Engine - Body Off
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
| 303-050 (T70P-6000) Lifting Bracket, Engine | |
|---|---|
| 303-1518 Bracket, Engine Removal TKIT-2009C-F TKIT-2009C-ROW | |
| 307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1998-LM (NavigatoR) TKIT-1997-F/FLM/LT | |
| Floor Crane | |
| Oil Drain Equipment | |
| Transmission Jack |
NOTE:
Change the engine oil any time the turbocharger is removed from the engine. The passages in the block, located underneath the turbocharger, are direct passages to the lubrication system. Debris and/or coolant may enter the lubrication system and engine damage may occur.
NOTE:
It is recommended that this component be serviced with the vehicle body removed. Refer to . If the body cannot be removed, refer to Engine - Body On .
NOTE:
During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel openings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.
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WARNING: Do not work on the fuel system until the pressure has been released and the engine has cooled. Fuel in the high-pressure fuel system is hot and under very high pressure. High-pressure fuel may cause cuts and contact with hot fuel may cause burns. Failure to follow these instructions may result in serious personal injury.
Refer to: Fuel System Pressure Release .
- Refer to: Body - 6.7L Power Stroke Diesel .
- Mark the location of the tires on the floor prior to rolling out the chassis. Roll the chassis out from under the body.
- Remove the oil pan plug and drain the engine oil. Use the General Equipment: Oil Drain Equipment
Torque: 19 lb.ft (26 Nm)
- Remove and discard the oil filter. Use the General Equipment: Oil Drain Equipment
- Remove and discard the exhaust downpipe bolts.
- Loosen the clamp for the exhaust downpipe.
- Remove and discard the nuts. Remove the exhaust downpipe.
- If equipped, disconnect the block heater electrical connector.
- Remove the starter cable cover.
- Remove the nuts and position aside the starter cables.
- Remove the bolts and the starter.
- Remove the retainers and the access cover.
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NOTE: Index-mark the end of one torque converter stud and the flexplate for installation.NOTE: Using the crankshaft pulley bolts, turn the engine clockwise.
Remove and discard the torque converter nuts.
- Remove the engine wire harness bracket bolt and the ground wire bolt. Position the wire harness on the engine.
- Disconnect the coolant hose retainer from the cooling fan stator.
- Remove the nuts and the cooling fan stator.
- Remove the bolt and position out the transmission cooling tubes.
- Remove the transmission cooler tube bracket nut from the RH side of the engine and position the transmission cooler tubes aside.
- Disconnect the heater hose from the retainers. Disconnect the heater hose retainer from the frame.
- Remove the fuel tube bracket bolt from the LH side of the transmission.
- Remove the fuel tube bracket bolts from the transmission bellhousing.
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NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components.
Disconnect the fuel tubes and position aside. Refer to: Quick Release Coupling .
- Remove the retainer from the power steering line bracket.
- Remove the bolt and the power steering hose.
- Remove and discard the power steering tube O-ring seal.
- Disconnect the coolant hoses from the engine front cover tubes.
- Disconnect the retainer from the upper intake manifold.
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- Disconnect the wiring harness retainers.
- Disconnect the MAP sensor, EP (exhaust pressure) sensor, EGRT sensor and the turbocharger actuator electrical connectors.
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- Remove the nut for the EP sensor tube.
- Remove the EP sensor tube assembly.
- Remove the bolt for the transmission fluid level indicator tube.
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- Remove the engine and transmission oil level indicator tube bolts.
- Remove the nut and position aside the tubes.
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NOTE: Cover or tape openings on the valve covers and lower intake manifold.
Loosen the retainers and remove the upper intake manifold.
- Remove and discard the upper intake manifold gaskets.
- Release the clip and remove the CAC pipe.
- Remove the bolts and the turbocharger heat shield.
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NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.
Remove and discard the RH turbocharger inlet pipe nuts.
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NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.
- Loosen the RH turbocharger inlet pipe clamp and remove the RH turbocharger inlet pipe.
- Remove and discard the clamp.
- Remove the discard the RH turbocharger inlet pipe gasket.
- Remove the bolt for the turbocharger outlet pipe.
- Remove the clamp and the turbocharger outlet pipe. Discard the clamp.
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NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.
Remove and discard the LH turbocharger inlet pipe nuts.
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NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.
- Loosen the LH turbocharger inlet pipe clamp and remove the LH turbocharger inlet pipe.
- Remove and discard the clamp.
- Remove the discard the LH turbocharger inlet pipe gasket.
- Remove and discard the bolt for the turbocharger coolant outlet tube.
- Loosen the turbocharger inlet boot clamps.
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NOTE: The turbocharger mounting bolts are torque-to-yield design and cannot be reused.NOTE: Lift the turbocharger off of the locating dowels before positioning rearward for removal.
Remove and discard the turbocharger mounting bolts.
- Remove the turbocharger.
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- Remove and discard the turbocharger mounting gasket.
- Remove the turbocharger inlet boot.
- Install Special Service Tool: 303-1518 Bracket, Engine Removal.
Torque: 41 lb.ft (55 Nm)
- Install Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.
Torque: 18 lb.ft (25 Nm)
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NOTE: Failure to replace the transmission support insulator nuts may result in transmission support insulator damage.
Loosen the transmission support insulator nuts.
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NOTE: Failure to replace the engine mount cross bolts may result in engine mount damage.
Remove and discard the LH engine mount cross through bolt.
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NOTE: Failure to replace the engine mount cross bolts may result in engine mount damage.
Remove and discard the RH engine mount cross bolt.
- Remove the lower bellhousing bolts.
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NOTE: Do not support the transmission by the fluid pan, failure to follow instruction may result in serious damage to the transmission.
Position a transmission jack and support the transmission. Use the General Equipment: Transmission Jack
- Remove the LH side bellhousing bolts.
- Remove the RH side bellhousing bolts.
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NOTE: During removal of the engine, the engine oil cooler will pass very close to the frame crossmember. Remove the engine slowly, continually checking to make sure the engine oil cooler does not hit the frame crossmember, or component damage may occur.NOTE: After the engine is removed, position the engine close to the floor in case of lifting crane failure. Failure to lower the engine may result in engine damage.
- Position a floor crane and connect to the engine removal bracket. Use the General Equipment: Floor Crane
- Install a suitable ratchet strap from the arm of the floor crane to the engine lifting bracket to adjust the angle of the engine.
- Raise and remove the engine from the vehicle.
- Install Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.
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NOTE: Failure to inspect the components for debris may result in repeat failures.NOTE: It may be necessary to use a borescope to inspect the components.
When an engine or turbocharger is replaced due to a failure, inspect the following components for potential metal debris. If evidence of debris is found, clean or replace the components as needed.
- CAC and the CAC tubes
- Intake air system
- Exhaust manifolds
- EGR cooler and pipes
- Diesel Oxidation Catalyst (DOC)
- Turbocharger (on engine failure only)