6.0L Engine Removal PDF

303-01C-1 303-01C-1 Engine 6.
0L Diesel
REMOVAL
Removal
Engine
All vehicles
Special Tool(s)
Diesel Engine Lifting Bracket
1. With the vehicle in NEUTRAL, position it on a
(D83T-6000-B) 303-D043
hoist. For additional information, refer to
Section 100-02.
2. Disconnect the LH and RH battery ground
cables. For additional information, refer to
Section 414-01.
Fuel Line Tool
(T90T-9550-S) 310-S039
Vehicles with manual transmission
3. NOTE: On vehicles equipped with manual
transmissions, the transmission must be
removed before the engine can be removed.
Remove the transmission. For additional
Heavy Duty Floor Crane
information, refer to Section 308-03. 014-00071
4. Remove the clutch disc and pressure plate. For
additional information, refer to Section 308-01.
All vehicles
Adapter For 303-D043
5. Remove the cooling fan stator. For additional
303-D043-02
information, refer to Section 303-03.
6. Remove the air cleaner assembly. For additional
7. Remove the charge air cooler. For additional
Adapter For 303-D043
303-D043-01
Vehicles with A/C
8. Remove the A/C condenser assembly. For
additional information, refer to Section 412-03.
Wrench, Fan Clutch Nut
All vehicles
303-591
9. Remove the radiator grille opening panel
reinforcement. For additional information, refer
to Section 501-02.
10. Remove the front bumper.
Copyright 2004, Ford Motor Company
Last updated: 4/7/2005 2005 F-250, 350, 450, 550 Super Duty, 10/2004
303-01C-2 303-01C-2 Engine 6.0L Diesel
REMOVAL (Continued)
11. Loosen the clamps and disconnect the power 14. Disconnect the transmission cooler hoses.
steering cooler hoses.
Plug or cap the openings as needed.
15. Remove the bolts and the transmission oil
12. Disconnect the power steering tubes from the cooler.
retaining clip and position aside.
16. Remove the retaining nut and position the body
13. Remove the bolts and power steering cooler. feed cable aside.
2005 F-250, 350, 450, 550 Super Duty, 10/2004
REMOVAL (Continued)
17. Remove the bolts and upper radiator support. 21. Disconnect the powertrain control module
(PCM) electrical connectors.
18. Remove the intake manifold. For additional
information, refer to Intake Manifold in this 22. Disconnect the 12-pin and 8-pin electrical
section. connectors.
19. Remove the bolts and the battery tray.
23. Disconnect the camshaft position (CMP) sensor
electrical connector.
20. Disconnect the LH glow plug electrical
connector.
2005 F-250, 350, 450, 550 Super Duty, 10/2004
REMOVAL (Continued)
24. Disconnect the heater hose at the front cover.
28. Remove the power steering pump upper
mounting bolts.
25. Remove the lower radiator hose clamp and the
hose.
29. Remove the bolt and position the power
steering pump aside.
26. Remove the clips and disconnect the fuel lines.
For additional information, refer to Section
310-00.
27. NOTE: Only one standoff shown.
Remove the stator standoffs.
2005 F-250, 350, 450, 550 Super Duty, 10/2004
REMOVAL (Continued)
30. Remove the nut and the battery cable bracket.
34. Disconnect the RH glow plug electrical
connector.
31. Remove the ground stud and the ground cable.
Vehicles with A/C
32. NOTE: Only one retainer shown.
35. Disconnect the A/C high-pressure switch and Disconnect the wire retainers from the valve
the A/C clutch electrical connectors. cover studs.
33. Disconnect the injection control pressure (ICP)
sensor electrical connector and wiring retainer.
Disconnect the glow plug module electrical
connectors.
2005 F-250, 350, 450, 550 Super Duty, 10/2004
REMOVAL (Continued)
Vehicles with automatic transmission
36. Remove the retaining nut and disconnect the
A/C hose.
39. Remove the automatic transmission fluid
Remove and discard the O-ring seal.
indicator and tube.
All vehicles
37. Remove the A/C compressor.
40. Remove the ground strap at the back of the
right head.
All vehicles
38. Disconnect the crankshaft position (CKP) sensor
41. Remove the solenoid cap and disconnect the
electrical connector and position the wiring
starter wiring.
aside.
2005 F-250, 350, 450, 550 Super Duty, 10/2004
REMOVAL (Continued)
All vehicles
42. If equipped, disconnect the block heater
electrical connector.
46. NOTE: LH shown, RH similar.
NOTE: Use a half -moon wrench to aid in
accessing the fasteners.
Remove the bolts for the turbocharger adapter
pipe.
43. Position the block heater and starter wiring
harness aside.
44. Remove the torque converter cover.
47. NOTE: RH shown, LH similar.
Remove the motor mount nuts.
45. Remove and discard the torque converter nuts.
48. Drain the engine oil.
2005 F-250, 350, 450, 550 Super Duty, 10/2004
REMOVAL (Continued)
Late build vehicles
49. Loosen the nuts at the turbocharger adapter pipe
flange.
52. Remove the bolts and heat shield.
53. To remove the exhaust pressure sensor tube
50. Remove the nine bellhousing bolts. assembly, remove the exhaust pressure sensor
tube retaining nut and disconnect the exhaust
pressure sensor tube fitting at the exhaust
manifold.
All vehicles
51. NOTE: It may be necessary to separate the
All vehicles
pipe to remove it.
Remove the turbocharger adapter pipe.
54. Remove the nuts and the fuel injector control
module bracket.
2005 F-250, 350, 450, 550 Super Duty, 10/2004
REMOVAL (Continued)
55. Remove the left rear valve cover stud.
59. Install the engine lifting eye on the RH cylinder
head.
56. Remove the transmission cooler line bracket.
60. Install the front lifting brackets.
57. Secure the turbocharger outlet pipe.
58. Remove the manufacturers lifting eye.
61. Position a suitable jack under the transmission.
All vehicles
62. Install the Heavy Duty Floor Crane and Diesel
Engine Lifting Bracket on the engine.
2005 F-250, 350, 450, 550 Super Duty, 10/2004
REMOVAL (Continued)
63. Raise the engine high enough to clear the No. 1 64. Remove the engine lifting equipment from the
crossmember and pull the engine forward and engine.
clear of the vehicle.
2005 F-250, 350, 450, 550 Super Duty, 10/2004

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