Section 634 (Engine - 3.0L Power Stroke Diesel): Disassembly: Engine

WARNING: This page is about a different car, the 2021 Ford F-150. 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 INFORMATION

Special Tool(s) / General Equipment

Courtesy of FORD MOTOR COMPANY	303-1670 Pins, Camshaft Locking
Courtesy of FORD MOTOR COMPANY	303-1671 Pin, Locking Crankshaft
Courtesy of FORD MOTOR COMPANY	303-1674 Tool, Holding Camshaft Sprocket
Courtesy of FORD MOTOR COMPANY	303-1675 Adapter, Seal Remover
Courtesy of FORD MOTOR COMPANY	303-1678 Remover, Fuel Pump Pulley Holding Tool
Courtesy of FORD MOTOR COMPANY	303-1681 Spreader Bar
Courtesy of FORD MOTOR COMPANY	308-375 Remover, Input Shaft Seal, TKIT-2005U-M, TKIT-1999-F/FLM/LT
Courtesy of FORD MOTOR COMPANY	310-266 Remover, Fuel Injector
Floor Crane
Mounting Stand
Hose Clamp Remover/Installer

Materials

Name	Specification
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 enters the oil passages, coolant passages or the oil pan, can cause engine failure.

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 the Engine Component View in the Description and Operation.

Remove the engine from the vehicle. Refer to: Engine - Body Off . Refer to: Engine - Body On .
Remove the bolts and the flexplate. Discard the bolts.

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NOTE: Install the engine stand bolts into the cylinder block only. Do not install the bolts into the engine block skirt stiffener.

Using a floor crane, install the engine on a mounting stand. Use the General Equipment: Floor Crane Use the General Equipment: Mounting Stand

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Remove the floor crane and the special tool. Use Special Service Tool: 303-1681 Spreader Bar. Use the General Equipment: Floor Crane

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Remove the bolt for the coolant tube.

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Disconnect the coolant hose. Remove the nut for the coolant hose bracket.

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Remove the nut and the coolant tube.

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Disconnect the A/C electrical connectors and the wire retainer.

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Remove the nuts, disconnect the wire harness retainer and remove the battery cable harness.

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Disconnect the coolant hose. Disconnect the retainers and remove the coolant hoses.

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Remove the bolts and the A/C compressor.

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Remove the LH fuel injector noise insulator.

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Remove the RH fuel injector noise insulator.

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Disconnect the oil pump electrical connector and the wire retainers.

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Disconnect the TB (throttle body) electrical connector and the wire retainer.

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Disconnect the CMP electrical connector and the wire retainer.

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Disconnect the CKP electrical connector and the wire retainer.

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Disconnect the EGR valve and the EP (exhaust pressure) sensor electrical connectors. Disconnect the wire retainers.

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Disconnect the EOP sensor electrical connector.

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Disconnect the electrical connectors and the wire retainers.

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Disconnect the fuel injectors electrical connectors and the wire retainers.

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Disconnect the electrical connectors and the wire retainer.

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Disconnect the turbocharger actuator electrical connector. Disconnect the EGRT electrical connector and the wire retainers.

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Disconnect the electrical connectors and the wire retainers.

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Disconnect the fuel injectors electrical connectors and the wire retainers.

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Disconnect the electrical connectors and the wire retainer.

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Disconnect the electrical connector and remove the bolt. Disconnect the wire harness retainers and remove the engine wire harness.

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Remove the nut and the ground strap.

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Disconnect the vacuum pump connector. Remove the retainers and remove the vacuum hose assembly. Refer to: Quick Release Coupling .

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Remove the bolts and the valve bracket.

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NOTE: If the engine was removed Body On, the lifting bracket will have a special tool bolted on.

Remove the bolts and the lifting bracket.

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Remove the retainers and the vacuum pump.

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Remove and discard the vacuum pump gasket.

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NOTE: If any snaps become undone on the exhaust crossover pipe wrap. Replace the exhaust crossover pipe wrap.

Remove the bolts for the exhaust crossover pipe.

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NOTE: If any snaps become undone on the exhaust crossover pipe wrap. Replace the exhaust crossover pipe wrap.

Remove the nuts and the exhaust crossover pipe. Discard the nuts.

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Remove and discard the exhaust crossover pipe gaskets and the studs.

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Remove the bolts and the exhaust crossover pipe bracket.

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Remove the bolt and the coolant return tube.

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1. Remove and discard the turbocharger coolant return tube O-ring seal.
2. NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.
  
  Clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage and make sure the retaining bracket is not bent, check for squareness of the O-ring area. Install new components if needed.
  
  Material
  
  : Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
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Remove the bolts and the turbocharger oil supply tube. Discard the turbocharger oil supply tube.

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Remove the bolts and the turbocharger oil return tube. Discard the turbocharger oil return tube.

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Remove the bolt for the turbocharger coolant supply tube. Disconnect the turbocharger coolant supply tube from the engine.

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Remove the nuts and the turbocharger. Discard the nuts.

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Remove and discard the turbocharger gasket and the studs.

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NOTE: Make note of turbocharger coolant tube manifold orientation to aid in proper installation.

Remove the bolt and the turbocharger coolant tube manifold. Discard the turbocharger coolant tube manifold.

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Remove the bolts and the RH engine mount bracket. Discard the bolts.

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Remove the bolts and the LH engine mount bracket. Discard the bolts.

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Remove the bolts and the coolant tube.

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Remove and discard the coolant tube O-ring seal.

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Release the clamps and remove the EGR cooler coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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Remove the bolts and the coolant tube assembly.

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Remove and discard the coolant tube assembly O-rings.

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Remove the bolt and the accessory drive belt tensioner.

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Remove the bolts and the fan pulley.

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Remove the nuts and the CAC tube bracket.

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Remove the bolts and the accessory drive belt tensioner.

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Remove the bolts and the crankshaft vibration damper.

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Remove the bolts and the coolant pump pulley.

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Remove the bolts and the A/C mounting bracket.

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Remove the bolts and the generator mounting bracket.

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- Disconnect the wire retainers.
- Remove the retainer from the timing belt cover.
- Remove the retainers and the EGR outlet tube.
- Remove and discard the gaskets.
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NOTE: Mark the locations of the fasteners before removal.

Remove the bolts, the stud bolts and the timing belt cover.

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Remove and discard the timing belt cover gasket.

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Remove the nuts and the fuel tube support bracket.

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Remove the nut and the front fuel tube support bracket.

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Remove the nut, the bolt and the LH exhaust manifold heat shield.

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Remove the stud bolt. Disconnect the tube nut and remove the EP sensor assembly.

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Remove the oil level indicator.

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- Disconnect the wire retainers from the oil level indicator tube.
- Remove the stud bolt, the bolt and the oil level indicator tube.
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Remove the bolts and the EGR coolant tube.

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Remove and discard the EGR coolant tube O-ring and the grommet.

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Remove the bolts and the EGR cooler-to-exhaust manifold pipe. Remove and discard the gaskets.

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Remove the bolts and the EGR cooler.

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Remove the bolts and the EGR cooler brackets.

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Remove the bolts and the coolant inlet connector,

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Remove and discard the coolant inlet connector O-ring.

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Disconnect the fuel line. Remove the bolt and the secondary fuel filter. Discard the secondary fuel filter. Refer to: Quick Release Coupling .

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Disconnect the retainers. Remove the nut, the bolt and the wiring harness bracket.

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Remove the accessory drive cover.

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Remove the stud bolts and the accessory drive cover.

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Remove the bolt. Disconnect and remove the fuel supply tube. Refer to: Quick Release Coupling .

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Disconnect and remove the fuel supply tube. Refer to: Quick Release Coupling .

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Remove and discard the fuel return tube assembly. Refer to: Quick Release Coupling .

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Remove the bolts and the front engine lifting eye.

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NOTE: Lift the front of the intake manifold up and slide the intake manifold to the right to remove.

Remove the stud bolt, the bolt and the intake manifold.

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Remove and discard the intake manifold gaskets.

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Remove the bolt and the wire harness bracket.

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Remove the bolts and the heater hose support bracket.

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Remove the retainers and the engine support bracket.

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Remove the bolts and the LH exhaust manifold heat shield. Discard the bolts.

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Remove the nuts and the LH exhaust manifold. Discard the nuts.

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- Remove and discard the LH exhaust manifold gasket.
- Inspect the exhaust manifold studs. Replace as necessary.
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Remove the bolts and the RH exhaust manifold heat shield. Discard the bolts.

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Remove the nuts and the RH exhaust manifold.

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- Remove and discard the RH exhaust manifold gasket.
- Inspect the exhaust manifold studs. Replace as necessary.
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Clean and inspect the exhaust manifolds. Refer to: Exhaust Manifold Cleaning and Inspection .
Remove the engine cover stud assemblies.

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Remove the fuel return hose assembly.

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Remove the fuel tube bracket bolt.

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Remove and discard the RH fuel supply tube.

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- Remove the bolt and the clamp.
- Remove and discard the RH fuel injector supply tubes.
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Remove the bolt. Remove and discard the LH fuel supply tube.

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- Remove the bolts and the clamps.
- Remove and discard the LH fuel injector supply tubes.
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Remove the bolt. Remove and discard the fuel injection pump balance tube.

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Remove the bolts and the RH fuel rail.

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Remove the bolts and the LH fuel rail.

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Remove the fuel injection pump noise insulator.

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Remove the LH fuel injector noise insulator.

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Remove the RH fuel injector noise insulator.

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Remove the bolts for the LH fuel injectors.

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Remove the bolts for the RH fuel injectors.

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NOTE: Only one fuel injector shown.

Using the special tool, remove the fuel injectors. Use Special Service Tool: 310-266 Remover, Fuel Injector.

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Remove and discard the sealing washer, the O-rings and the fuel injector hold down.

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Remove the bolts and the LH fuel rail bracket.

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Remove the bolts and the RH fuel rail bracket.

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Remove the nuts and the LH fuel tube bracket.

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Remove the nuts and the RH fuel tube bracket.

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Remove the bolt and the CMP sensor.

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Remove the vacuum pump stud.

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Disconnect the LH glow plug electrical connector.

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NOTE: Mark the location of the fasteners prior to removing the valve cover.

Loosen the fasteners and remove the LH valve cover.

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Remove and discard the LH valve cover gasket.

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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Remove the nut, the bolt and the turbocharger heat shield.

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Disconnect the RH glow plug electrical connector.

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Remove the oil fill cap assembly.

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NOTE: Mark the location of the fasteners prior to removing the valve cover.

Loosen the fasteners and remove the RH valve cover.

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Remove and discard the RH valve cover gasket.

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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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Remove the timing pin bolt at the left front of the engine.

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Install special tool.
- NOTE: Only rotate the crankshaft clockwise.
  
  NOTE: Verify that the camshaft timing holes are aligned with the cylinder head.
  
  NOTE: The Locking Crankshaft Pin must be bottomed out against the cylinder block.
  
  Rotate the crankshaft clockwise so the crankshaft contacts the locking crankshaft pin. Use Special Service Tool: 303-1671 Pin, Locking Crankshaft.
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Using the special tool, rotate the fuel pump sprocket to push down on the READ belt tensioner until the openings are aligned, install the lock pin. Use Special Service Tool: 303-1678 Remover, Fuel Pump Pulley Holding Tool.

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NOTE: Note the position of the camshaft pulley prior to removal.

Remove the bolts, the camshaft pulley and the READ belt.

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Remove the bolt and the READ belt tensioner.

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NOTE: Use the original bolts for the special tool.

Using the special tool, remove the bolt and the camshaft gear hub. Discard the bolt. Use Special Service Tool: 303-1674 Tool, Holding Camshaft Sprocket.

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Remove the nut, the bolt and the accessory drive cover.

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Using the special tool, remove the nut for the fuel injection pump pulley. Use Special Service Tool: 303-1678 Remover, Fuel Pump Pulley Holding Tool.

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Using the special tool, remove the fuel injection pump pulley. Use Special Service Tool: 303-1678 Remover, Fuel Pump Pulley Holding Tool.

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Remove the bolts and the rear engine lifting bracket.

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Remove the bolts and the fan drive.

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Using the special tools, verify the camshaft timing. Use Special Service Tool: 303-1670 Pins, Camshaft Locking.

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NOTE: The crankshaft or camshafts must not be rotated while the timing belt is removed.
1. Loosen the timing belt tensioner bolt.
2. Rotate the timing belt tensioner clockwise.
3. Remove the timing belt.
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NOTE: Note the position of the camshaft pulleys prior to removal.

Remove the bolts and the camshaft pulleys.

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NOTE: Use the original bolts for the special tool.

Using the special tool, remove the bolts and the camshaft gear hubs. Discard the bolts. Use Special Service Tool: 303-1674 Tool, Holding Camshaft Sprocket.

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NOTE: Replace the timing belt tensioner if damage or excessive wear is found.

Remove the bolt and the timing belt tensioner. Discard the bolt.

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Remove the bolts and the coolant pump.

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Remove and discard the coolant pipe O-ring.

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Remove the bolts and the coolant outlet connector.

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Remove and discard the oil cooler O-ring.

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Remove and discard the coolant outlet connector gaskets.

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NOTE: Replace the timing belt idler pulleys if damage or excessive wear is found.

Remove the bolts and the timing belt idler pulleys. Remove the dust shield. Discard the bolts.

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Remove the EOP sensor.

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NOTE: Right side shown, left side front and rear similar.

Using the special tools, remove and discard the camshaft seals. Use Special Service Tool: 303-1675 Adapter, Seal Remover., 308-375 Remover, Input Shaft Seal.

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Compress the camshaft chain and install the retaining pin.

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NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Remove the bolts and the camshaft bearing caps.

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Remove the bolts and the LH camshafts, camshaft chain and the secondary timing chain tensioner.

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Compress the camshaft chain and install the retaining pin.

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NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

Remove the bolts and the camshaft bearing caps.

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Remove the bolts and the RH camshafts, camshaft chain and the secondary timing chain tensioner.

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NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

Remove the RH camshaft roller follower and hydraulic lash adjuster assemblies.

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NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

Remove the LH camshaft roller follower and hydraulic lash adjuster assemblies.

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Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.

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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 glow plugs protrude past the lower face of the cylinder head, any impact on the tip of the glow plug may result in glow plug damage.

NOTE: The 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 bolts from the RH cylinder head.
- Remove the cylinder head.
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Remove and discard the RH cylinder head gasket and the cylinder head dowels.

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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 glow plugs protrude past the lower face of the cylinder head, any impact on the tip of the glow plug may result in glow plug damage.

NOTE: The 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 bolts from the LH cylinder head.
- Remove the cylinder head.
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Remove and discard the LH cylinder head gasket and the cylinder head dowels.

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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.

NOTE: Clean the cylinder block bolt holes using compressed air. Make sure all coolant, oil or other foreign material is removed.
- Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block surface.
- Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
- Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
NOTE: In the event of catastrophic engine failure, always install a new oil cooler assembly. Foreign material cannot be removed from the oil cooler and engine damage may occur.

Remove the bolts and the oil cooler.

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Remove and discard the oil cooler O-rings.

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Remove the bolts for the fuel injection pump bracket.

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Remove the bolts and the fuel injection pump.

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Remove the bolts and the fuel injection pump mounting bracket.

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If necessary, remove the lower CCV (crankcase vent) separator.

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Remove the oil pan bolts and the oil pan.

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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .
Remove the bolts and the engine block skirt stiffener.

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Remove and discard the engine block skirt stiffener gasket.

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Remove the engine block skirt stiffener alignment dowels.

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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .
Remove the CKP sensor cover.

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Remove the retainer and the CKP sensor.

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NOTE: Care must be taken not to damage the crankshaft sealing surface when removing the crankshaft trigger wheel.

Remove and discard the CKP timing trigger wheel.

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- Remove the bolts and the crankshaft rear seal retainer.
- Discard the crankshaft rear seal retainer.
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Remove the bolt and the crankshaft sprocket. Discard the bolt.

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Remove Special Service Tool: 303-1671 Pin, Locking Crankshaft.

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Using the special tools, remove and discard the crankshaft front oil seal. Use Special Service Tool: 303-1675 Adapter, Seal Remover., 308-375 Remover, Input Shaft Seal.

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Remove the oil pump inserts.

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Remove the bolts and the oil pump.

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Remove and discard the oil pump gasket.

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Inspect and clean the specified component with a abrasive pad.

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NOTE: The connecting rod cap bolts are a torque-to-yield design. The original connecting rod cap bolts will be used when measuring the connecting rod large end bore during assembly. The connecting rod cap bolts will be discarded after measurement.

NOTE: Clearly mark the position and orientation of the connecting rods, connecting rod caps and connecting rod bearings for reassembly.

Remove the connecting rod cap bolts and caps.

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NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod while removing the pistons.

Remove the piston/rod assembly from the engine block.

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NOTE: If the connecting rod bearings are being reused, mark them for correct position and orientation for reassembly.

Remove the bearings from the connecting rods.

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Inspect the pistons. Refer to: Piston Inspection .
NOTE: RH side shown, LH similar.

Remove the side bolts.

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NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

Remove the bolts and the main bearing caps.

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NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

Remove the crankshaft main bearings from the main bearing caps.

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Remove the crankshaft.

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NOTE: If the main bearings are being reused, mark them for correct position and orientation for reassembly.

Remove the crankshaft main bearings from the cylinder block.

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Remove the bolts and the piston cooling jets.

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Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .
Remove and discard the CCV gaskets.

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Remove and discard the engine oil filter.

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Inspect the engine alignment dowels, replace if necessary.

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If equipped. Remove the block heater.

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