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Section 13 (Engine - 6.0L Diesel): Disassembly: Engine: Disassembly

WARNING: This page is about a different variant/trim than selected.
  1. Remove the bolts and the flexplate/flywheel.
    Fig 1: Identifying Flexplate Bolts
    G01549683Courtesy of FORD MOTOR CO.
  2. Mount the engine on an engine stand.
  3. Remove the rear lifting eye.
  4. Remove the front lifting brackets.
    Fig 2: Removing Front Lifting Brackets
    G01549684Courtesy of FORD MOTOR CO.
  5. Remove the three bolts and the starter.
    Fig 3: Identifying Starter Bolts
    G01549685Courtesy of FORD MOTOR CO.
  6. Remove the bolts and the LH and RH motor mounts.
    NOTE: Left side shown, right side similar.
    Fig 4: Identifying Motor Mount Bolts
    G01549686Courtesy of FORD MOTOR CO.
  7. Remove the retaining nuts and the glow plug control module and mounting bracket.
    Fig 5: Identifying Glow Plug Control Module Retaining Nuts
    G01549687Courtesy of FORD MOTOR CO.
  8. Remove the oil level indicator and tube.
    • Remove the nut.
    • Remove and discard the O-ring.
    Fig 6: Identifying Oil Level Indicator Tube Bolts
    G01549688Courtesy of FORD MOTOR CO.
  9. Disconnect the exhaust backpressure tube at the exhaust manifold.
    Fig 7: Identifying Exhaust Backpressure Tube
    G01549689Courtesy of FORD MOTOR CO.
  10. Remove the retaining nut and the exhaust backpressure tube assembly.
    Fig 8: Identifying Retaining Nut & Exhaust Backpressure Tube Assembly
    G01549690Courtesy of FORD MOTOR CO.
  11. Remove the thermostat.
    • Remove the stud bolt and bolt.
    • Remove and discard the O-ring.
    Fig 9: Identifying Thermostat Housing Bolts
    G01549691Courtesy of FORD MOTOR CO.
  12. Remove the bolt and the fuel lines and bracket.
    Fig 10: Identifying Fuel Line Bracket
    G01549692Courtesy of FORD MOTOR CO.
  13. Remove the left cylinder head banjo fitting and fuel line. Discard the sealing washers.
    Fig 11: Identifying Left Cylinder Head Banjo Fuel Line Fitting
    G01549693Courtesy of FORD MOTOR CO.
  14. Remove the bolt and serpentine belt idler.
    Fig 12: Identifying Serpentine Belt Idler Pulley Bolt
    G01549694Courtesy of FORD MOTOR CO.
  15. Remove the bolts and serpentine belt tensioner.
    Fig 13: Identifying Serpentine Belt Tensioner
    G01549695Courtesy of FORD MOTOR CO.
  16. Remove and discard the O-rings from the oil filter base.
    Fig 14: Identifying Oil Filter Base O-Ring
    G01549696Courtesy of FORD MOTOR CO.
  17. Remove the exhaust gas recirculation (EGR) cooler coolant supply port cover.
    • Remove the bolts.
    • Clean and inspect the gaskets. Replace if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 15: Identifying EGR Cooler Coolant Supply Port Cover Bolts
    G01549697Courtesy of FORD MOTOR CO.
  18. Remove the oil filter base.
    • Remove the bolts.
    • Clean and inspect the gaskets. Replace if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 16: Identifying Oil Filter Base Bolts
    G01549698Courtesy of FORD MOTOR CO.
  19. Remove the oil cooler assembly.
    NOTE: The oil cooler is replaced as an assembly.
    • Remove the bolts.
    • Clean and inspect the gaskets. Replace if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 17: Identifying Oil Cooler Bolts
    G01549699Courtesy of FORD MOTOR CO.
  20. Remove the oil pump inlet strainer. Clean and inspect for tears and other damage.
    Fig 18: Identifying Oil Pump Inlet Strainer
    G01549700Courtesy of FORD MOTOR CO.
  21. Remove bolts and the turbocharger heat shield.
    Fig 19: Identifying Turbocharger Heat Shield
    G01549701Courtesy of FORD MOTOR CO.
  22. Remove the high-pressure oil pump cover.
    • Remove the bolts.
    • Use a thin gasket scraper to separate the cover from the crankcase.
    • Clean and inspect the gaskets. Replace if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 20: Identifying High Pressure Oil Pump Cover
    G01549702Courtesy of FORD MOTOR CO.
  23. Remove the bolts from the high-pressure oil pump discharge pipe.
    Fig 21: Identifying High-Pressure Oil Pump Discharge Pipe Bolts
    G01549703Courtesy of FORD MOTOR CO.
  24. Using the special tool, disconnect and remove the high-pressure oil pump discharge pipe.
    • Remove and discard the D-ring seal.
    Fig 22: Disconnecting High-Pressure Oil Pump Discharge Pipe
    G01549704Courtesy of FORD MOTOR CO.
  25. Remove and discard the high-pressure pump O-ring seal.
    Fig 23: Identifying High Pressure Pump O-Ring
    G01549705Courtesy of FORD MOTOR CO.
  26. Remove the bolts and the high-pressure oil pump.
    Fig 24: Identifying High Pressure Oil Pump Bolts
    G01549706Courtesy of FORD MOTOR CO.
  27. Remove and discard the lower O-ring seal.
    Fig 25: Identifying Lower O-Ring Seal
    G01549707Courtesy of FORD MOTOR CO.
  28. Remove the glow plug buss bar.
    NOTE: Left side shown, right side similar.
    Fig 26: Identifying Glow Plug Buss Bar
    G01549708Courtesy of FORD MOTOR CO.
  29. Remove the eight glow plugs.
    Fig 27: Identifying Glow Plug
    G01549709Courtesy of FORD MOTOR CO.
  30. Remove the valve covers.
    NOTE: Mark the location of the stud bolts.
    • Remove the stud bolts and bolts.
    • Clean and inspect the gaskets. Replace if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 28: View Of Valve Cover
    G01549710Courtesy of FORD MOTOR CO.
  31. Remove the bolts and the coolant pump pulley.
    Fig 29: Identifying Coolant Pump Pulley Bolts
    G01549711Courtesy of FORD MOTOR CO.
  32. Remove the coolant pump.
    • Remove the bolts.
    • Remove and discard the O-ring.
    Fig 30: Identifying Coolant Pump Bolts
    G01549712Courtesy of FORD MOTOR CO.
  33. Check the crankshaft vibration damper runout.
    • Remove the paint from the face of the crankshaft vibration damper at four points 90 degrees apart.
    • Attach the special tool to the cylinder block. Position the special tool on one of the unpainted surfaces.
    • Using a suitable tool, pry the crankshaft forward. Zero the dial indicator.
    • Rotate the crankshaft 90 degrees. Pry the crankshaft forward. Record the measurement. Repeat at each unpainted surface.
      NOTE: Pry the crankshaft forward at the same point to eliminate possible error caused by crankshaft end play.
      • If the runout exceeds specification, install a new crankshaft vibration damper.
    Fig 31: Checking Crankshaft Vibration Damper Runout
    G01549713Courtesy of FORD MOTOR CO.
  34. Remove the bolts and the crankcase vibration damper.
    WARNING: To avoid personal injury, support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft very easily.
    • Discard the bolts.
    Fig 32: Identifying Crankshaft Vibration Damper Bolts
    G01549714Courtesy of FORD MOTOR CO.
  35. Punch two holes in the seal.
    Fig 33: Identifying Crankshaft Seal
    G01549715Courtesy of FORD MOTOR CO.
  36. Using the special tool, remove the crankshaft seal.
    Fig 34: Removing Crankshaft Seal
    G01549716Courtesy of FORD MOTOR CO.
  37. If equipped, remove the crankshaft damper wear sleeve with the special tool.
    NOTE: Production engine will not have a wear sleeve.
    Fig 35: Removing Crankshaft Damper Wear Sleeve
    G01549717Courtesy of FORD MOTOR CO.
  38. Remove the gerotor oil pump cover.
    • Remove the bolts.
    • Remove and discard the O-ring seal.
    Fig 36: Identifying Gerotor Oil Pump Cover Bolts
    G01549718Courtesy of FORD MOTOR CO.
  39. Remove the inner and outer gerotors.
    NOTE: Mark the front of each gerotor for proper reassembly orientation.
    Fig 37: Identifying Inner & Outer Gerotors
    G01549719Courtesy of FORD MOTOR CO.
  40. Remove the engine front cover.
    • Remove the bolts.
    • Clean and inspect the gaskets. Replace if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 38: Identifying Engine Front Cover Bolts
    G01549720Courtesy of FORD MOTOR CO.
  41. Remove the flywheel adapter.
    Fig 39: Identifying Flywheel Adapter
    G01549721Courtesy of FORD MOTOR CO.
  42. Punch two holes across from each other in the rear main seal.
    Fig 40: Identifying Punched Holes In Rear Main Seal
    G01549722Courtesy of FORD MOTOR CO.
  43. Using the special tool, remove the rear main seal.
    Fig 41: Removing Rear Main Seal
    G01549723Courtesy of FORD MOTOR CO.
  44. If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
    NOTE: Production engines will not have wear sleeve.
    Fig 42: Removing Crankshaft Wear Sleeve
    G01549724Courtesy of FORD MOTOR CO.
  45. Clean and inspect the crankshaft sealing surface.
    Fig 43: Inspecting Crankshaft Sealing Surface
    G01549725Courtesy of FORD MOTOR CO.
  46. Remove the rear engine cover.
    • Remove the bolts.
    • Clean and inspect the gaskets. Replace if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 44: Identifying Rear Engine Cover
    G01549726Courtesy of FORD MOTOR CO.
  47. Remove the bolts and the RH exhaust manifold.
    Fig 45: Identifying RH Exhaust Manifold Bolts
    G01549727Courtesy of FORD MOTOR CO.
  48. Remove the bolts and the LH exhaust manifold.
    Fig 46: Identifying LH Exhaust Manifold Bolts
    G01549728Courtesy of FORD MOTOR CO.
  49. Using the special tool, disconnect the high-pressure oil rail supply line at the high-pressure oil rail.
    Fig 47: Disconnecting High-Pressure Oil Rail Supply Line At The High-Pressure Oil Rail
    G01549729Courtesy of FORD MOTOR CO.
  50. Using the special tool, disconnect and remove the high-pressure oil supply line.
    Fig 48: Disconnecting High-Pressure Oil Rail Supply Line
    G01549730Courtesy of FORD MOTOR CO.
  51. Remove the bolts and the high pressure oil rail.
    Fig 49: Identifying High Pressure Oil Rail Bolts
    G01549731Courtesy of FORD MOTOR CO.
  52. Using a socket, push the fuel injector electrical connector out of the rocker arm carrier.
    CAUTION: Do not  attempt to put battery voltage to the fuel injector or damage to the fuel injector will occur.
    Fig 50: Identifying Fuel Injector Electrical Connector
    G01549732Courtesy of FORD MOTOR CO.
  53. Remove the bolt, the fuel injector hold down and the fuel injector.
    CAUTION: To prevent engine damage, Do not  use air tools to remove the fuel injectors. The clip that extracts the injector can dislodge and fall into the oil drain hole.
    NOTE: If engine oil is found in the engine coolant or engine coolant is found in the combustion chambers, new injector sleeves may need to be installed.
    Fig 51: Identifying Fuel Injector Hold Down Bolt
    G01549733Courtesy of FORD MOTOR CO.
  54. Remove and discard the crankcase-to-head tube assembly.
    Fig 52: Identifying Crankcase-To-Head Tube Assembly
    G01549734Courtesy of FORD MOTOR CO.
  55. Remove the 10 head bolts.
    Fig 53: Identifying Cylinder Head Bolts
    G01549735Courtesy of FORD MOTOR CO.
  56. Remove the 16 bolts and the rocker arm assemblies.
    Fig 54: Identifying Rocker Arm Bolts
    G01549736Courtesy of FORD MOTOR CO.
  57. Remove the rocker arm carrier from the cylinder head.
    • Remove the bolts.
    • Clean and inspect the gaskets. Replace if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 55: Identifying Rocker Arm Carrier Bolts
    G01549737Courtesy of FORD MOTOR CO.
  58. Remove the 16 valve bridges.
    NOTE: Mark the location of the valve bridges before removing.
    Fig 56: Identifying Valve Bridges
    G01549738Courtesy of FORD MOTOR CO.
  59. Remove the 16 push rods.
    Fig 57: Identifying Push Rods
    G01549739Courtesy of FORD MOTOR CO.
  60. Remove the 10 outer head bolts.
    Fig 58: Identifying Cylinder Head Outer Bolts
    G01549740Courtesy of FORD MOTOR CO.
  61. Remove the cylinder heads.
    1. Install the special tool.
    2. Install the bolts.
    Fig 59: Installing Tool To Remove Cylinder Head
    G01549741Courtesy of FORD MOTOR CO.
  62. Remove and discard the cylinder head gasket.
  63. Remove and discard the four cylinder head dowel sleeves.
    Fig 60: Identifying Cylinder Head Dowel Sleeves
    G01549743Courtesy of FORD MOTOR CO.
  64. Remove the bolts from the rear engine tube assembly.
    Fig 61: Identifying Rear Engine Tube Assembly Bolt
    G01549744Courtesy of FORD MOTOR CO.
  65. Remove the bolt and the rear engine tube assembly.
    Fig 62: Identifying Rear Engine Tube Assembly
    G01549745Courtesy of FORD MOTOR CO.
  66. Remove the bolts and the roller follower guides.
    Fig 63: Identifying Roller Follower Guide Bolt
    G01549746Courtesy of FORD MOTOR CO.
  67. Remove the oil pan.
    • Remove the 16 bolts.
    • Remove the oil pan.
    • Clean and inspect the gaskets. Replace if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 64: Identifying Oil Pan Bolts
    G01549747Courtesy of FORD MOTOR CO.
  68. Remove the oil pick-up tube and the screen.
    • Remove the bolts.
    • Remove and discard the O-ring.
    Fig 65: Identifying Oil Pick-Up Tube & Screen Bolts
    G01549748Courtesy of FORD MOTOR CO.
  69. Remove the upper oil pan.
    • Remove the bolts.
    • Clean and inspect the gaskets. Replace if necessary.
    • Clean and inspect the sealing surfaces.
    Fig 66: Identifying Upper Oil Pan Bolts
    G01549749Courtesy of FORD MOTOR CO.
  70. Remove the bolts and the connecting rod caps.
    Fig 67: Identifying Connecting Rod Cap Bolts
    G01549750Courtesy of FORD MOTOR CO.
  71. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.
    Fig 68: Pushing Connecting Rod & Piston Assembly From Cylinder
    G01549751Courtesy of FORD MOTOR CO.
  72. Remove the piston rings.
    1. Remove the top compression ring.
    2. Remove the intermediate compression ring.
    3. Remove the oil control ring.
    Fig 69: Identifying Piston Rings
    G01549752Courtesy of FORD MOTOR CO.
  73. Remove and discard the connecting rod bearings.
    Fig 70: Identifying Connecting Rod Bearings
    G01549753Courtesy of FORD MOTOR CO.
  74. Remove the bolt and the crankshaft position (CKP) sensor.
    Fig 71: Identifying Crankshaft Position Sensor
    G01549754Courtesy of FORD MOTOR CO.
  75. Remove the bolt and the camshaft position (CMP) sensor.
    Fig 72: Identifying Camshaft Position Sensor
    G01549755Courtesy of FORD MOTOR CO.
  76. Remove the block heater.
    Fig 73: Identifying Block Heater
    G01549756Courtesy of FORD MOTOR CO.
  77. Remove the 20 lower case bolts and the 8 outside lower crankcase bolts. Remove the lower crankcase assembly.
    Fig 74: Identifying Lower Case Bolts
    G01549757Courtesy of FORD MOTOR CO.
  78. Remove the lower crankcase seals and the lower bearings and discard.
    Fig 75: Identifying Lower Crankcase Seals
    G01549758Courtesy of FORD MOTOR CO.
  79. Using the appropriate lifting device, remove the crankshaft assembly.
    Fig 76: Identifying Crankshaft Assembly
    G01549759Courtesy of FORD MOTOR CO.
  80. Remove and discard the crankshaft upper bearings and crankshaft upper thrust bearing.
    Fig 77: Identifying Crankshaft Upper Bearings & Crankshaft Upper Thrust Bearing
    G01549760Courtesy of FORD MOTOR CO.
  81. Remove the thrust plate mounting bolts and remove the camshaft and gear.
    CAUTION: Do not  nick or scratch the camshaft bearings with the camshaft lobes or engine damage will occur.
    Fig 78: Identifying Thrust Plate Mounting Bolts
    G01549761Courtesy of FORD MOTOR CO.
  82. Remove the bolts and the eight piston cooling tubes.
    CAUTION: This patch bolt is unique - Do not  substitute or engine damage can occur.
    Fig 79: Identifying Piston Cooling Tube Bolts
    G01549762Courtesy of FORD MOTOR CO.
  83. Using the special tool, remove the camshaft bearings and discard.
    Fig 80: Removing Camshaft Bearings
    G01549763Courtesy of FORD MOTOR CO.
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