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Section 1136 (Engine - 6.0L (99P E-Series) Diesel): Removal: Engine: Removal

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  2. Remove the cooling module. For additional information, refer to ENGINE COOLING article.
  3. Remove the front bumper. For additional information, refer to BUMPERS article.
    4. NOTE: LH shown, RH similar.
  4. Remove the pushpin retainers and the front bumper shields.
    5. Fig 1: Locating Pushpin Retainers & Front Bumper Shields
    GF0044562Courtesy of FORD MOTOR CO.
  5. Remove the radiator grille support. For additional information, refer to FRONT END BODY PANELS article.
    6. NOTE: LH shown, RH similar.
  6. Remove the pushpin retainers and the side shields.
    7. Fig 2: Locating Pushpin Retainers & Side Shields
    GF0044563Courtesy of FORD MOTOR CO.
    NOTE: Mark the latch location before removal.
  7. Disconnect the cable retainer. Remove the 2 bolts and position the hood latch aside.
    8. Fig 3: Locating Cable Retainer, Bolts & Positioning Hood Latch Aside
    GF0044564Courtesy of FORD MOTOR CO.
  8. Disconnect the pushpin retainers and the transmission cooler hose. Remove the bolt and the transmission cooler.
    9. Fig 4: Locating Pushpin Retainers & Transmission Cooler Hose
    GF0044565Courtesy of FORD MOTOR CO.
  9. Disconnect the horn electrical connector.
    10. Fig 5: Locating Horn Electrical Connector
    GF0044566Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  10. Remove the 4 bolts and the radiator upper support brackets.
    11. Fig 6: Locating Bolts & Radiator Upper Support Brackets
    GF0044567Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  11. Remove the 8 bolts and the radiator upper support.
    12. Fig 7: Locating Bolts & Radiator Upper Support
    GF0044568Courtesy of FORD MOTOR CO.
  12. Disconnect the front impact severity sensor electrical connector.
    13. Fig 8: Locating Front Impact Severity Sensor Electrical Connector
    GF0044569Courtesy of FORD MOTOR CO.
  13. Remove the bolt for the ground wire. Disconnect the pushpin retainers and position aside the headlamp wire harness.
    14. Fig 9: Locating Bolt For Ground Wire & Pushpin Retainers
    GF0044570Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  14. Remove the pushpins and the side shields. Position the power steering cooler aside.
    15. Fig 10: Locating Pushpins & Side Shields
    GF0044571Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  15. Remove the 12 bolts and the lower radiator support.
    16. Fig 11: Identifying Lower Radiator Support Bolts
    G03886640Courtesy of FORD MOTOR CO.
  16. Remove the intake manifold. For additional information, refer to Intake Manifold .
  17. Remove the RH fan stator stand-off. Remove the bolt and position the cable aside.
    18. Fig 12: Identifying Cable and RH Fan Stator Stand-Off
    G03887257Courtesy of FORD MOTOR CO.
  18. Disconnect the A/C electrical connector.
    19. Fig 13: Locating A/C Electrical Connector
    GF0044572Courtesy of FORD MOTOR CO.
  19. Remove the nut and disconnect the A/C fitting.
    • Remove and discard the O-ring seal and gasket.
    • Cap or plug the A/C openings as needed.
    20. Fig 14: Locating Nut & A/C Fitting
    GF0044573Courtesy of FORD MOTOR CO.
  20. Remove the bolt and disconnect the A/C pressure switch electrical connector.
    21. Fig 15: Locating Bolt & A/C Pressure Switch Electrical Connector
    GF0044574Courtesy of FORD MOTOR CO.
  21. Remove the bolts and A/C compressor.
    22. Fig 16: Locating A/C Compressor Bolts
    GF0011862Courtesy of FORD MOTOR CO.
  22. Disconnect the heater hose and position the heater hose aside.
    23. Fig 17: Locating Heater Hose
    GF0044575Courtesy of FORD MOTOR CO.
  23. Remove the bolt and idler pulley.
    24. Fig 18: Identifying Idler Pulley Bolt
    G03887298Courtesy of FORD MOTOR CO.
    NOTE: The nut behind the pulley is accessed through one of the holes in the pulley.
  24. Remove the nuts and the coolant hose shield.
    25. Fig 19: Coolant Hose Shield & Nuts
    GF0011849Courtesy of FORD MOTOR CO.
  25. Loosen the clamp and disconnect the engine coolant fill hose.
    26. Fig 20: Engine Coolant Fill Hose & Clamp
    GF0011850Courtesy of FORD MOTOR CO.
  26. Disconnect the vacuum pump hose.
    27. Fig 21: Vacuum Pump Hose
    GF0011864Courtesy of FORD MOTOR CO.
    NOTE: The stud bolt behind the pulley is accessed through one of the holes in the pulley.
  27. Remove the stud bolts and the vacuum pump.
    28. Fig 22: Vacuum Pump & Stud Bolts
    GF0011865Courtesy of FORD MOTOR CO.
  28. Remove the power steering upper mounting bolts.
    29. Fig 23: Identifying Power Steering Pump Upper Mounting Bolts
    G03887251Courtesy of FORD MOTOR CO.
  29. Remove the LH fan stator stand-off.
    30. Fig 24: Identifying LH Fan Stator Stand-Off
    G03887252Courtesy of FORD MOTOR CO.
    NOTE: The front bolt will remain in the power steering pump.
  30. Remove the 2 bolts and position the power steering pump aside.
    31. Fig 25: Identifying Power Steering Pump Bolts
    G03887253Courtesy of FORD MOTOR CO.
  31. Remove the lower radiator hose.
    32. Fig 26: Identifying Lower Radiator Hose Clamp
    G03887303Courtesy of FORD MOTOR CO.
  32. Disconnect the fuel tube spring lock couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
    33. Fig 27: Fuel Tube Spring Lock Couplings
    GF0011866Courtesy of FORD MOTOR CO.
  33. Disconnect the crankshaft position (CKP) sensor electrical connector and retaining clips.
    34. Fig 28: Crankshaft Position (CKP) Sensor Electrical Connector & Retaining Clip
    GF0011867Courtesy of FORD MOTOR CO.
  34. Disconnect the injection control pressure (ICP) sensor electrical connector. Disconnect the glow plug electrical connector and wire retainers.
    35. Fig 29: Injection Control Pressure (ICP) Sensor Electrical Connector, Glow Plug Electrical Connector & Wire Retainers
    GF0011868Courtesy of FORD MOTOR CO.
  35. Disconnect the camshaft position (CMP) sensor electrical connector and retaining clips.
    36. Fig 30: Camshaft Position (CMP) Sensor Electrical Connector & Retaining Clips
    GF0011869Courtesy of FORD MOTOR CO.
  36. Disconnect the electrical connector and wire retainers at the transmission.
    37. Fig 31: Electrical Connector & Wire Retainers
    GF0011870Courtesy of FORD MOTOR CO.
  37. Disconnect the glow plug module electrical connectors.
    38. Fig 32: Glow Plug Module Electrical Connectors
    GF0011844Courtesy of FORD MOTOR CO.
  38. Disconnect the exhaust pressure sensor electrical connector and pushpin retainer.
    39. Fig 33: Identifying Exhaust Pressure Sensor Electrical Connector and Retainer
    G03887203Courtesy of FORD MOTOR CO.
  39. Disconnect the LH glow plug electrical connector.
    40. Fig 34: Left Glow Plug Electrical Connector
    GF0011871Courtesy of FORD MOTOR CO.
  40. Disconnect the 2 engine-to-vehicle electrical connectors.
    41. Fig 35: Engine-To-Vehicle Electrical Connectors
    GF0011872Courtesy of FORD MOTOR CO.
  41. Disconnect the 2 PCM electrical connectors and position the engine wiring harness aside.
    42. Fig 36: PCM Electrical Connectors
    GF0011873Courtesy of FORD MOTOR CO.
  42. Remove the 3 bolts and the oil filter assembly.
    43. Fig 37: Oil Filter Assembly & Bolts
    GF0011874Courtesy of FORD MOTOR CO.
  43. Remove the engine-to-transmission bolt for the transmission cooler tubes.
    44. Fig 38: Locating Engine-To-Transmission Bolt
    GF0044576Courtesy of FORD MOTOR CO.
  44. Remove the nut and remove the transmission cooling tubes support bracket off the stud.
    45. Fig 39: Transmission Cooling Tubes Support Bracket Nut
    GF0011875Courtesy of FORD MOTOR CO.
  45. Remove the torque converter cover.
    46. Fig 40: Torque Converter Access Plug
    GF0011878Courtesy of FORD MOTOR CO.
  46. Remove and discard the torque converter nuts.
    47. Fig 41: Torque Converter Nuts
    GF0011879Courtesy of FORD MOTOR CO.
  47. Disconnect the block heater electrical connector.
    48. Fig 42: Identifying Block Heater Electrical Connector
    G03887446Courtesy of FORD MOTOR CO.
  48. Remove the nut. Disconnect the battery cable bracket at the starter and position aside.
    49. Fig 43: Battery Cable Bracket Nut
    GF0011880Courtesy of FORD MOTOR CO.
  49. Remove the starter solenoid protective cap.
    50. Fig 44: Identifying Starter Motor Solenoid Protective Cap
    G03887448Courtesy of FORD MOTOR CO.
  50. Disconnect the starter motor electrical connections.
    51. Fig 45: Starter Motor Electrical Connections
    GF0011881Courtesy of FORD MOTOR CO.
  51. Remove the bolts and the starter motor.
    52. Fig 46: Starter Motor Bolts
    GF0011882Courtesy of FORD MOTOR CO.
    NOTE: Right side shown, left side similar.
  52. Remove the cylinder block drain plugs and drain the coolant from the block.
    53. Fig 47: Locating Cylinder Block Coolant Drain Plug
    G03887451Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine oil to the O-ring seal prior to installation.
  53. Install the cylinder block drain plugs.
    • Tighten to 20 Nm (15 lb-ft).
    54. Fig 48: Locating Cylinder Block Coolant Drain Plug
    G03887451Courtesy of FORD MOTOR CO.
    NOTE: Left side shown, right side similar.
  54. Remove the 4 engine mount nuts.
    55. Fig 49: Identifying Engine Mount Nuts
    G03887256Courtesy of FORD MOTOR CO.
  55. Remove the lower engine-to-transmission bolts.
    56. Fig 50: Locating Lower Engine-To-Transmission Bolts
    GF0044577Courtesy of FORD MOTOR CO.
  56. Remove the mounting bolts from the lifting bracket and remove the tubes.
    57. Fig 51: Lifting Bracket Mounting Bolts
    GF0011884Courtesy of FORD MOTOR CO.
  57. Disconnect the glow plug wire retainer and remove the nut and the oil indicator and tube.
    • Discard the O-ring seal.
    58. Fig 52: Glow Plug Wire Retainer & Oil Indicator Tube Nut
    GF0011885Courtesy of FORD MOTOR CO.
  58. Disconnect the exhaust pressure tube at the exhaust manifold.
    59. Fig 53: Exhaust Pressure Tube At Exhaust Manifold
    GF0011886Courtesy of FORD MOTOR CO.
  59. Remove the nuts and glow plug module.
    60. Fig 54: Glow Plug Module & Nuts
    GF0011887Courtesy of FORD MOTOR CO.
  60. Remove the nuts and the glow plug module mounting bracket.
    61. Fig 55: Glow Plug Module Mounting Bracket & Nuts
    GF0011888Courtesy of FORD MOTOR CO.
    NOTE: Mark the location of the studs prior to removal.
  61. Remove the bolts and the LH valve cover.
    • Remove the valve cover gasket.
    • Cover the cylinder head after the valve cover is removed.
    62. Fig 56: Left Valve Cover & Bolts
    GF0011889Courtesy of FORD MOTOR CO.
  62. Remove the ICP sensor.
    • Plug or cap the opening as needed.
    63. Fig 57: Injection Control Pressure (ICP) Sensor
    GF0011890Courtesy of FORD MOTOR CO.
    NOTE: Do not tighten the bolts at this time.
  63. Install the special tools.
    64. Fig 58: Locating Engine Lift Adapters (303-D043-01)
    G04614140Courtesy of FORD MOTOR CO.
  64. Remove the turbocharger exhaust pipe.
  65. Remove the bolt and the ground strap.
    66. Fig 59: Ground Strap Bolt
    GF0011891Courtesy of FORD MOTOR CO.
  66. Remove the factory-installed engine lifting bracket.
    67. Fig 60: Factory-Installed Engine Lifting Bracket
    GF0011892Courtesy of FORD MOTOR CO.
  67. Install the special tool.
    68. Fig 61: Special Tool (303-D043-02)
    GF0005812Courtesy of FORD MOTOR CO.
  68. Install the engine lifting attachment and lifting crane.
    69. Fig 62: Engine Lifting Attachment & Lifting Crane
    GF0005813Courtesy of FORD MOTOR CO.
  69. Remove the oil pan drain plug and drain the engine oil.
    70. Fig 63: Locating Oil Pan Drain Plug
    G03887254Courtesy of FORD MOTOR CO.
    NOTE: It may be necessary to raise the engine for oil pan removal. Disconnect the linkage from the engine lifting attachment to raise the engine.
    NOTE: The oil pan bolts must be reinstalled in their original positions. Mark the location of the longer bolts to aid in installation.
  70. Remove the bolts and position back the oil pan until the oil pickup tube bolts are accessible.
    71. Fig 64: Oil Pan Bolts
    GF0005766Courtesy of FORD MOTOR CO.
  71. Remove the 2 bolts and let the oil pickup tube go into the oil pan. Remove the oil pan.
    72. Fig 65: Locating Oil Pickup Tube Bolts
    G03887261Courtesy of FORD MOTOR CO.
  72. Remove the press-in-place gasket and discard.
    73. Fig 66: Oil Pan Gasket
    GF0005767Courtesy of FORD MOTOR CO.
  73. Remove and discard the oil pickup tube O-ring seal.
    74. Fig 67: Locating Oil Pickup Tube O-Ring Seal
    G03887262Courtesy of FORD MOTOR CO.
  74. Position a suitable transmission jack under the transmission.
  75. Remove the upper engine-to-transmission bolts.
    76. Fig 68: Top Engine-To-Transmission Bolts
    GF0011893Courtesy of FORD MOTOR CO.
  76. Raise the engine.
  77. Remove the 4 bolts and LH engine mount.
    78. Fig 69: Left Engine Mount Bolts
    GF0011894Courtesy of FORD MOTOR CO.
  78. Remove the 4 bolts and the RH engine mount.
    79. Fig 70: Right Engine Mount Bolts
    GF0011895Courtesy of FORD MOTOR CO.
    NOTE: The engine must be moved to the driver side for removal.
  79. Remove the engine from the vehicle.
    80. Fig 71: Removing Engine
    GF0011896Courtesy of FORD MOTOR CO.
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