Engine - Body On

For information on Ford Color Coded Illustrations refer to OEM COLOR CODING INFORMATION

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1681 Spreader Bar
Courtesy of FORD MOTOR COMPANY	303-1684 Lifting Eye
Courtesy of FORD MOTOR COMPANY	307-625 Fixture, Bench Mounting, TKIT-2008ET-FLM, TKIT-2008ET-ROW
Floor Crane
Oil Drain Equipment
Trolley Jack
Hose Clamp Remover/Installer
Wooden Block

4WD/LHD RWD 

1. With the vehicle in NEUTRAL, position it on a hoist. Refer to: Jacking and Lifting - Overview .
2. Disconnect the battery ground cable. Refer to: Battery Disconnect and Connect .
3. Remove the engine appearance cover.

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4. Release the fuel system pressure. Refer to: Fuel System Pressure Release .
5. NOTE: The oil filter housing needs a minimum of 1 minute to allow the oil to drain out of the oil filter housing to minimize oil spillage.

   Loosen the oil filter cap and let the oil filter housing drain. Remove the oil filter cap.

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6. Remove and discard the oil filter cap O-ring seal.

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7. Remove and discard the oil filter. Use the General Equipment: Oil Drain Equipment

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8. Install the oil filter cap

   Torque: 18 lb.ft (25 Nm)

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9. Remove the nut. Remove the bolts and the transmission housing cover.

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10. If equipped. Remove the bolts and the underbody shield.

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11. If equipped. Remove the bolts and the skid plate.

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12. Remove the oil pan plug and drain the engine oil. Use the General Equipment: Oil Drain Equipment

    Torque: 18 lb.ft (25 Nm)

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13. Drain the cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
14. Remove the following items:
    1. Remove the degas bottle. Refer to: Degas Bottle .
    2. Remove the cooling module. Refer to: Cooling Module .
    3. Remove the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
    4. Remove the battery tray. Refer to: Battery Tray .
    5. Remove the LH and the RH fender splash shields. Refer to: Fender Splash Shield .
    6. Remove the turbocharger. Refer to: Turbocharger .

15. Disconnect the electrical connector and position side the wire harness.

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16. Disconnect the retainer. Remove the lower radiator hose. Use the General Equipment: Hose Clamp Remover/Installer

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17. Disconnect the electrical connector and the wire retainer.

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18. NOTE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.

    Loosen the clamp, release the clip and remove the LH CAC intake pipe.

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19. Remove the upper radiator hose. Use the General Equipment: Hose Clamp Remover/Installer

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20. NOTE: Make sure that all openings are sealed.
    • Remove the nut and disconnect the A/C compressor inlet line.
    • Remove and discard the O-ring seal.
    • Disconnect the A/C pressure transducer electrical connector.

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21. Disconnect the heater hoses and the retainers. Use the General Equipment: Hose Clamp Remover/Installer

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22. Disconnect the coolant hose connector and the retainers.

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23. • Disconnect the electrical connector and the coolant hose retainer.
    • Remove the bolts and the coolant pump.

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24. Remove the following items:
    1. Remove the cowl panel. Refer to: Cowl Panel .
    2. Remove the generator. Refer to: Generator - 3.0L Power Stroke Diesel .

25. Disconnect the coolant hoses and position aside. Use the General Equipment: Hose Clamp Remover/Installer

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26. If equipped. Disconnect the block heater cord retainers.

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27. Remove the bolts and the lower radiator coolant tube.

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28. Remove and discard the lower radiator coolant tube O-ring seal.

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29. If equipped. Disconnect the block heater cord retainer and the electrical connector.

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30. Disconnect the transmission electrical connectors and the retainers. Position aside the wiring harness.

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31. Disconnect the PCM electrical connector and the electrical connector. Disconnect the retainers and position aside.

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32. Disconnect the electrical connectors.

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33. Disconnect and position aside the wire bracket.

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34. Remove the power distribution box cover.

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35. 1. Remove the nuts and position out the battery wire harness.
    2. Remove the bolt for the ground wire.
    3. Disconnect the wire harness retainers and position aside.

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36. Remove the bolts and position out the power steering power cable. Position the battery cable harness on the engine.

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37. Disconnect the ground strap retainer. Remove the nut and position aside the ground strap.

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38. Disconnect and position aside the fuel tubes. Refer to: Quick Release Coupling .

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39. Disconnect the secondary fuel filter lines. Refer to: Quick Release Coupling .

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40. Remove the bolt and the secondary fuel filter. Discard the secondary fuel filter.

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41. Remove the following items:
    1. If equipped, remove the front driveshaft. Refer to: Front Driveshaft .
    2. Remove the starter motor. Refer to: Starter Motor .

42. Remove the retainers and the access cover.

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43. NOTE: Index-mark the end of one torque converter stud and the flexplate for installation.
    NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.

    Remove and discard the torque converter nuts.

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44. NOTE: Only use hand tools when removing the transmission mount-to-crossmember nuts or damage to the transmission mount can occur.

    Loosen the transmission mount-to-crossmember nuts.

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45. NOTE: Mark the location of the bolts during removal.

    Remove the RH side bellhousing bolts.

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46. Remove the LH side bellhousing bolts.

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47. Remove the upper bellhousing bolts.

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48. NOTE: Only use hand tools when removing the engine mount nuts and studs or damage to the engine mount can occur.
    NOTE: The engine mount studs may come off with the nuts.

    Remove and discard the RH engine mount nuts. Remove the engine mount studs.

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49. NOTE: Only use hand tools when loosening or tightening the engine mount through bolts or damage to the engine mount-to-cylinder block bracket can occur.

    Remove and discard the RH engine mount through bolt.

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50. NOTE: Only use hand tools when loosening or tightening the engine mount through bolts or damage to the engine mount-to-cylinder block bracket can occur.

    Remove and discard the LH engine mount through bolt.

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51. NOTE: Do not support the transmission by the fluid pan, failure to follow instruction may result in serious damage to the transmission.

    Support the bellhousing of the transmission with a suitable floor jack and a block of wood. Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block

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    4WD 

52. Using a holding device, hold the steering wheel in the straight-ahead position.

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53. 1. WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).

       Remove and discard the steering column shaft bolt.

    2. Separate the steering column shaft U-joint from the steering gear.

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54. Remove the steering gear boot.

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55. • If equipped, support the front axle with a trolley jack. Use the General Equipment: Trolley Jack
    • NOTE: After loosening the top bolt, it may be necessary to reposition the axle assembly to prevent interference with the steering components when removing the top bolt.

      Remove and discard the front axle nuts and bolts.

    • Lower the front axle.

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    4WD/LHD RWD 

56. NOTE: Only use hand tools when loosening or tightening the engine mount-to-frame bolts or damage to the engine mount-to-frame nut plate can occur.
    NOTE: Leave the LH engine mount in place.

    Remove and discard the LH engine mount bolts.

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57. Remove the bolts and the upper lifting bracket.

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58. Install the special tool and the bolts. Use Special Service Tool: 303-1684 Lifting Eye.

    Torque: 17 lb.ft (23 Nm)

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59. Install the factory lifting eye with the special tool on the engine.

    Torque: 17 lb.ft (23 Nm)

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60. NOTE: Use a commercially available quick link.

    Install the special tools and the floor crane. Use Special Service Tool: 303-1681 Spreader Bar., 303-1684 Lifting Eye. Use the General Equipment: Floor Crane

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61. NOTE: The use of a ratchet strap may be needed to level the engine.

    Using the floor crane and the Spreader Bar, lift the engine.

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62. Remove the LH engine mount.

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63. Remove the RH engine mount.

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64. Using the floor crane and the spreader bar, remove the engine. Use the General Equipment: Floor Crane

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65. Install Special Service Tool: 307-625 Fixture, Bench Mounting.

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