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Section 24 (Engine Mechanical - 6.7L Diesel): Disassembly: Engine: Disassembly

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
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: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel opening to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.
NOTE: For EXPORT ONLY vehicles (outside US/Canada) an Export Supplement is provided and should be referenced to identify differences that can impact service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US EPA or CARB Regulations".
  1. Remove the engine. For additional information, refer to ENGINE - BODY OFF  or ENGINE - BODY ON .
  2. NOTE: Discard the engine support insulator bracket bolts and install new bolts or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.
    NOTE: Left side shown, right side similar.

    Remove the 8 bolts and the LH and RH engine support insulator brackets.

    • Discard the bolts.
      Fig 1: Locating LH And RH Engine Support Insulator Brackets Mounting Bolts
      G08593403Courtesy of FORD MOTOR CO.
  3. NOTE: Use a suitable engine stand with 6 mounting arms or equivalent to support the engine. Failure to correctly support the engine may result in engine damage.

    Using the Floor Crane, install the engine on a suitable engine stand.

    G08593404
  4. Disconnect the EGR cooler hose retainer.
    Fig 2: Locating EGR Cooler Hose Retainer
    G08593405Courtesy of FORD MOTOR CO.
  5. Remove the EGR cooler hose from the EGR cooler.
    Fig 3: Locating EGR Cooler Hose Clamp
    G08593406Courtesy of FORD MOTOR CO.
  6. Disconnect the coolant hose from the vacuum hose retainer.
    Fig 4: Locating Vacuum Hose Retainer
    G08593407Courtesy of FORD MOTOR CO.
  7. Disconnect and remove the EGR cooler hose and the vent hose.
    Fig 5: Locating EGR Cooler Hose And Vent Hose Retainers
    G08593408Courtesy of FORD MOTOR CO.
  8. Disconnect the fan clutch electrical connector.
    G08593409
  9. Remove the fan clutch electrical connector bolt.
    Fig 6: Locating Fan Clutch Electrical Connector Bolt
    G08593410Courtesy of FORD MOTOR CO.
  10. Using the Fan Clutch Nut Wrench and Wrench, remove the fan clutch.
    Fig 7: Removing Fan Clutch Using Fan Clutch Nut Wrench And Wrench
    G08593411Courtesy of FORD MOTOR CO.
  11. NOTE: Single generator shown, dual generator similar.

    Remove the accessory drive belt.

    G08593412
  12. Disconnect the A/C compressor electrical connectors and the wire retainer.
    Fig 8: Locating A/C Compressor Electrical Connectors And Wire Retainers
    G08593413Courtesy of FORD MOTOR CO.
  13. Remove the 3 bolts and the A/C compressor.
    Fig 9: Locating A/C Compressor Mounting Bolts
    G08593414Courtesy of FORD MOTOR CO.
  14. Remove the bolt and the accessory drive belt tensioner.
    Fig 10: Locating Accessory Drive Belt Tensioner Mounting Bolts
    G08593415Courtesy of FORD MOTOR CO.
  15. Remove the 4 bolts and the secondary coolant pump assembly.
    Fig 11: Locating Secondary Coolant Pump Assembly Mounting Bolts
    G08593416Courtesy of FORD MOTOR CO.
  16. Remove the 4 bolts and the cooling fan drive assembly.
    Fig 12: Locating Cooling Fan Drive Assembly Mounting Bolts
    G08593417Courtesy of FORD MOTOR CO.
  17. Disconnect the engine vacuum hose connector at the tee. If equipped, disconnect and remove the brake booster vacuum hose.
    Fig 13: Locating Engine Vacuum Hose Connector And Brake Booster Vacuum Hose
    G08593418Courtesy of FORD MOTOR CO.
  18. Remove the 2 stator standoffs.
    Fig 14: Locating Stator Standoffs
    G08593419Courtesy of FORD MOTOR CO.
  19. NOTE: Hose retainer not shown.

    Disconnect the oil cooler outlet hose from the lower radiator hose and hose retainer.

    Fig 15: Locating Lower Radiator Hose Retainer
    G08593420Courtesy of FORD MOTOR CO.
  20. Remove the clip and the lower radiator hose.
    G08593421
  21. Remove the engine fill hose from the engine front cover.
    Fig 16: Locating Engine Fill Hose Clip
    G08593422Courtesy of FORD MOTOR CO.
  22. Remove the clip and the upper radiator hose.
    Fig 17: Locating Upper Radiator Hose Clip
    G08593423Courtesy of FORD MOTOR CO.
  23. NOTE: Use care when removing the hose from the oil cooler, damage to the oil cooler may occur during removal.

    Remove the oil cooler inlet hose.

    Fig 18: Locating Oil Cooler Inlet Hose Retainers
    G08593424Courtesy of FORD MOTOR CO.
  24. NOTE: Boot positioned back for clarity.

    Disconnect the generator electrical connector, remove the terminal nut and B+ terminal.

    G08593425
  25. Disconnect the lower engine wire harness retainer from the power steering bracket.
    Fig 19: Locating Engine Wire Harness Retainer
    G08593426Courtesy of FORD MOTOR CO.
  26. NOTE: RH side shown, LH side similar.

    Remove the 2 lower engine wire harness ground bolts.

    G08593427
  27. Disconnect the power steering tube from the retainer.
    Fig 20: Locating Power Steering Tube Retainer
    G08593428Courtesy of FORD MOTOR CO.
  28. NOTE: Power steering pump mounting bracket removed for clarity.

    Remove the 2 lower engine wire harness bolts.

    Fig 21: Locating Lower Engine Wire Harness Bolts
    G08593429Courtesy of FORD MOTOR CO.
  29. Disconnect the Engine Oil Temperature (EOT) sensor and the Engine Oil Pressure (EOP) switch electrical connectors.
    Fig 22: Locating Engine Oil Temperature Sensor And Engine Oil Pressure Switch Electrical Connector
    G08593430Courtesy of FORD MOTOR CO.
  30. Remove the lower engine wire harness nut at the oil filter adapter.
    Fig 23: Locating Oil Filter Adapter Lower Engine Wire Harness Nut
    G08593431Courtesy of FORD MOTOR CO.
  31. Remove the lower engine wire harness nut.
    Fig 24: Locating Lower Engine Wire Harness Nut
    G08593432Courtesy of FORD MOTOR CO.
  32. Remove the 2 front retaining nuts and the lower engine wire harness from the engine.
    Fig 25: Locating Front Retaining Nuts
    G08593433Courtesy of FORD MOTOR CO.
  33. Remove the bolt and oil fill pipe.
    • Remove and discard the O-ring seal.
      Fig 26: Locating Oil Fill Pipe Mounting Bolt
      G08593434Courtesy of FORD MOTOR CO.
  34. Remove the oil level indicator tube.
    • Remove and discard the O-ring seals.
      G08593435
  35. Remove the 2 bolts and EGR valve inlet tube bracket.
    • Discard the bolts.
      Fig 27: Locating EGR Valve Inlet Tube Bracket Mounting Bolts
      G08593436Courtesy of FORD MOTOR CO.
  36. NOTE: Exhaust side shown, EGR cooler side similar.

    Remove the 4 bolts and the EGR valve inlet tube.

    • Remove and discard the gaskets.
      G08593437
  37. Disconnect the Exhaust Gas Recirculation Temperature (EGRT) electrical connector and 2 wire retainers.
    Fig 28: Locating Exhaust Gas Recirculation Temperature Electrical Connector And Wire Retainer
    G08593438Courtesy of FORD MOTOR CO.
  38. Remove the 4 bolts and the EGR bypass outlet tube.
    • Remove and discard the gaskets.
      Fig 29: Locating EGR Bypass Outlet Tube Mounting Bolts
      G08593439Courtesy of FORD MOTOR CO.
  39. NOTE: LH side shown, RH side similar.

    Remove the 2 bolts and 2 ground straps from the back of the cylinder heads.

    G08593440
  40. Disconnect the 2 wire harness retainers.
    Fig 30: Locating Wire Harness Retainers
    G08593441Courtesy of FORD MOTOR CO.
  41. Disconnect the EGR valve, bypass solenoid and EGR Engine Coolant Temperature (ECT) sensor electrical connectors. Disconnect the vacuum hose and the wire retainer.
    G08593442
  42. Remove the 2 engine wire harness bolts at the EGR cooler.
    Fig 31: Locating EGR Cooler Engine Wire Harness Bolts
    G08593443Courtesy of FORD MOTOR CO.
  43. Remove the 7 bolts and the EGR cooler assembly.
    • Remove and discard the gaskets.
      Fig 32: Locating EGR Cooler Assembly Mounting Bolts
      G08593444Courtesy of FORD MOTOR CO.
  44. Disconnect the Throttle Body (TB) electrical connector.
    G08593445
  45. NOTE: The oil separator hose contains a collar at the lower intake manifold fitting. Rotate the collar counterclockwise to release the hose.

    Disconnect the crankcase vent oil separator hose sensor electrical connector. Disconnect the crankcase vent oil separator hose from the lower intake manifold.

    G08593446
  46. Remove the 3 bolts and the lower intake manifold.
    Fig 33: Locating Lower Intake Manifold Mounting Bolts
    G08593447Courtesy of FORD MOTOR CO.
  47. Disconnect the Camshaft Position (CMP) sensor electrical connector and the 3 pin type retainers.
    Fig 34: Locating Camshaft Position Sensor Electrical Connector And Pin Type Retainers
    G08593448Courtesy of FORD MOTOR CO.
  48. Disconnect the fuel volume control valve electrical connector.
    Fig 35: Locating Fuel Volume Control Valve Electrical Connector
    G08593449Courtesy of FORD MOTOR CO.
  49. Disconnect the vacuum hose retainer from the secondary fuel filter stud.
    G08593450
  50. Disconnect the turbocharger wastegate control valve vacuum and electrical connector.
    Fig 36: Locating Turbocharger Wastegate Control Vacuum And Electrical Connector
    G08593451Courtesy of FORD MOTOR CO.
  51. Disconnect the ECT sensor electrical connector and wire retainer.
    Fig 37: Locating ECT Sensor Electrical Connector And Wire Retainer
    G08593452Courtesy of FORD MOTOR CO.
  52. Disconnect the fuel pressure switch and the fuel temperature sensor electrical connectors. Disconnect the wire retainer.
    G08593453
  53. Disconnect the Fuel Rail Pressure (FRP) sensor electrical connector and 2 wire harness retainers.
    Fig 38: Locating Fuel Rail Pressure Sensor Electrical Connector And Wire Harness Retainer
    G08593454Courtesy of FORD MOTOR CO.
  54. Disconnect the fuel pressure control valve electrical connector.
    Fig 39: Locating Fuel Pressure Control Valve Electrical Connector
    G08593455Courtesy of FORD MOTOR CO.
  55. Remove the cylinder block opening cover.
    G08593456
  56. NOTE: Only one wire retainer shown.

    Disconnect the Crankshaft Position (CKP) sensor electrical connector and the 3 wire retainers.

    Fig 40: Locating Crankshaft Position Sensor Electrical Connector And Wire Retainer
    G08593457Courtesy of FORD MOTOR CO.
  57. NOTE: Only one fuel injector and glow plug electrical connector shown.

    Disconnect the 8 fuel injector and 8 glow plug electrical connectors.

    Fig 41: Locating Fuel Injector And Glow Plug Electrical Connector
    G08593458Courtesy of FORD MOTOR CO.
  58. Disconnect the 3 wire retainers from the LH valve cover.
    Fig 42: Locating LH Valve Cover Wire Retainers
    G08593459Courtesy of FORD MOTOR CO.
  59. NOTE: Only one retainer shown.

    Disconnect the 6 retainers from the fuel supply manifolds.

    Fig 43: Locating Fuel Supply Manifold Retainer
    G08593460Courtesy of FORD MOTOR CO.
  60. Remove the bolt and disconnect the 2 engine wire harness retainers.
    • Pull forward to disconnect the engine wire harness retainer and then pull up to disconnect the other retainer. Remove the engine wire harness from the engine.
      Fig 44: Locating Engine Wire Harness And Mounting Bolt
      G08593461Courtesy of FORD MOTOR CO.
  61. Remove the 4 bolts and the power steering mounting bracket.
    Fig 45: Locating Power Steering Mounting Bracket Mounting Bolts
    G08593462Courtesy of FORD MOTOR CO.
  62. Disconnect the fuel injection pump hose from the fuel rail.
    G08593463
  63. Disconnect the fuel injector return hose and retainer from the secondary fuel filter. Disconnect the secondary outlet hose from the fuel injection pump supply tube.
    G08593464
  64. Remove the 2 fuel injection pump supply tube assembly bolts.
    Fig 46: Locating Fuel Injection Pump Supply Tube Assembly Bolts
    G08593465Courtesy of FORD MOTOR CO.
  65. Remove the fuel injection pump supply tube assembly stud bolt.
    Fig 47: Locating Fuel Injection Pump Supply Tube Assembly Stud Bolt
    G08593466Courtesy of FORD MOTOR CO.
  66. Remove the bolt and the fuel injection pump supply tube assembly.
    • Remove and discard the O-ring seals.
      Fig 48: Locating Fuel Injection Pump Supply Tube Assembly Mounting Bolt
      G08593467Courtesy of FORD MOTOR CO.
  67. NOTE: Only 2 bolts shown.

    Remove the 4 bolts and crankcase vent oil separator.

    • Remove and discard the gaskets.
      Fig 49: Locating Crankcase Vent Oil Separator Mounting Bolt
      G08593468Courtesy of FORD MOTOR CO.
  68. Remove the 3 bolts and the secondary fuel filter assembly.
    Fig 50: Locating Secondary Fuel Filter Assembly Mounting Bolts
    G08593469Courtesy of FORD MOTOR CO.
  69. Remove the turbocharger coolant tube.
    G08593470
  70. Remove the 2 bolts and heater supply tube.
    • Remove and discard the O-ring seal.
      G08593471
  71. NOTE: The center lock of the fuel injector return hose connectors must be pulled completely out before the connector can be removed from the fuel injector or damage may occur to the connector.

    Push down on the tabs and pull up on the center of the fuel injector return hose fitting to unlock the fitting.

    • Disconnect the 8 fuel injector return hose fittings from the fuel injectors.
      Fig 51: Pulling Center Of Fuel Injector Return Hose Fitting
      G08593472Courtesy of FORD MOTOR CO.
  72. NOTE: RH valve cover shown, other connectors similar.

    Disconnect and remove the fuel injector return hose and vacuum hose assembly from the retaining clips.

    G08593473
  73. NOTE: Only one fuel injector supply tube shown.

    Remove and discard the 8 fuel injector supply tubes.

    Fig 52: Locating Fuel Injector Supply Tube Fittings
    G08593474Courtesy of FORD MOTOR CO.
  74. NOTE: LH side shown, RH side similar.

    Disconnect the 4 fuel rail supply tube assembly from the fuel rails.

    Fig 53: Locating Fuel Rail Supply Tube Assembly
    G08593475Courtesy of FORD MOTOR CO.
  75. Disconnect the 2 fuel rail supply tube assembly at the high-pressure fuel injection pump.
    G08593476
  76. Remove the 5 bolts and fuel rail supply tube assembly.
    • Discard the fuel rail supply tube assembly.
      G08593477
  77. Remove the 2 bolts and LH fuel rail.
    Fig 54: Locating LH Fuel Rail Mounting Bolts
    G08593478Courtesy of FORD MOTOR CO.
  78. Remove the 2 bolts and RH fuel rail.
    Fig 55: Locating RH Fuel Rail Mounting Bolts
    G08593479Courtesy of FORD MOTOR CO.
  79. Remove the 3 bolts, thermostat housing and thermostat.
    Fig 56: Locating Thermostat Housing Mounting Bolts
    G08593480Courtesy of FORD MOTOR CO.
  80. Remove the 5 bolts and the coolant crossover manifold assembly.
    • Discard the gaskets.
      Fig 57: Locating Coolant Crossover Manifold Assembly Mounting Bolts
      G08593481Courtesy of FORD MOTOR CO.
  81. WARNING: Support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft. Failure to follow this instruction may result in serious personal injury.
    NOTE: To prevent engine damage, always install 4 new bolts when installing the crankshaft pulley.

    Remove the 4 bolts and the crankshaft pulley.

    • Discard the bolts.
      G08593482
  82. Remove the 4 bolts and the vacuum pump.
    • Discard the gasket.
      Fig 58: Locating Vacuum Pump Mounting Bolts
      G08593483Courtesy of FORD MOTOR CO.
  83. Remove the 10 bolts and flexplate.
    • Discard the bolts.
      G08593484
  84. NOTE: Do not use magnetic screwdrivers or other magnetic tools around the Crankshaft Position (CKP) sensor and the crankshaft sensor pulse ring or damage to the components may occur.

    Remove the crankshaft sensor pulse ring.

    G08593485
  85. Remove the bolt and the CKP sensor.
    Fig 59: Locating Crankshaft Position Sensor Bolt
    G08593486Courtesy of FORD MOTOR CO.
  86. Remove the 4 bolts and the LH exhaust manifold heat shield.
    Fig 60: Locating LH Exhaust Manifold Heat Shield Mounting Bolts
    G08593487Courtesy of FORD MOTOR CO.
  87. Remove the 5 bolts and the RH exhaust manifold heat shield.
    Fig 61: Locating RH Exhaust Manifold Heat Shield Mounting Bolts
    G08593488Courtesy of FORD MOTOR CO.
  88. Remove the 8 nuts, 8 spacers and the LH exhaust manifold.
    • Remove and discard the LH exhaust manifold gasket and nuts.
    • Replace any exhaust manifold stud(s) that is damaged or removed with the nut.
      G08593489
  89. Remove the 8 nuts, 8 spacers and the RH exhaust manifold.
    • Remove and discard the RH exhaust manifold gasket and nuts.
    • Replace any exhaust manifold stud(s) that is damaged or removed with the nut.
      G08593490
  90. NOTE: The fuel injector hold-down clamp bolts are torque-to-yield and cannot be reused.

    Remove the 8 fuel injector bolts and fuel injector hold-downs.

    • Discard the fuel injector bolts.
      G08593491
  91. Using the Fuel Injector Remover tool, remove the 8 fuel injectors.
    1. Install the Fuel Injector Remover tool to the fuel injector and fully hand-tighten the Fuel Injector Remover tool mounting bolt.
    2. Install the allen head push bolt and tighten to remove the fuel injector.
    3. Remove the Fuel Injector Remover tool mounting bolt and the lower portion of the Fuel Injector Remover tool.
    4. Remove and discard the O-ring seal and the copper combustion gasket from the fuel injector.
    5. Remove and discard the fuel injector return fuel O-ring.
      • Position the fuel injector in the Fuel Injector Holding Rack and Injector Cups.
        G08593492Courtesy of
  92. NOTE: Only one glow plug shown.

    Remove the 8 glow plugs.

    Fig 62: Locating Glow Plugs
    G08593493Courtesy of FORD MOTOR CO.
  93. Remove the 15 bolts, 3 stud bolts and the LH valve cover.
    • Discard the LH valve cover gasket.
      Fig 63: Locating LH Valve Cover Mounting Bolts
      G08593494Courtesy of FORD MOTOR CO.
  94. Remove the 16 bolts, 2 stud bolts and the RH valve cover.
    • Discard the RH valve cover gasket.
      Fig 64: Locating RH Valve Cover Mounting Bolts
      G08593495Courtesy of FORD MOTOR CO.
  95. NOTE: Failure to remove the oil spray bar in steps may result in damage to the oil spray bar.
    NOTE: The nuts for the oil spray bar are captured nuts and remain on the oil spray bar.

    Remove the LH oil spray bar. Loosen the nuts 2 revolutions at a time in the sequence shown in the illustration until the LH oil spray bar can be removed.

    • Inspect the O-ring seal, replace if necessary.
      Fig 65: Identifying LH Oil Spray Bar And Mounting Nuts Loosening Sequence
      G08593496Courtesy of FORD MOTOR CO.
  96. NOTE: Failure to remove the oil spray bar in steps may result in damage to the oil spray bar.
    NOTE: The nuts for the oil spray bar are captured nuts and remain on the oil spray bar.

    Remove the RH oil spray bar. Loosen the nuts 2 revolutions at a time in the sequence shown in the illustration until the RH oil spray bar can be removed.

    • Inspect the O-ring seal, replace if necessary.
      Fig 66: Identifying RH Oil Spray Bar And Mounting Nuts Loosening Sequence
      G08593497Courtesy of FORD MOTOR CO.
  97. NOTE: Mark the location of the rocker arm assemblies prior to removing.
    NOTE: Only one cylinder shown.

    Remove the 8 rocker arm assemblies.

    Fig 67: Locating Rocker Arm Assemblies Mounting Screws
    G08593498Courtesy of FORD MOTOR CO.
  98. NOTE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
    NOTE: Only one cylinder shown.

    Remove the 32 push rods.

    Fig 68: Locating Push Rods
    G08593499Courtesy of FORD MOTOR CO.
  99. NOTE: Discard the M12 cylinder head bolts and install new bolts. They are torque-to-yield design and cannot be reused.

    Remove the 18 M12 cylinder head bolts and 5 M8 cylinder head bolts for the LH cylinder head.

    • Discard the 18 M12 cylinder head bolts.
      Fig 69: Locating LH Cylinder Head Bolts
      G08593500Courtesy of FORD MOTOR CO.
  100. NOTE: Discard the M12 cylinder head bolts and install new bolts. They are torque-to-yield design and cannot be reused.

    Remove the 18 M12 cylinder head bolts and 4 M8 cylinder head bolts for the RH cylinder head.

    • Discard the 18 M12 cylinder head bolts.
      Fig 70: Locating RH Cylinder Head Bolts
      G08593501Courtesy of FORD MOTOR CO.
  101. NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.
    NOTE: RH side shown, LH side similar.

    Remove the cylinder heads.

    G08593502Courtesy of
  102. Check for cylinder head distortion. For additional information, refer to CYLINDER HEAD DISTORTION .
  103. NOTE: LH side shown, RH side similar.

    Remove and discard the 2 cylinder head gaskets from the cylinder block.

    G08593503
  104. NOTE: Only one cylinder head dowel shown.

    Remove and discard the 4 cylinder head dowels from the cylinder block.

    Fig 71: Locating Cylinder Head Dowel
    G08593504Courtesy of FORD MOTOR CO.
  105. Check for cylinder block distortion. For additional information, refer to CYLINDER BLOCK DISTORTION .
  106. NOTE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original positions or engine damage may occur.
    NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.
    NOTE: Only one valve tappet guide shown.
    NOTE: Some valve tappets will be removed with the valve tappet guides.

    Remove the 8 valve tappet guides.

    • Remove the 16 valve tappets from the valve tappet guides.
      Fig 72: Locating Valve Tappet Guides
      G08593505Courtesy of FORD MOTOR CO.
  107. NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.

    Remove the remaining valve tappets from the engine.

    Fig 73: Locating Valve Tappets
    G08593506Courtesy of FORD MOTOR CO.
  108. NOTE: Late build oil pan shown.

    Remove the 15 bolts and the lower oil pan.

    • On early build vehicles, remove and discard the gasket.
    • On late build vehicles, clean and inspect the sealing surfaces.
      G08593507
  109. NOTE: Use care when removing the hose from the oil cooler, damage to the oil cooler may occur during removal.

    Disconnect the hose retainer. Remove the oil cooler outlet hose assembly.

    Fig 74: Locating Oil Cooler Outlet Hose Retainer
    G08593508Courtesy of FORD MOTOR CO.
  110. NOTE: Failure to remove the oil cooler nut may result in damage to the oil cooler.
    NOTE: On late build vehicles the internal nut is no longer on the oil cooler.

    If equipped, remove the oil cooler nut.

    Fig 75: Locating Oil Cooler Nut
    G08593509Courtesy of FORD MOTOR CO.
  111. NOTE: In the event of a catastrophic engine failure, or if installing a new short block, always install a new oil cooler. Foreign material cannot be removed from the oil cooler and engine damage may occur. Long blocks are equipped with a new oil cooler.

    Remove the 7 bolts and the oil cooler assembly.

    • Remove and discard the oil cooler gaskets.
      G08593510
  112. Remove the 4 bolts, stud bolt and the oil filter adapter.
    • Remove and discard the oil filter adapter gasket.
      Fig 76: Locating Oil Filter Adapter Mounting Bolts
      G08593511Courtesy of FORD MOTOR CO.
  113. Remove the 25 bolts and the upper oil pan.
    • Remove and discard the upper oil pan gasket.
      Fig 77: Locating Upper Oil Pan Mounting Bolts
      G08593512Courtesy of FORD MOTOR CO.
  114. NOTE: Use extreme care when removing the slinger or damage to the engine front cover may occur.

    Using 2 pocket screwdrivers, carefully remove and discard the front crankshaft slinger.

    • It will be necessary to remove the slinger from the sides as well as the top and bottom.
      G08593513
  115. NOTE: Do not scratch or damage the crankshaft during removal or installation of the front crankshaft seal.

    Using the Front Crank Seal Remover, remove and discard the front crankshaft seal from the engine front cover.

    Fig 78: Removing Front Crankshaft Seal From Engine Front Cover Using Front Crank Seal Remover
    G08593514Courtesy of FORD MOTOR CO.
  116. NOTE: Use care when removing the engine front cover to not scratch the crankshaft sealing surface.

    Remove the 14 bolts and the engine front cover.

    • Remove and discard the engine front cover and gaskets.
      Fig 79: Locating Engine Front Cover Mounting Bolts
      G08593515Courtesy of FORD MOTOR CO.
  117. NOTE: Do not scratch or damage the crankshaft during removal or installation of the rear crankshaft seal.

    Using the Rear Crank Seal Remover, remove and discard the rear crankshaft seal.

    Fig 80: Removing Rear Crankshaft Seal Using Rear Crank Seal Remover
    G08593516Courtesy of FORD MOTOR CO.
  118. NOTE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.

    Remove the 10 bolts and the engine rear cover.

    • Remove and discard the engine rear cover gasket.
      Fig 81: Locating Engine Rear Cover Mounting Bolts
      G08593517Courtesy of FORD MOTOR CO.
  119. NOTE: Prior to removing any piston and rod assemblies, it is recommended that piston protrusion be evaluated. This will help identify bent or twisted connecting rods.

    Install the Dial Indicator Gauge with Holding Fixture. Check the piston protrusion above the crankcase as follows.

    • Zero the Dial Indicator Gauge with Holding Fixture on the crankcase deck surface.
    • Position the Dial Indicator Gauge tip on the piston head at the 3 or 9 o'clock position.
    • Rotate the crankshaft to measure the maximum piston protrusion and record.
    • Reposition the Dial Indicator Gauge tip onto the piston head at the opposite position.
    • Rotate the crankshaft to measure the maximum piston protrusion and record.
    • Average the readings. If the average is lower than specification, the piston is lower in the bore than it should be. This indicates a bent or twisted connecting rod.
      Fig 82: Checking Piston Protrusion Using Dial Indicator Gauge
      G08593518Courtesy of FORD MOTOR CO.
  120. NOTE: If evident from the top of the cylinder bore, remove the carbon ridge prior to removing the rod and piston assemblies. This reduces the chance of piston ring land damage during removal.

    Using a knife or emery board, scrape the carbon ridge from the top of the cylinder bore.

  121. Using a Feeler Gauge Set, check the connecting rod side clearance. Compare to SPECIFICATIONS .
    Fig 83: Checking Connecting Rod Side Clearance Using Feeler Gauge Set
    G08593519Courtesy of FORD MOTOR CO.
  122. NOTE: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage may occur.
    NOTE: Mark the location of connecting rod cap prior to removal.
    NOTE: Only one connecting rod cap shown.

    Remove the 2 connecting rod bolts and connecting rod cap.

    Fig 84: Locating Connecting Rod Cap Mounting Bolts
    G08593520Courtesy of FORD MOTOR CO.
  123. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.
    G08593521
  124. Remove and discard the piston rings.
    1. Remove the top compression ring.
    2. Remove the intermediate ring.
    3. Remove the oil control ring.
      Fig 85: Identifying Top Compression Ring, Oil Control Ring And Intermediate Ring
      G08593522Courtesy of FORD MOTOR CO.
  125. Remove and discard the connecting rod bearings.
    Fig 86: Locating Connecting Rod Bearings
    G08593523Courtesy of FORD MOTOR CO.
  126. Using the Dial Indicator Gauge with Holding fixture, check the high-pressure fuel injection pump drive gear backlash. For additional information, refer to SPECIFICATIONS .
    Fig 87: Checking High-Pressure Fuel Injection Pump Drive Gear Backlash Using Dial Indicator Gauge
    G08593524Courtesy of FORD MOTOR CO.
  127. NOTE: The crankshaft gear contains a single timing mark. The camshaft contains a single timing mark. The high-pressure fuel injection pump drive gear contains a double timing mark. The engine is timed correctly when the single mark on the crankshaft drive gear is aligned with the double mark on the camshaft gear, and the single mark on the camshaft drive gear is aligned with the double mark on the high-pressure fuel injection pump drive gear. Additionally, the keyway on the high-pressure fuel injection pump drive gear must be at 12 o'clock position.

    Rotate the crankshaft clockwise, as viewed from the front, until the single mark on the camshaft drive gear and the double mark on the high-pressure fuel injection pump drive gear are aligned.

    Fig 88: Aligning Crankshaft With Camshaft Drive Gear And High-Pressure Fuel Injection Pump Drive Gear
    G08593525Courtesy of FORD MOTOR CO.
  128. Remove the high-pressure fuel injection pump drive gear nut.
    Fig 89: Locating High-Pressure Fuel Injection Pump Drive Gear Nut
    G08593526Courtesy of FORD MOTOR CO.
  129. Using a Universal Puller, remove the high-pressure fuel injection pump drive gear.
    Fig 90: Removing High-Pressure Fuel Injection Pump Drive Gear Using Universal Puller
    G08593527Courtesy of FORD MOTOR CO.
  130. Remove the 2 bolts and the fuel rail supply tube bracket.
    G08593528
  131. NOTE: Do not pry against the mating surface of the high-pressure fuel injection pump or damage to the high-pressure fuel injection pump may occur.

    Remove the 3 high-pressure fuel injection pump spacers and high-pressure fuel injection pump.

    • Discard the O-ring seal.
      G08593529
  132. Install the Dial Indicator Gauge with Holding Fixture, measure the camshaft gear backlash. For additional information, refer to SPECIFICATIONS 
    Fig 91: Measuring Camshaft Gear Backlash Using Dial Indicator Gauge
    G08593530Courtesy of FORD MOTOR CO.
  133. Install the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play. For additional information, refer to SPECIFICATIONS 
    Fig 92: Measuring Camshaft End Play Using Dial Indicator Gauge
    G08593531Courtesy of FORD MOTOR CO.
  134. Install the Dial Indicator Gauge with Holding Fixture, measure the crankshaft end play. For additional information, refer to SPECIFICATIONS 
    Fig 93: Checking Crankshaft End Play Using Dial Indicator Gauge
    G08593532Courtesy of FORD MOTOR CO.
  135. NOTE: RH side shown, LH side similar.

    Remove the 10 crankshaft main bearing cap side bolts.

    G08593533Courtesy of
  136. Remove the 20 crankshaft main bearing cap bolts.
    Fig 94: Locating Crankshaft Main Bearing Cap Bolts
    G08593534Courtesy of FORD MOTOR CO.
  137. Remove the 5 crankshaft main bearing caps from the cylinder block.
    • Remove and discard the lower crankshaft main bearing thrust washer.
    • Remove and discard the 5 lower crankshaft main bearings from the crankshaft main bearing caps.
      Fig 95: Locating Lower Crankshaft Main Bearing Caps
      G08593535Courtesy of FORD MOTOR CO.
  138. Remove the crankshaft from the cylinder block.
    Fig 96: Locating Cylinder Block Crankshaft
    G08593536Courtesy of FORD MOTOR CO.
  139. NOTE: Only one upper bearing shown.

    Remove and discard the 2 upper crankshaft main bearing thrust washers. Remove and discard the 5 upper crankshaft main bearings from the cylinder block.

    Fig 97: Locating Upper Crankshaft Main Bearing Thrust Washers
    G08593537Courtesy of FORD MOTOR CO.
  140. Remove the bolt and camshaft gear.
    • Using 2 suitable pry tools, carefully walk the camshaft gear off the camshaft.
      Fig 98: Locating Camshaft Gear Mounting Bolt
      G08593538Courtesy of FORD MOTOR CO.
  141. Remove the 2 bolts and the camshaft thrust plate.
    Fig 99: Locating Camshaft Thrust Plate Mounting Bolts
    G08593539Courtesy of FORD MOTOR CO.
  142. NOTE: If the camshaft is being replaced, the camshaft bearings have to be replaced and machined by a machine shop. Failure to follow this may result in engine damage.
    NOTE: Use care when removing the camshaft from the engine or damage to the camshaft and the bearings may occur.
    NOTE: Use the slide hammer as a handle for the camshaft. Using the slide hammer as intended may result in engine damage.
    NOTE: Use care when removing the camshaft, the camshaft will slide out the other end of the cylinder block.

    Using the Camshaft Remover/Installer and the Slide Hammer, remove the camshaft.

    G08593540Courtesy of
  143. Remove the 8 bolts and the 8 piston cooling tubes.
    Fig 100: Locating Piston Cooling Tube Mounting Bolt
    G08593541Courtesy of FORD MOTOR CO.
  144. Remove the high-pressure fuel injection pump mounting bolts. Inspect the front cover roll pin for wear or damage, replace if necessary.
    Fig 101: Locating High-Pressure Fuel Injection Pump Mounting Bolts
    G08593542Courtesy of FORD MOTOR CO.
  145. NOTE: Only one pipe plug shown.

    If necessary, remove the pipe plugs.

    Fig 102: Locating Pipe Plug
    G08593543Courtesy of FORD MOTOR CO.
  146. If equipped, remove the block heater.
    G08593544
  147. If damaged, remove and discard the turbocharger alignment dowels.
    G08593545
  148. If damaged, remove and discard the cylinder block zero clearance patch from the engine.
    Fig 103: Locating Engine Cylinder Block Zero Clearance Patch
    G08593546Courtesy of FORD MOTOR CO.
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