Section 256 (Engine - 6.7L Power Stroke Diesel): Disassembly: Engine
WARNING: This page is about a different car, the 2019 Ford F-550 Super Duty, 2019 Ford F-450 Super Duty, 2019 Ford F-350 Super Duty, and 2019 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.
For information on Ford Color Coded Illustrations refer to OEM Color Coding
Special Tool(s) / General Equipment
| 100-001 (T50T-100-A) Slide Hammer | |
|---|---|
| 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge | |
| 205-036 (T70P-4067-A) Wrench | |
| 303-050 (T70P-6000) Lifting Bracket, Engine | |
| 303-1510 Remover, Front Crank Seal | |
| 303-1513 Remover, Rear Crank Seal | |
| 303-1517 Adapter, Camshaft Remover/Installer TKIT-2009C-F TKIT-2009C-ROW | |
| 303-1518 Bracket, Engine Removal TKIT-2009C-F TKIT-2009C-ROW | |
| 303-214 (T83T-6312-B) Wrench, Fan Clutch Nut | |
| 310-230 Remover, Fuel Injector TKIT-2010FT-F TKIT-2010F T-ROW | |
| Feeler Gauge | |
| Floor Crane | |
| Mounting Stand | |
| Hose Clamp Remover/Installer |
NOTE:
During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enter the oil passages, coolant passages or the oil pan, may cause engine failure.
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:
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:
Disassembly of the engine requires various inspections/measurements of the engine components. These inspections/measurements will aid in determining if the engine components will require replacement.
NOTE:
Refer to the exploded view under the Engine Component View
in the Description and Operation.
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".
- Remove the engine. Refer to: Engine - Body Off . Refer to: Engine - Body On .
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NOTE: Discard the engine mount bracket bolts and install new bolts or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.
- Remove the bolts and the LH engine mount bracket.
- Discard the bolts.
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NOTE: Discard the engine mount bracket bolts and install new bolts or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.
- Remove the bolts and the RH engine mount bracket.
- Discard the bolts.
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NOTE: Use Rotunda Part Number 209-78203 or equivalent to support the engine on the mounting stand. Failure to correctly support the engine may result in engine damage.
Mount the engine to a mounting stand. Remove the ratchet strap and the floor crane. Use the General Equipment: Mounting Stand Use the General Equipment: Floor Crane
- Remove Special Service Tool: 303-1518 Bracket, Engine Removal.
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- Disconnect the coolant hose assembly. Use the General Equipment: Hose Clamp Remover/Installer
- If equipped, disconnect the vacuum hose connector. Remove the coolant hose assembly.
- Loosen the clamp and remove the air cleaner outlet pipe.
- Remove the clip and the CAC pipe.
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- Disconnect the fan clutch electrical connector.
- Remove the fan clutch electrical connector bolt.
- Using the special tools, remove the fan clutch. Use Special Service Tool: 205-036 (T70P-4067-A) Wrench., 303-214 (T83T-6312-B) Wrench, Fan Clutch Nut.
- Remove the clip and disconnect the coolant hose.
- Remove the clip and the lower radiator hose.
- Remove the coolant engine fill hose. Use the General Equipment: Hose Clamp Remover/Installer
- If equipped with dual generators, remove the accessory drive belt.
- If equipped with single generator, remove the accessory drive belt.
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- Position back the boot and remove the nut.
- Disconnect the generator electrical connector.
- Disconnect the battery wire harness retainer from the bracket.
- Remove the bolts from the battery wire harness.
- Remove the LH ground bolt.
- Remove the clip and disconnect the heater hose.
- Disconnect the oil pressure switch and the oil temperature sensor electrical connectors.
- Remove the nut for the battery wire harness.
- Remove the RH ground bolt.
- Disconnect the A/C pressure switch electrical connector.
- Disconnect the A/C clutch electrical connector and the wire retainers.
- Remove the nut for the battery wire harness.
- Remove the nuts and the battery wire harness.
- Remove the bolts and the A/C compressor.
- Remove the bolt and the accessory drive belt tensioner.
- If equipped with dual generators, disconnect the wire harness retainer.
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NOTE: Dual generator shown, single generator similar.
Remove the bolts and the secondary coolant pump.
- Remove the bolts, lifting eye and the cooling fan drive assembly. Use Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.
- If equipped with dual generators, remove the idler pulley.
- Remove the bolts and the power steering pump mounting bracket.
- Disconnect the engine vacuum hose at the tee.
- Remove the nut, bolt and the transmission oil cooler coolant tube.
- Remove the stud bolt and the transmission oil cooler coolant tube.
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NOTE: Only one tube shown.
Remove and discard the transmission oil cooler coolant tube O-rings.
- Remove the stator standoffs.
- Remove the push pins and the RH sound shield.
- Remove the push pins and the LH sound shield.
- Remove the bolt and oil fill pipe.
- Remove and discard the O-ring seal.
- Remove the oil level indicator tube.
- Remove and discard the oil level indicator tube O-rings.
- Disconnect the retainer for the PCM wire harness.
- Disconnect the EGR valve electrical connector and the wire retainer.
- Disconnect the electrical connector and the vacuum hoses from the bypass valve solenoid. Detach the wire harness retainer.
- Remove the bolts and EGR cooler inlet pipe bracket. Discard the bolts.
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- Remove the bolts and the EGR cooler inlet pipe.
- Remove and discard the gaskets.
- Disconnect the EGRT electrical connector and wire retainers.
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- Remove the bolts and the EGR cooler outlet pipe.
- Remove and discard the gaskets.
- Remove the bolts and position aside the engine wire harness.
- Remove the bolts and the EGR cooler assembly.
- Remove and discard the EGR cooler gaskets.
- Disconnect the TB (throttle body) electrical connector.
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NOTE: The crankcase vent oil separator must be replaced whenever the crankcase vent oil separator hose is disconnected from the lower intake.
Cut the rubber sleeve cover and peel it back out of the way.
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- Release the crankcase vent oil separator outlet hose retainers, break the tabs as needed.
- Disconnect the crankcase vent oil separator outlet hose from the lower intake manifold.
- Remove the bolts and the lower intake manifold.
- Remove the CKP sensor cover.
- Disconnect the CKP sensor electrical connector and the wire retainer.
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- Remove the bolt and the ground strap.
- Disconnect the wire retainers.
- Disconnect the LH valve cover wiring.
- Disconnect the fuel pressure and temperature sensor electrical connector and the wire retainer.
- Disconnect the ECT sensor electrical connector and the wire retainer.
- Disconnect the CMP sensor electrical connector and the retainers.
- Disconnect the fuel volume control valve electrical connector.
- Disconnect the RH valve cover wiring.
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- Remove the bolt and disconnect the 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.
- Disconnect the fuel injection pump hose from the fuel rail. Refer to: Spring Lock Couplings
.
- Disconnect the fuel injector return hose and retainer from the fuel line. Remove the fuel injection pump supply tube. Refer to: Quick Release Coupling
.
- Remove and discard the fuel injection pump supply tube assembly bolts.
- Remove and discard the fuel injection pump supply tube assembly bolt.
- Remove the bolt and the fuel injection pump supply tube assembly. Discard the bolt.
- Remove and discard the O-ring seals.
- Remove the bolts and crankcase vent oil separator. Discard the crankcase vent oil separator.
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NOTE: Rotate the fuel filter counter clockwise to remove.
Remove and discard the secondary fuel filter.
- Remove the bolts and the secondary fuel filter bracket.
- Remove the turbocharger coolant tube. Use the General Equipment: Hose Clamp Remover/Installer
- Remove and discard the O-ring seal.
- Remove the bolts and heater supply tube.
- Remove and discard the O-ring seal.
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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 fuel injector return hose fittings from the fuel injectors.
- Disconnect and remove the fuel injector return hose and vacuum hose assembly from the retaining clips.
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NOTE: Only one shown.
Remove and discard the fuel injector supply tubes.
- Disconnect the fuel rail supply tube assembly from the LH fuel rail.
- Disconnect the fuel rail supply tube assembly from the RH fuel rail.
- Disconnect the fuel rail supply tube assembly at the high-pressure fuel injection pump.
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- Remove the bolts for the fuel rail supply tube assembly.
- Remove and discard the fuel rail supply tube assembly.
- Remove the bolts and the LH fuel rail.
- Remove the bolts and the RH fuel rail.
- Remove the bolts, thermostat housing and the thermostat.
- Remove the bolts and the coolant crossover manifold.
- Remove and discard the coolant crossover manifold gaskets.
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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 new bolts when installing the crankshaft pulley.
- Remove the bolts and the crankshaft pulley.
- Discard the bolts.
- Remove the bolts and the vacuum pump.
- Remove and discard the vacuum pump gasket.
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- Remove the bolts and the flexplate.
- Discard the bolts.
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NOTE: Do not use magnetic screwdrivers or other magnetic tools around the CKP sensor and the crankshaft sensor pulse ring or damage to the components may occur.
Remove the crankshaft sensor pulse ring.
- Remove the bolt and the CKP sensor.
- Remove the bolts and the LH exhaust manifold heat shield.
- Remove the bolts and the RH exhaust manifold heat shield.
- Remove and discard the exhaust manifold studs.
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NOTE: Mark the location of the spacers before removal.
- Remove the nuts, spacers and the LH exhaust manifold.
- Discard the nuts.
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NOTE: Cylinder number 8 will have longer studs.
Remove and discard the exhaust manifold gasket.
- Replace any exhaust manifold stud(s) that are damaged or removed with the nut.
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NOTE: Mark the location of the spacers before removal.
- Remove the nuts, spacers and the RH exhaust manifold.
- Discard the nuts.
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NOTE: Cylinder number 4 will have longer studs.
Remove and discard the exhaust manifold gasket.
- Replace any exhaust manifold stud(s) that are damaged or removed with the nut.
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NOTE: The fuel injector hold-down clamp bolts are torque-to-yield and cannot be reused.
- Remove and discard the fuel injector bolts.
- Remove the fuel injector hold-downs.
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NOTE: Mark the location of the fuel injector prior to removal.
- Install the special tool to the fuel injector and fully hand-tighten the special tool mounting bolt. Use Special Service Tool: 310-230 Remover, Fuel Injector.
- Install the push bolt and tighten to remove the fuel injector.
- Remove the special tool mounting bolt and the lower portion of the special tool. Remove the fuel injector.
- Remove and discard the O-rings and the copper combustion gasket.
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NOTE: Only one glow plug shown.
Remove the glow plugs.
- Remove the bolts, stud bolts and the LH valve cover.
- Remove and discard the valve cover gasket.
- Remove the bolts, stud bolts and the RH valve cover.
- Remove and discard the valve cover gasket.
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NOTE: Use the notch in the valve cover to aid in removing the fuel injector-to-valve cover seal.
Remove and discard the fuel injector-to-valve cover seals.
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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 until the LH oil spray bar can be removed.
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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 until the RH oil spray bar can be removed.
- Inspect the O-ring seals, replace if necessary.
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NOTE: Mark the location of the rocker arm assemblies prior to removing.NOTE: Only one cylinder shown.
Remove the rocker arm assemblies.
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NOTE: Do not disassemble the rocker arm assembly. They are serviced as an assembly only.
- Looking from the side of the rocker arm assembly, inspect each rocker arm ball for scuffing. Install new rocker arm assemblies as required.
- Inspect each rocker arm pivot foot and cup for pitting and scuffing. Install new rocker arm assemblies as required.
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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 push rods.
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- Inspect each push rod for wear and deposits which may restrict the flow of oil into the rocker arm assembly. Install a new push rod as needed.
- Inspect the ball end of the push rod, if the end does not have a polished look, replace the push rod.
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NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surfaceNOTE: The M12 cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
- Remove and discard the M12 bolts from the cylinder head. Remove the M8 cylinder head bolts.
- Remove the LH cylinder head.
- Remove and discard the LH cylinder head gasket and the cylinder head dowels.
- Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
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NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.NOTE: Clean the cylinder block bolt holes using compressed air. Make sure all coolant, oil or other foreign material is removed.
Clean and inspect the cylinder block mating surface.
- Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
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NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surfaceNOTE: The M12 cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
- Remove and discard the M12 bolts from the cylinder head. Remove the M8 cylinder head bolts.
- Remove the RH cylinder head.
- Remove and discard the RH cylinder head gasket and the cylinder head dowels.
- Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
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NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.NOTE: Clean the cylinder block bolt holes using compressed air. Make sure all coolant, oil or other foreign material is removed.
Clean and inspect the cylinder block mating surface.
- Check the cylinder block distortion. Refer to: Cylinder Block Distortion .
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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 valve tappet guides.
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NOTE: If installing a new short block, always install new valve tappets.NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.NOTE: Only one cylinder shown.
Remove the valve tappets from the engine.
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NOTE: To prevent engine damage, keep the hydraulic lash adjuster in the order in which they were removed. Install all hydraulic lash adjuster back in their original positions or engine damage may occur.
Inspect the valve tappet and the hydraulic lash adjuster for wear or damage. If any wear or damage is found, inspect the camshaft lobe for wear or damage. Replace components as necessary.
- Remove the bolts and the lower oil pan. Discard the lower oil pan.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .
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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. Use the General Equipment: Hose Clamp Remover/Installer
- Disconnect the hose retainers. Remove the oil cooler outlet hose. Use the General Equipment: Hose Clamp Remover/Installer
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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 bolts and the oil cooler assembly.
- Remove and discard the oil cooler gaskets.
- Remove the retainers and the oil filter adapter.
- Remove and discard the oil filter adapter gasket.
- Remove the bolts and the upper oil pan.
- Remove and discard the press-in-place gaskets.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .
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NOTE: Use extreme care when removing the slinger or damage to the engine front cover may occur.NOTE: It will be necessary to remove the slinger from the sides as well as the top and bottom.
Using 2 screwdrivers, carefully remove and discard the front crankshaft slinger.
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NOTE: Do not scratch or damage the crankshaft during removal or installation of the front crankshaft seal.NOTE: The Front Crank Seal Remover needs to be threaded in until it stops turning.
Using the special tool, remove and discard the front crankshaft seal. Use Special Service Tool: 303-1510 Remover, Front Crank Seal.
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NOTE: Use care when removing the engine front cover to not scratch the crankshaft sealing surface.NOTE: Mark the location of the engine front cover bolts prior to removing them.
- Remove the engine front cover bolts.
- Remove the engine front cover.
- Remove and discard the engine front cover gaskets.
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NOTE: Do not scratch or damage the crankshaft during removal or installation of the rear crankshaft seal.
Using the special tool, remove and discard the rear crankshaft seal. Use Special Service Tool: 303-1513 Remover, Rear Crank Seal.
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NOTE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.
Remove the bolts and the engine rear cover.
- Remove and discard the engine rear cover gasket.
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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.
Check the piston protrusion. Refer to: Piston Protrusion Check .
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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.
- Inspect the ridge.
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NOTE: Remove the carbon buildup, do not scratch the cylinder wall. Remove all debris from the cylinder.
Using a abrasive pad, remove the carbon ridge from the top of the cylinder bore.
- Using a feeler gauge, check the connecting rod side clearance. Refer to: Specifications .
Use the General Equipment: Feeler Gauge
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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 connecting rod bolts and connecting rod caps.
- Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.
- Remove and discard the connecting rod bearings.
- Using the special tool, check the high-pressure fuel injection pump drive gear backlash. Refer to: Specifications .
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
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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.
- Remove the high-pressure fuel injection pump drive gear nut.
- Remove the bolts and the fuel rail supply tube bracket.
- Remove the high-pressure fuel injection pump spacers.
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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.
Position the high-pressure fuel injection pump rearward until the gear contacts the cylinder block. Using a mallet, tap the high-pressure fuel injection pump shaft to free the gear from the pump. Remove the high-pressure fuel injection pump and drive gear.
- Remove and discard the O-ring seal
- Using the special tool, measure the camshaft gear backlash. Refer to: Specifications .
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Using the special tool, measure the camshaft end play. Refer to: Specifications .
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- Using the special tool, measure the crankshaft end play. Refer to: Specifications .
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
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NOTE: RH side shown, LH side similar.
Remove the crankshaft main bearing cap side bolts.
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- Remove the crankshaft main bearing cap bolts.
- Remove the crankshaft main bearing caps from the cylinder block.
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NOTE: Only the number 5 crankshaft main bearing cap has a thrust washer.
Remove and discard the lower crankshaft main bearing thrust washer. Remove and discard the lower crankshaft main bearings from the crankshaft main bearing caps.
- Remove the crankshaft from the cylinder block.
- Remove and discard the upper crankshaft main bearing thrust washers. Remove and discard the upper crankshaft main bearings from the cylinder block.
- Remove the bolt and camshaft gear.
- Remove the bolts and the camshaft thrust plate.
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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 special tools, remove the camshaft. Use Special Service Tool: 303-1517 Adapter, Camshaft Remover/Installer., 100-001 (T50T-100-A) Slide Hammer.
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NOTE: Only one piston cooling tube shown.
Remove the bolts and the piston cooling tubes.
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- Remove the high-pressure fuel injection pump mounting bolts.
- Inspect the front cover roll pin for wear or damage, replace if necessary.
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NOTE: Only pipe plug shown.
If necessary, remove the pipe plugs.
- If equipped, remove the block heater.
- Inspect the turbocharger alignment dowels for wear and damage, replace if necessary.
- Inspect the cylinder block zero clearance patch for wear or damage, replace if necessary.