Engine - Body On
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 | |
| 307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1998-LM (NavigatoR) TKIT-1997-F/FLM/LT | |
| Floor Crane | |
| Oil Drain Equipment | |
| Transmission Jack | |
| Hose Clamp Remover/Installer |
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. If the body can be removed, refer to Engine - Body Off .
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.
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."
- Refer to: Jacking and Lifting - Overview .
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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 .
- Remove the following items:
- Refer to: Cooling Module .
- Refer to: Charge Air Cooler (CAC) Intake Pipe .
- Refer to: Charge Air Cooler (CAC) Outlet Pipe .
- Refer to: Charge Air Cooler (CAC) .
- Refer to: Air Cleaner .
- Refer to: Air Cleaner Outlet Pipe .
- Remove the RH and LH battery trays. Refer to: Battery Tray .
- Refer to: Cowl Panel Grille .
- Disconnect the coolant hoses and the retainer. Use the General Equipment: Hose Clamp Remover/Installer
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NOTE: Vehicle with brake booster shown, vehicles with Hydro-Boost ® similar.
Disconnect the vacuum hose and retainers. Position aside the coolant and vacuum hoses.
- Remove the nuts and the cooling fan stator.
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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.
- If equipped with dual generators, remove the accessory drive belt.
- If equipped with single generator, remove the accessory drive belt.
- Remove the retainer from the power steering line bracket.
- Remove the bolts and position aside the power steering pump.
- Disconnect the coolant hoses from the engine front cover tubes.
- Remove the bolts for the lower radiator hose.
- Remove the clip and disconnect the coolant hose.
- Remove the clip and remove the lower radiator hose.
- 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 for the ground strap and position aside.
- Remove the power distribution cover.
- Remove the nut and disconnect the retainer. Position out the cable.
- Disconnect the battery cable retainer.
- Disconnect the electrical connector at the RH front fender.
- Remove the bolt and position the ground cable.
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NOTE: Dual generator battery cable harness shown.
- Remove the nut and separate the cables.
- Disconnect the electrical connectors and disconnect the retainers as needed.
- Remove the engine wire harness bracket bolt and the ground wire bolt. Position aside the wire harness on the engine.
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- Disconnect the engine PCM electrical connector and the electrical connectors.
- Disconnect the retainer and position aside the wire harness.
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- Disconnect the PCM electrical connectors and the electrical connector.
- Remove the retainer and disconnect the ground wire.
- Disconnect the retainers and position the wire harnesses aside.
- Remove the nuts, the bracket and the PCM.
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NOTE: Make sure that all openings are sealed.
Remove the nut from the evaporator-to-compressor suction tube fitting and position aside the tube.
- Remove and discard the O-ring seal.
- Disconnect the heater hose.
- Disconnect the heater hose retainers.
- Disconnect the heater hose from the heater supply tube.
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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.
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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.
Loosen the retainers and remove the upper intake manifold.
- Remove and discard the upper intake manifold gaskets.
- Refer to: Crankcase Vent Oil Separator .
- Disconnect the TB (throttle body) electrical connector.
- Disconnect the EGRT sensor electrical connector and the wire retainers.
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- Remove the bolts and the EGR cooler outlet pipe.
- Remove and discard the gaskets.
- Loosen the turbocharger inlet hose clamps.
- Remove the bolts and the lower intake manifold.
- Remove the turbocharger inlet hose.
- 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 and discard the RH turbocharger inlet pipe gasket.
- Refer to: Exhaust Downpipe .
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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 and discard the LH turbocharger inlet pipe gasket.
- Remove and discard the bolt for the turbocharger coolant outlet tube.
- Remove the bolts and the heater supply tube.
- Remove and discard the O-ring seal.
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NOTE: The turbocharger mounting bolts are torque-to-yield design and cannot be reused.
Remove and discard the turbocharger mounting bolts.
- Remove the turbocharger.
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- Remove and discard the turbocharger mounting gasket.
- Refer to: Exhaust Gas Recirculation (EGR) Cooler .
- 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
- If equipped, disconnect the block heater electrical connector.
- Refer to: Starter Motor .
- 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 transmission cooler tube bracket nut from the RH side of the engine and position the transmission cooler tubes aside.
- Refer to: Transmission Filler Tube - 6.7L Power Stroke Diesel .
- Remove the oil level indicator tube.
- Remove and discard the oil level indicator tube O-rings.
- Install Special Service Tool: 303-1518 Bracket, Engine Removal.
- 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 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
- Raise the engine until the engine is near the cowl.
- Rolling the engine forward, continue to raise the engine until the engine clears the cross member.
- Install a ratchet strap and level 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)