembly >> Engine

Section 37 (Engine - 6.7L Power Stroke Diesel): Disassembly: Engine

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 

GFD202746Courtesy of FORD MOTOR COMPANY
100-001 (T50T-100-A) Slide Hammer
GFD202747Courtesy of FORD MOTOR COMPANY
100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
GFD202748Courtesy of FORD MOTOR COMPANY
205-036 (T70P-4067-A) Wrench
GFD202749Courtesy of FORD MOTOR COMPANY
303-050 (T70P-6000) Lifting Bracket, Engine
GFD202750Courtesy of FORD MOTOR COMPANY
303-1510 Remover, Front Crank Seal
GFD202751Courtesy of FORD MOTOR COMPANY
303-1513 Remover, Rear Crank Seal
GFD202752Courtesy of FORD MOTOR COMPANY
303-1517 Adapter, Camshaft Remover/Installer TKIT-2009C-F TKIT-2009C-ROW
GFD202753Courtesy of FORD MOTOR COMPANY
303-1518 Bracket, Engine Removal TKIT-2009C-F TKIT-2009C-ROW
GFD202754Courtesy of FORD MOTOR COMPANY
303-214 (T83T-6312-B) Wrench, Fan Clutch Nut
GFD202755Courtesy of FORD MOTOR COMPANY
310-230 Remover, Fuel Injector TKIT-2010FT-F TKIT-2010FT-ROW
Feeler Gauge
Floor Crane
Mounting Stand
Plastic Scraper
Hose Clamp Remover/Installer

Materials 

Name Specification
Motorcraft ® Silicone Gasket Remover ZC-30-A -
Motorcraft ® Metal Surface Prep Wipes ZC-31-B -
Motorcraft ® Metal Brake Parts Cleaner PM-4-A, PM-4-B -
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enter the oil passages, coolant passages or the oil pan, may cause engine failure.
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: 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: Disassembly of the engine requires various inspections/measurements of the engine components. These inspections/measurements will aid in determining if the engine components will require replacement.
NOTE: Refer to the exploded view under Engine Component View .
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 . Refer to: Engine - Body On .
  2. 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.

    GFD202756Courtesy of FORD MOTOR COMPANY
  3. 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.

    GFD202757Courtesy of FORD MOTOR COMPANY
  4. NOTE: Use Rotunda Part Number 209-78203 or equivalent to support the engine on the mounting stand. Failure to correctly support the engine may result in engine damage.

    Mount the engine to a mounting stand. Remove the ratchet strap and the floor crane. Use the General Equipment: Mounting Stand Use the General Equipment: Floor Crane

    GFD202758Courtesy of FORD MOTOR COMPANY
  5. Remove Special Service Tool: 303-1518 Bracket, Engine Removal.
    GFD202759Courtesy of FORD MOTOR COMPANY
    • 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.

    GFD202760Courtesy of FORD MOTOR COMPANY
  6. Loosen the clamp and remove the air cleaner outlet pipe.
    GFD202761Courtesy of FORD MOTOR COMPANY
  7. Remove the clip and the CAC pipe.
    GFD202762Courtesy of FORD MOTOR COMPANY
    • Disconnect the fan clutch electrical connector.

    • Remove the fan clutch electrical connector bolt.

    GFD202763Courtesy of FORD MOTOR COMPANY
  8. 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.
    GFD202764Courtesy of FORD MOTOR COMPANY
  9. Remove the clip and disconnect the coolant hose.
    GFD202765Courtesy of FORD MOTOR COMPANY
  10. Remove the clip and the lower radiator hose.
    GFD202766Courtesy of FORD MOTOR COMPANY
  11. Remove the coolant engine fill hose. Use the General Equipment: Hose Clamp Remover/Installer
    GFD202767Courtesy of FORD MOTOR COMPANY
  12. If equipped with dual generators, remove the accessory drive belt.
    GFD202768Courtesy of FORD MOTOR COMPANY
  13. If equipped with single generator, remove the accessory drive belt.
    GFD202769Courtesy of FORD MOTOR COMPANY
    • Position back the boot and remove the nut.

    • Disconnect the generator electrical connector.

    GFD202770Courtesy of FORD MOTOR COMPANY
  14. Disconnect the battery wire harness retainer from the bracket.
    GFD202771Courtesy of FORD MOTOR COMPANY
  15. Remove the bolts from the battery wire harness.
    GFD202772Courtesy of FORD MOTOR COMPANY
  16. Remove the LH ground bolt.
    GFD202773Courtesy of FORD MOTOR COMPANY
  17. Remove the clip and disconnect the heater hose.
    GFD202774Courtesy of FORD MOTOR COMPANY
  18. Disconnect the oil pressure switch and the oil temperature sensor electrical connectors.
    GFD202775Courtesy of FORD MOTOR COMPANY
  19. Remove the nut for the battery wire harness.
    GFD202776Courtesy of FORD MOTOR COMPANY
  20. Remove the RH ground bolt.
    GFD202777Courtesy of FORD MOTOR COMPANY
  21. Disconnect the A/C pressure switch electrical connector.
    GFD202778Courtesy of FORD MOTOR COMPANY
  22. Disconnect the A/C clutch electrical connector and the wire retainers.
    GFD202779Courtesy of FORD MOTOR COMPANY
  23. Remove the nut for the battery wire harness.
    GFD202780Courtesy of FORD MOTOR COMPANY
  24. Remove the nuts and the battery wire harness.
    GFD202781Courtesy of FORD MOTOR COMPANY
  25. Remove the bolts and the A/C compressor.
    GFD202782Courtesy of FORD MOTOR COMPANY
  26. Remove the bolt and the accessory drive belt tensioner.
    GFD202783Courtesy of FORD MOTOR COMPANY
  27. If equipped with dual generators, disconnect the wire harness retainer.
    GFD202784Courtesy of FORD MOTOR COMPANY
  28. NOTE: Dual generator shown, single generator similar.

    Remove the bolts and the secondary coolant pump.

    GFD202785Courtesy of FORD MOTOR COMPANY
  29. Remove the bolts, lifting eye and the cooling fan drive assembly. Use Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.
    GFD202786Courtesy of FORD MOTOR COMPANY
  30. If equipped with dual generators, remove the idler pulley.
    GFD202787Courtesy of FORD MOTOR COMPANY
  31. Remove the bolts and the power steering pump mounting bracket.
    GFD202788Courtesy of FORD MOTOR COMPANY
  32. Disconnect the engine vacuum hose at the tee.
    GFD202789Courtesy of FORD MOTOR COMPANY
  33. Remove the nut, bolt and the transmission oil cooler coolant tube.
    GFD202790Courtesy of FORD MOTOR COMPANY
  34. Remove the stud bolt and the transmission oil cooler coolant tube.
    GFD202791Courtesy of FORD MOTOR COMPANY
  35. NOTE: Only one tube shown.

    Remove and discard the transmission oil cooler coolant tube O-rings.

    GFD202792Courtesy of FORD MOTOR COMPANY
  36. Remove the stator standoffs.
    GFD202793Courtesy of FORD MOTOR COMPANY
  37. Remove the push pins and the RH sound shield.
    GFD202794Courtesy of FORD MOTOR COMPANY
  38. Remove the push pins and the LH sound shield.
    GFD202795Courtesy of FORD MOTOR COMPANY
  39. Remove the bolt and oil fill pipe.
    GFD202796Courtesy of FORD MOTOR COMPANY
  40. Remove and discard the O-ring seal.
    GFD202797Courtesy of FORD MOTOR COMPANY
  41. Remove the oil level indicator tube.
    GFD202798Courtesy of FORD MOTOR COMPANY
  42. Remove and discard the oil level indicator tube O-rings.
    GFD202799Courtesy of FORD MOTOR COMPANY
  43. Disconnect the retainer for the PCM wire harness.
    GFD202800Courtesy of FORD MOTOR COMPANY
  44. Disconnect the EGR valve electrical connector and the wire retainer.
    GFD202801Courtesy of FORD MOTOR COMPANY
  45. Disconnect the electrical connector and the vacuum hoses from the bypass valve solenoid. Detach the wire harness retainer.
    GFD202802Courtesy of FORD MOTOR COMPANY
  46. Remove the bolts and EGR cooler inlet pipe bracket. Discard the bolts.
    GFD202803Courtesy of FORD MOTOR COMPANY
    • Remove the bolts and the EGR cooler inlet pipe.

    • Remove and discard the gaskets.

    GFD202804Courtesy of FORD MOTOR COMPANY
  47. Disconnect the EGRT electrical connector and wire retainers.
    GFD202805Courtesy of FORD MOTOR COMPANY
    • Remove the bolts and the EGR cooler outlet pipe.

    • Remove and discard the gaskets.

    GFD202806Courtesy of FORD MOTOR COMPANY
  48. Remove the bolts and position aside the engine wire harness.
    GFD202807Courtesy of FORD MOTOR COMPANY
  49. Remove the bolts and the EGR cooler assembly.
    GFD202808Courtesy of FORD MOTOR COMPANY
  50. Remove and discard the EGR cooler gaskets.
    GFD202809Courtesy of FORD MOTOR COMPANY
  51. Disconnect the TB (throttle body) electrical connector.
    GFD202810Courtesy of FORD MOTOR COMPANY
  52. 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.

    GFD202811Courtesy of FORD MOTOR COMPANY
    • 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.

    GFD202812Courtesy of FORD MOTOR COMPANY
  53. Remove the bolts and the lower intake manifold.
    GFD202813Courtesy of FORD MOTOR COMPANY
  54. Remove the CKP sensor cover.
    GFD202814Courtesy of FORD MOTOR COMPANY
  55. Disconnect the CKP sensor electrical connector and the wire retainer.
    GFD202815Courtesy of FORD MOTOR COMPANY
    • Remove the bolt and the ground strap.

    • Disconnect the wire retainers.

    GFD202816Courtesy of FORD MOTOR COMPANY
  56. Disconnect the LH valve cover wiring.
    GFD202817Courtesy of FORD MOTOR COMPANY
  57. Disconnect the fuel pressure and temperature sensor electrical connector and the wire retainer.
    GFD202818Courtesy of FORD MOTOR COMPANY
  58. Disconnect the ECT sensor electrical connector and the wire retainer.
    GFD202819Courtesy of FORD MOTOR COMPANY
  59. Disconnect the CMP sensor electrical connector and the retainers.
    GFD202820Courtesy of FORD MOTOR COMPANY
  60. Disconnect the fuel volume control valve electrical connector.
    GFD202821Courtesy of FORD MOTOR COMPANY
  61. Disconnect the RH valve cover wiring.
    GFD202822Courtesy of FORD MOTOR COMPANY
    • 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.

    GFD202823Courtesy of FORD MOTOR COMPANY
  62. Disconnect the fuel injection pump hose from the fuel rail. Refer to: Spring Lock Couplings .
    GFD202824Courtesy of FORD MOTOR COMPANY
  63. Disconnect the fuel injector return hose and retainer from the fuel line. Remove the fuel injection pump supply tube. Refer to: Quick Release Coupling .
    GFD202825Courtesy of FORD MOTOR COMPANY
  64. Remove and discard the fuel injection pump supply tube assembly bolts.
    GFD202826Courtesy of FORD MOTOR COMPANY
  65. Remove and discard the fuel injection pump supply tube assembly bolt.
    GFD202827Courtesy of FORD MOTOR COMPANY
  66. Remove the bolt and the fuel injection pump supply tube assembly. Discard the bolt.
    GFD202828Courtesy of FORD MOTOR COMPANY
  67. Remove and discard the O-ring seals.
    GFD202829Courtesy of FORD MOTOR COMPANY
  68. Remove the bolts and crankcase vent oil separator. Discard the crankcase vent oil separator.
    GFD202830Courtesy of FORD MOTOR COMPANY
  69. NOTE: Rotate the fuel filter counter clockwise to remove.

    Remove and discard the secondary fuel filter.

    GFD202831Courtesy of FORD MOTOR COMPANY
  70. Remove the bolts and the secondary fuel filter bracket.
    GFD202832Courtesy of FORD MOTOR COMPANY
  71. Remove the turbocharger coolant tube. Use the General Equipment: Hose Clamp Remover/Installer
    GFD202833Courtesy of FORD MOTOR COMPANY
  72. Remove and discard the O-ring seal.
    GFD202834Courtesy of FORD MOTOR COMPANY
  73. Remove the bolts and heater supply tube.
    GFD202835Courtesy of FORD MOTOR COMPANY
  74. Remove and discard the O-ring seal.
    GFD202836Courtesy of FORD MOTOR COMPANY
    • 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.

    GFD202837Courtesy of FORD MOTOR COMPANY
  75. NOTE: Only one shown.

    Remove and discard the fuel injector supply tubes.

    GFD202838Courtesy of FORD MOTOR COMPANY
  76. Disconnect the fuel rail supply tube assembly from the LH fuel rail.
    GFD202839Courtesy of FORD MOTOR COMPANY
  77. Disconnect the fuel rail supply tube assembly from the RH fuel rail.
    GFD202840Courtesy of FORD MOTOR COMPANY
  78. Disconnect the fuel rail supply tube assembly at the high-pressure fuel injection pump.
    GFD202841Courtesy of FORD MOTOR COMPANY
    • Remove the bolts for the fuel rail supply tube assembly.

    • Remove and discard the fuel rail supply tube assembly.

    GFD202842Courtesy of FORD MOTOR COMPANY
  79. Remove the bolts and the LH fuel rail.
    GFD202843Courtesy of FORD MOTOR COMPANY
  80. Remove the bolts and the RH fuel rail.
    GFD202844Courtesy of FORD MOTOR COMPANY
  81. Remove the bolts, thermostat housing and the thermostat.
    GFD202845Courtesy of FORD MOTOR COMPANY
  82. Remove the bolts and the coolant crossover manifold.
    GFD202846Courtesy of FORD MOTOR COMPANY
  83. Remove and discard the coolant crossover manifold gaskets.
    GFD202847Courtesy of FORD MOTOR COMPANY
  84. 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.

    GFD202848Courtesy of FORD MOTOR COMPANY
  85. Remove the bolts and the vacuum pump.
    GFD202849Courtesy of FORD MOTOR COMPANY
  86. Remove and discard the vacuum pump gasket.
    GFD202850Courtesy of FORD MOTOR COMPANY
    • Remove the bolts and the flexplate.

    • Discard the bolts.

    GFD202851Courtesy of FORD MOTOR COMPANY
  87. 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.

    GFD202852Courtesy of FORD MOTOR COMPANY
  88. Remove the bolt and the CKP sensor.
    GFD202853Courtesy of FORD MOTOR COMPANY
  89. Remove the bolts and the LH exhaust manifold heat shield.
    GFD202854Courtesy of FORD MOTOR COMPANY
  90. Remove the bolts and the RH exhaust manifold heat shield.
    GFD202855Courtesy of FORD MOTOR COMPANY
  91. Remove and discard the exhaust manifold studs.
    GFD202856Courtesy of FORD MOTOR COMPANY
  92. NOTE: Mark the location of the spacers before removal.

    • Remove the nuts, spacers and the LH exhaust manifold.

    • Discard the nuts.

    GFD202857Courtesy of FORD MOTOR COMPANY
    • NOTE: Cylinder number 8 will have longer studs.

      Remove and discard the exhaust manifold gasket.

    • Replace any exhaust manifold stud(s) that are damaged or removed with the nut.

    GFD202858Courtesy of FORD MOTOR COMPANY
  93. NOTE: Mark the location of the spacers before removal.

    • Remove the nuts, spacers and the RH exhaust manifold.

    • Discard the nuts.

    GFD202859Courtesy of FORD MOTOR COMPANY
    • NOTE: Cylinder number 4 will have longer studs.

      Remove and discard the exhaust manifold gasket.

    • Replace any exhaust manifold stud(s) that are damaged or removed with the nut.

    GFD202860Courtesy of FORD MOTOR COMPANY
  94. 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.

    GFD202861Courtesy of FORD MOTOR COMPANY
  95. 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.

    GFD202862Courtesy of FORD MOTOR COMPANY
  96. Remove and discard the O-rings and the copper combustion gasket.
    GFD202863Courtesy of FORD MOTOR COMPANY
  97. NOTE: Only one glow plug shown.

    Remove the glow plugs.

    GFD202864Courtesy of FORD MOTOR COMPANY
  98. Remove the bolts, stud bolts and the LH valve cover.
    GFD202865Courtesy of FORD MOTOR COMPANY
  99. Remove and discard the valve cover gasket.
    GFD202866Courtesy of FORD MOTOR COMPANY
  100. Remove the bolts, stud bolts and the RH valve cover.
    GFD202867Courtesy of FORD MOTOR COMPANY
  101. Remove and discard the valve cover gasket.
    GFD202868Courtesy of FORD MOTOR COMPANY
  102. NOTE: Use the notch in the valve cover to aid in removing the fuel injector-to-valve cover seal.

    Remove and discard the fuel injector-to-valve cover seals.

    GFD202869Courtesy of FORD MOTOR COMPANY
  103. NOTE: Failure to remove the oil spray bar in steps may result in damage to the oil spray bar.
    NOTE: The nuts for the oil spray bar are captured nuts and remain on the oil spray bar.

    Remove the LH oil spray bar. Loosen the nuts 2 revolutions at a time in the sequence shown until the LH oil spray bar can be removed.

    GFD202870Courtesy of FORD MOTOR COMPANY
  104. NOTE: Failure to remove the oil spray bar in steps may result in damage to the oil spray bar.
    NOTE: The nuts for the oil spray bar are captured nuts and remain on the oil spray bar.

    Remove the RH oil spray bar. Loosen the nuts 2 revolutions at a time in the sequence shown until the RH oil spray bar can be removed.

    GFD202871Courtesy of FORD MOTOR COMPANY
  105. Inspect the O-ring seals, replace if necessary.
    GFD202872Courtesy of FORD MOTOR COMPANY
  106. NOTE: Mark the location of the rocker arm assemblies prior to removing.
    NOTE: Only one cylinder shown.

    Remove the rocker arm assemblies.

    GFD202873Courtesy of FORD MOTOR COMPANY
  107. NOTE: Do not disassemble the rocker arm assembly. They are serviced as an assembly only.

    • Looking from the side of the rocker arm assembly, inspect each rocker arm ball for scuffing. Install new rocker arm assemblies as required.

    • Inspect each rocker arm pivot foot and cup for pitting and scuffing. Install new rocker arm assemblies as required.

    GFD202874Courtesy of FORD MOTOR COMPANY
  108. NOTE: 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.
    NOTE: Only one cylinder shown.

    Remove the push rods.

    GFD202875Courtesy of FORD MOTOR COMPANY
    • Inspect each push rod for wear and deposits which may restrict the flow of oil into the rocker arm assembly. Install a new push rod as needed.

    • Inspect the ball end of the push rod, if the end does not have a polished look, replace the push rod.

    GFD202876Courtesy of FORD MOTOR COMPANY
  109. NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface
    NOTE: The M12 cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.

    • Remove and discard the M12 bolts from the cylinder head. Remove the M8 cylinder head bolts.

    • Remove the LH cylinder head.

    GFD202877Courtesy of FORD MOTOR COMPANY
  110. Remove and discard the LH cylinder head gasket and the cylinder head dowels.
    GFD202878Courtesy of FORD MOTOR COMPANY
  111. NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
    NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface
    NOTE: The M12 cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.

    • Remove and discard the M12 bolts from the cylinder head. Remove the M8 cylinder head bolts.

    • Remove the RH cylinder head.

    GFD202879Courtesy of FORD MOTOR COMPANY
  112. Remove and discard the RH cylinder head gasket and the cylinder head dowels.
    GFD202880Courtesy of FORD MOTOR COMPANY
  113. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.

    Make sure that the mating faces are clean and free of foreign material. Use the General Equipment: Plastic Scraper

    Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A

    Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

  114. Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
  115. Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
  116. NOTE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original positions or engine damage may occur.
    NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.
    NOTE: Only one valve tappet guide shown.
    NOTE: Some valve tappets will be removed with the valve tappet guides.

    Remove the valve tappet guides.

    GFD202881Courtesy of FORD MOTOR COMPANY
  117. NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.
    NOTE: Only one cylinder shown.

    Remove the valve tappets from the engine.

    GFD202882Courtesy of FORD MOTOR COMPANY
  118. Remove the bolts and the lower oil pan.
    GFD202883Courtesy of FORD MOTOR COMPANY
  119. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper

    Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A

    Material: Motorcraft ® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

  120. NOTE: Use care when removing the hose from the oil cooler, damage to the oil cooler may occur during removal.

    Remove the oil cooler inlet hose. Use the General Equipment: Hose Clamp Remover/Installer

    GFD202884Courtesy of FORD MOTOR COMPANY
  121. Disconnect the hose retainers. Remove the oil cooler outlet hose. Use the General Equipment: Hose Clamp Remover/Installer
    GFD202885Courtesy of FORD MOTOR COMPANY
  122. NOTE: In the event of a catastrophic engine failure, or if installing a new short block, always install a new oil cooler. Foreign material cannot be removed from the oil cooler and engine damage may occur. Long blocks are equipped with a new oil cooler.

    Remove the bolts and the oil cooler assembly.

    GFD202886Courtesy of FORD MOTOR COMPANY
  123. Remove and discard the oil cooler gaskets.
    GFD202887Courtesy of FORD MOTOR COMPANY
  124. Remove the retainers and the oil filter adapter.
    GFD202888Courtesy of FORD MOTOR COMPANY
  125. Remove and discard the oil filter adapter gasket.
    GFD202889Courtesy of FORD MOTOR COMPANY
  126. Remove the bolts and the upper oil pan.
    GFD202890Courtesy of FORD MOTOR COMPANY
  127. Remove and discard the press-in-place gaskets.
    GFD202891Courtesy of FORD MOTOR COMPANY
  128. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths.

    Make sure that the mating faces are clean and free of foreign material. Refer to: RTV Sealing Surface Cleaning and Preparation . Use the General Equipment: Plastic Scraper

    Material: Motorcraft ® Silicone Gasket Remover / ZC-30-A

    Material: Motorcraft ® Metal Brake Parts Cleaner / PM-4-A, PM-4-B

    Material: Motorcraft ® Metal Surface Prep Wipes / ZC-31-B

  129. NOTE: Use extreme care when removing the slinger or damage to the engine front cover may occur.
    NOTE: It will be necessary to remove the slinger from the sides as well as the top and bottom.

    Using 2 screwdrivers, carefully remove and discard the front crankshaft slinger.

    GFD202892Courtesy of FORD MOTOR COMPANY
  130. NOTE: Do not scratch or damage the crankshaft during removal or installation of the front crankshaft seal.

    Using the special tool, remove and discard the front crankshaft seal. Use Special Service Tool: 303-1510 Remover, Front Crank Seal.

    GFD202893Courtesy of FORD MOTOR COMPANY
  131. NOTE: Use care when removing the engine front cover to not scratch the crankshaft sealing surface.
    NOTE: Mark the location of the engine front cover bolts prior to removing them.

    • Remove the engine front cover bolts.

    • Remove the engine front cover.

    GFD202894Courtesy of FORD MOTOR COMPANY
  132. Remove and discard the engine front cover gaskets.
    GFD202895Courtesy of FORD MOTOR COMPANY
  133. NOTE: Do not scratch or damage the crankshaft during removal or installation of the rear crankshaft seal.

    Using the special tool, remove and discard the rear crankshaft seal. Use Special Service Tool: 303-1513 Remover, Rear Crank Seal.

    GFD202896Courtesy of FORD MOTOR COMPANY
  134. NOTE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.

    Remove the bolts and the engine rear cover.

    GFD202897Courtesy of FORD MOTOR COMPANY
  135. Remove and discard the engine rear cover gasket.
    GFD202898Courtesy of FORD MOTOR COMPANY
  136. NOTE: Prior to removing any piston and rod assemblies, it is recommended that piston protrusion be evaluated. This will help identify bent or twisted connecting rods.

    • Install the special tool. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

    • Zero the special tool on the crankcase deck surface.

    • Position the special tool 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 special tool tip onto the piston head at the opposite position.

    • Rotate the crankshaft to measure the maximum piston protrusion and record.

    • Average the readings. If the average is lower than specification, the piston is lower in the bore than it should be. This indicates a bent or twisted connecting rod. Refer to: Specifications .

    GFD202899Courtesy of FORD MOTOR COMPANY
  137. NOTE: If evident from the top of the cylinder bore, remove the carbon ridge prior to removing the rod and piston assemblies. This reduces the chance of piston ring land damage during removal.

    • Inspect the ridge.

    • NOTE: Remove the carbon buildup, do not scratch the cylinder wall. Remove all debris from the cylinder.

      Using a abrasive pad, remove the carbon ridge from the top of the cylinder bore.

    GFD202900Courtesy of FORD MOTOR COMPANY
  138. Using a feeler gauge, check the connecting rod side clearance. Refer to: Specifications . Use the General Equipment: Feeler Gauge
    GFD202901Courtesy of FORD MOTOR COMPANY
  139. NOTE: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage may occur.
    NOTE: Mark the location of connecting rod cap prior to removal.
    NOTE: Only one connecting rod cap shown.

    • Remove the connecting rod bolts and connecting rod caps.

    • Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.

    GFD202902Courtesy of FORD MOTOR COMPANY
  140. Remove and discard the connecting rod bearings.
    GFD202903Courtesy of FORD MOTOR COMPANY
  141. Using the special tool, check the high-pressure fuel injection pump drive gear backlash. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD202904Courtesy of FORD MOTOR COMPANY
  142. NOTE: The crankshaft gear contains a single timing mark. The camshaft contains a single timing mark. The high-pressure fuel injection pump drive gear contains a double timing mark. The engine is timed correctly when the single mark on the crankshaft drive gear is aligned with the double mark on the camshaft gear, and the single mark on the camshaft drive gear is aligned with the double mark on the high-pressure fuel injection pump drive gear. Additionally, the keyway on the high-pressure fuel injection pump drive gear must be at 12 o'clock position.

    Rotate the crankshaft clockwise, as viewed from the front, until the single mark on the camshaft drive gear and the double mark on the high-pressure fuel injection pump drive gear are aligned.

    GFD202905Courtesy of FORD MOTOR COMPANY
  143. Remove the high-pressure fuel injection pump drive gear nut.
    GFD202906Courtesy of FORD MOTOR COMPANY
  144. Remove the bolts and the fuel rail supply tube bracket.
    GFD202907Courtesy of FORD MOTOR COMPANY
  145. Remove the high-pressure fuel injection pump spacers.
    GFD202908Courtesy of FORD MOTOR COMPANY
  146. 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.

    GFD202909Courtesy of FORD MOTOR COMPANY
  147. Remove and discard the O-ring seal
    GFD202910Courtesy of FORD MOTOR COMPANY
  148. Using the special tool, measure the camshaft gear backlash. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD202911Courtesy of FORD MOTOR COMPANY
  149. Using the special tool, measure the camshaft end play. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD202912Courtesy of FORD MOTOR COMPANY
  150. Using the special tool, measure the crankshaft end play. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
    GFD202913Courtesy of FORD MOTOR COMPANY
  151. NOTE: RH side shown, LH side similar.

    Remove the crankshaft main bearing cap side bolts.

    GFD202914Courtesy of FORD MOTOR COMPANY
    • Remove the crankshaft main bearing cap bolts.

    • Remove the crankshaft main bearing caps from the cylinder block.

    GFD202915Courtesy of FORD MOTOR COMPANY
  152. NOTE: Only the number 5 crankshaft main bearing cap has a thrust washer.

    Remove and discard the lower crankshaft main bearing thrust washer. Remove and discard the lower crankshaft main bearings from the crankshaft main bearing caps.

    GFD202916Courtesy of FORD MOTOR COMPANY
  153. Remove the crankshaft from the cylinder block.
    GFD202917Courtesy of FORD MOTOR COMPANY
  154. Remove and discard the upper crankshaft main bearing thrust washers. Remove and discard the upper crankshaft main bearings from the cylinder block.
    GFD202918Courtesy of FORD MOTOR COMPANY
  155. Remove the bolt and camshaft gear.
    GFD202919Courtesy of FORD MOTOR COMPANY
  156. Remove the bolts and the camshaft thrust plate.
    GFD202920Courtesy of FORD MOTOR COMPANY
  157. NOTE: If the camshaft is being replaced, the camshaft bearings have to be replaced and machined by a machine shop. Failure to follow this may result in engine damage.
    NOTE: Use care when removing the camshaft from the engine or damage to the camshaft and the bearings may occur.
    NOTE: Use the slide hammer as a handle for the camshaft. Using the slide hammer as intended may result in engine damage.
    NOTE: Use care when removing the camshaft, the camshaft will slide out the other end of the cylinder block.

    Using the special tools, remove the camshaft. Use Special Service Tool: 303-1517 Adapter, Camshaft Remover/Installer., 100-001 (T50T-100-A) Slide Hammer.

    GFD202921Courtesy of FORD MOTOR COMPANY
  158. NOTE: Only one piston cooling tube shown.

    Remove the bolts and the piston cooling tubes.

    GFD202922Courtesy of FORD MOTOR COMPANY
    • Remove the high-pressure fuel injection pump mounting bolts.

    • Inspect the front cover roll pin for wear or damage, replace if necessary.

    GFD202923Courtesy of FORD MOTOR COMPANY
  159. NOTE: Only pipe plug shown.

    If necessary, remove the pipe plugs.

    GFD202924Courtesy of FORD MOTOR COMPANY
  160. If equipped, remove the block heater.
    GFD202925Courtesy of FORD MOTOR COMPANY
  161. Inspect the turbocharger alignment dowels for wear and damage, replace if necessary.
    GFD202926Courtesy of FORD MOTOR COMPANY
  162. Inspect the cylinder block zero clearance patch for wear or damage, replace if necessary.
GFD202927Courtesy of FORD MOTOR COMPANY