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Section 249 (Engine - 7.3L Diesel): Disassembly: Engine: Disassembly

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the engine lifting equipment from the engine.
  2. Remove the flywheel from the engine.
  3. Mount the engine on a work stand, using special tool 303-D097 (D94T-6000-A).
  4. Remove the exhaust adapter pipes.
    1. Remove the four mounting bolts and nuts.
    2. Remove the exhaust adapter pipes.
    Fig 1: Removing Exhaust Adapter Pipes
    G01537786Courtesy of FORD MOTOR CO.
  5. Disconnect the fuel injector/glow plug nine pin connectors.
    1. Disconnect the retaining clip.
    2. Disconnect the nine pin connector.
    Fig 2: Disconnecting Fuel Injector/Glow Plug Nine Pin Connectors
    G01537787Courtesy of FORD MOTOR CO.
  6. Disconnect the exhaust back pressure solenoid electrical connector.
    Fig 3: Disconnecting Exhaust Back Pressure Solenoid Electrical Connector
    G01537788Courtesy of FORD MOTOR CO.
  7. Disconnect the fuel heater/water sensor electrical connector.
    Fig 4: Disconnecting Fuel Heater/Water Sensor Electrical Connector
    G01537789Courtesy of FORD MOTOR CO.
  8. Disconnect the injection pressure regulator electrical connector.
    Fig 5: Disconnecting Injection Pressure Regulator Electrical Connector
    G01537790Courtesy of FORD MOTOR CO.
  9. Disconnect the injection oil pressure sensor electrical connector.
    Fig 6: Disconnecting Injection Oil Pressure Sensor Electrical Connector
    G01537791Courtesy of FORD MOTOR CO.
  10. Disconnect the engine oil temperature sensor.
    Fig 7: Disconnecting Engine Oil Temperature Sensor
    G01537792Courtesy of FORD MOTOR CO.
  11. Disconnect the engine oil pressure sensor electrical connector.
    Fig 8: Disconnecting Engine Oil Pressure Sensor Electrical Connector
    G01537793Courtesy of FORD MOTOR CO.
  12. Disconnect the exhaust back pressure sensor and engine coolant temperature (ECT) sensor electrical connectors.
    Fig 9: Disconnecting Exhaust Back Pressure Sensor And ECT Sensor Electrical Connectors
    G01537794Courtesy of FORD MOTOR CO.
  13. Disconnect the camshaft position sensor electrical connector.
    Fig 10: Disconnecting Camshaft Position Sensor Electrical Connector
    G01537795Courtesy of FORD MOTOR CO.
  14. Remove the engine harness.
    1. Disconnect the pushpin retainer.
    2. Remove the engine harness.
    Fig 11: Removing Engine Harness
    G01537796Courtesy of FORD MOTOR CO.
  15. Remove the turbocharger pedestal.
    1. Remove the bolts.
    2. Remove the pedestal.
    Fig 12: Removing Turbocharger Pedestal
    G01537797Courtesy of FORD MOTOR CO.
  16. Remove and discard the two O-ring seals.
    Fig 13: Removing O-Ring Seals
    G01537798Courtesy of FORD MOTOR CO.
  17. Remove the oil level indicator tube.
    1. Remove the nut.
    2. Pull upward and remove the oil level indicator tube.
    Fig 14: Removing Oil Level Indicator Tube
    G01537799Courtesy of FORD MOTOR CO.
    18. NOTE: Both the left side and the right side valve covers are removed the same way. Only the right side valve cover is shown.
    Fig 15: Removing Valve Covers
    G01537800Courtesy of FORD MOTOR CO.
  18. Remove the valve covers.
    1. Remove the mounting bolts.
    2. Remove the valve cover.
    19. NOTE: Both the left side and the right side valve cover gaskets are removed the same way. Only the right side valve cover gasket is shown.
    Fig 16: Removing Valve Cover Gaskets
    G01537801Courtesy of FORD MOTOR CO.
  19. Remove the valve cover gaskets.
    1. Disconnect the four fuel injector electrical connectors.
    2. Disconnect the four glow plug electrical connectors.
    3. Remove the valve cover gasket.
  20. Using the special tool, remove the two high pressure oil lines.
    Fig 17: Removing High Pressure Oil Lines
    G01537802Courtesy of FORD MOTOR CO.
  21. Drain the fuel galleries in the cylinder heads.
    • Loosen the fuel gallery plug and drain the fuel. After the fuel has drained, tighten the fuel gallery plug.
    Fig 18: Loosening Fuel Gallery Plug
    G01537803Courtesy of FORD MOTOR CO.
  22. Drain the cylinder head oil galleries.
    • Remove the two oil gallery plugs. After the oil has drained, tighten the oil gallery plugs.
    Fig 19: Removing Oil Gallery Plugs
    G01537804Courtesy of FORD MOTOR CO.
  23. Remove the rocker arms.
    1. Remove the bolts.
    2. Remove the rocker arms and the push rods.
    Fig 20: Removing Rocker Arms
    G01537805Courtesy of FORD MOTOR CO.
  24. Remove the oil deflectors.
    1. Remove the bolt.
    2. Remove the oil deflector.
    Fig 21: Removing Oil Deflectors
    G01537806Courtesy of FORD MOTOR CO.
  25. Remove the four outboard fuel injector hold-down bolts.
    Fig 22: Removing Outboard Fuel Injector Hold-Down Bolts
    G01537807Courtesy of FORD MOTOR CO.
  26. Using the special tool, remove the four fuel injectors.
    Fig 23: Removing Fuel Injectors
    G01537808Courtesy of FORD MOTOR CO.
  27. Remove the fuel line from each of the cylinder heads.
    Fig 24: Removing Fuel Line From Each Of Cylinder Heads
    G01537809Courtesy of FORD MOTOR CO.
  28. Remove the fuel line and clamp.
    1. Remove the nut.
    2. Remove the fuel line and clamp from the stud bolt.
    Fig 25: Removing Fuel Line And Clamp
    G01537810Courtesy of FORD MOTOR CO.
  29. Disconnect the exhaust back pressure tube.
    Fig 26: Disconnecting Exhaust Back Pressure Tube
    G01537811Courtesy of FORD MOTOR CO.
  30. Remove the inboard fuel injector hold-down bolts.
    Fig 27: Removing Inboard Fuel Injector Hold-Down Bolts
    G01537812Courtesy of FORD MOTOR CO.
  31. Remove the 18 cylinder head bolts.
    Fig 28: Removing Cylinder Head Bolts
    G01537813Courtesy of FORD MOTOR CO.
  32. Remove the cylinder heads.
    1. Position the special tool.
    2. Install the four bolts.
    3. Attach the special tool and remove the cylinder head.
    Fig 29: Removing Cylinder Heads
    G01537814Courtesy of FORD MOTOR CO.
  33. Remove the oil cooler.
    1. Remove the bolts.
    2. Remove the oil cooler and the gaskets.
    Fig 30: Removing Oil Cooler
    G01537815Courtesy of FORD MOTOR CO.
  34. Remove the bolt from the fuel drain tube retainer clamp.
    Fig 31: Removing Bolt From Fuel Drain Tube Retainer Clamp
    G01537816Courtesy of FORD MOTOR CO.
  35. Remove the fuel filter/water separator assembly.
    1. Remove the bolts.
    2. Remove the fuel filter/water separator assembly.
    Fig 32: Removing Fuel Filter/Water Separator Assembly
    G01537817Courtesy of FORD MOTOR CO.
  36. Remove the plug. Using special tool 303-D104 (D94T-9000-A), draw the oil from the reservoir.
    Fig 33: Removing Plug
    G01537818Courtesy of FORD MOTOR CO.
  37. Remove the bolts and the access cover.
    Fig 34: Removing Access Cover
    G01537819Courtesy of FORD MOTOR CO.
  38. Remove the high pressure oil pump drive gear retaining bolt and washer.
    Fig 35: Removing High Pressure Oil Pump Drive Gear Retaining Bolt And Washer
    G01537820Courtesy of FORD MOTOR CO.
  39. Remove the high pressure oil pump.
    1. Remove the bolts.
    2. Remove the high pressure oil pump, and the gasket.
    Fig 36: Removing High Pressure Oil Pump
    G01537821Courtesy of FORD MOTOR CO.
  40. Remove the high pressure oil pump reservoir.
    1. Remove the bolts.
    2. Remove the reservoir and gasket. Remove the high pressure oil pump drive gear.
    Fig 37: Removing High Pressure Oil Pump Reservoir
    G01537822Courtesy of FORD MOTOR CO.
  41. Remove the exhaust back pressure sensor and tube.
    1. Remove the nut.
    2. Remove the sensor and tube.
    Fig 38: Removing Exhaust Back Pressure Sensor And Tube
    G01537823Courtesy of FORD MOTOR CO.
  42. Remove the camshaft position sensor.
    1. Remove the bolt.
    2. Remove the camshaft position sensor retainer clamp.
    3. Remove the camshaft position sensor.
    Fig 39: Removing Camshaft Position Sensor
    G01537824Courtesy of FORD MOTOR CO.
  43. Remove the bolt. Using the special tool, remove the crankshaft vibration damper.
    Fig 40: Removing Crankshaft Vibration Damper
    G01537825Courtesy of FORD MOTOR CO.
  44. Remove the oil pump.
    1. Remove the bolts.
    2. Remove the oil pump housing and the O-ring.
    Fig 41: Removing Oil Pump
    G01537826Courtesy of FORD MOTOR CO.
  45. Remove the inner gerotor gear.
    Fig 42: Removing Inner Gerotor Gear
    G01537827Courtesy of FORD MOTOR CO.
  46. Remove the engine mounts.
    1. Remove the three bolts.
    2. Remove the mounts.
    Fig 43: Removing Engine Mounts (1 Of 2)
    G01537828Courtesy of FORD MOTOR CO.
    Fig 44: Removing Engine Mounts (2 Of 2)
    G01537829Courtesy of FORD MOTOR CO.
  47. Drain the engine oil pan.
  48. Remove the oil pan bolts.
    Fig 45: Removing Oil Pan Bolts
    G01537830Courtesy of FORD MOTOR CO.
  49. Remove the oil pan.
    1. Cut the oil pan sealant all the way around the oil pan.
    2. Carefully pry the oil pan up and away from the engine block.
    Fig 46: Removing Oil Pan
    G01537831Courtesy of FORD MOTOR CO.
  50. Remove the oil pickup tube.
    1. Remove the nut.
    2. Remove the two bolts.
    3. Remove the pickup tube and gasket.
    Fig 47: Removing Oil Pickup Tube
    G01537832Courtesy of FORD MOTOR CO.
  51. Remove the engine front cover.
    1. Remove the bolts.
    2. Remove the engine front cover and the gaskets.
    Fig 48: Removing Engine Front Cover
    G01537833Courtesy of FORD MOTOR CO.
    52. CAUTION: Do not bend the engine rear cover. If the rear cover is bent, it will not reseal causing engine oil leaks.
    Fig 49: Removing Engine Rear Cover
    G01537834Courtesy of FORD MOTOR CO.
  52. Remove the engine rear cover.
    1. Remove the bolts.
    2. Using a putty knife, carefully cut the sealant between the engine rear cover and the engine. Remove the cover.
    53. NOTE: All sixteen lifters are removed the same way. Only two lifters are shown.
    Fig 50: Removing Lifters
    G01537835Courtesy of FORD MOTOR CO.
  53. Remove the lifters. Note the order of removal.
    1. Remove the bolt.
    2. Remove the lifter retainer.
    3. Remove the lifters.
  54. Remove the camshaft.
    1. Remove the two retainer bolts.
    2. Remove the camshaft and the drive gear.
    Fig 51: Removing Camshaft And Drive Gear
    G01537836Courtesy of FORD MOTOR CO.
  55. Remove the carbon ridge from the top of the cylinder bores.
    56. NOTE: Mark and record all eight piston rods to make sure that they are installed into their correct cylinder bores during assembly.
    NOTE: All eight pistons and rod assemblies are removed the same way. Only one piston and rod assembly is shown.
    Fig 52: Removing Piston And Rod Assemblies
    G01537837Courtesy of FORD MOTOR CO.
  56. Remove the piston and rod assemblies.
    1. Remove the bolts.
    2. Remove the rod cap and bearing half.
    3. Install the rod bolt protector sleeves.
    4. Push the rod and piston assembly down and out of the engine block.
  57. Remove the crankshaft.
    1. Remove the bolts.
    2. Remove the main bearing caps and the bearing halves.
    3. Using a suitable sling and special tool 014-00071, remove the crankshaft.
    Fig 53: Removing Crankshaft
    G01537838Courtesy of FORD MOTOR CO.
    58. NOTE: All eight piston oil cooling jets are removed the same way. Only one jet is shown.
    Fig 54: Removing Piston Oil Cooling Jets
    G01537839Courtesy of FORD MOTOR CO.
  58. Remove the piston oil cooling jets.
    1. Remove the bolt.
    2. Remove the cooling jet.
  59. Remove the short circuit valve check ball retainer cap.
    Fig 55: Removing Short Circuit Valve Check Ball Retainer Cap
    G01537840Courtesy of FORD MOTOR CO.
  60. Remove the spring.
    Fig 56: Removing Spring
    G01537841Courtesy of FORD MOTOR CO.
  61. Remove the short circuit valve check ball.
    Fig 57: Removing Short Circuit Valve Check Ball
    G01537842Courtesy of FORD MOTOR CO.
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