Engine - 6.0l Diesel -- e350 & e450 Ford Cutaway E350

GENERAL SPECIFICATIONS

GENERAL SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

STANDARD TORQUE PIPE THREAD

STANDARD TORQUE PIPE THREAD

STANDARD TORQUES CLASS 10.9 METRIC BOLTS AND STUDS

STANDARD TORQUES CLASS 10.9 METRIC BOLTS AND STUDS

STANDARD TORQUES CLASS 12.9 METRIC BOLTS AND STUDS

STANDARD TORQUES CLASS 12.9 METRIC BOLTS AND STUDS

Engine Description

The 6.0L diesel engine is

1. a four-cycle turbocharged V-8 with overhead valves.
2. 6.0 liter (365 cubic inch) displacement.
3. separated into two banks, with the right bank numbered 1, 3, 5, 7 and the left bank numbered 2, 4, 6, 8.
4. rated at 235 horsepower and 440 lb-ft torque.

The cylinder block has been designed to withstand the loads of diesel operations by using

1. a two-piece crankcase.
2. internal piston cooling oil jets.
3. a forged steel crankshaft.
4. powdered metal, fractured connecting rods.

The pistons are

1. made of an aluminum alloy.
2. fitted with an upper keystone compression ring.
3. fitted with a lower rectangular compression ring.
4. fitted with oil control rings.

The piston pins are

1. a free-floating type, permitting the piston pin to move/float freely in the piston pin bore.
2. retained in the piston-by-piston pin retainers.

The camshaft is

1. supported by five insert-type camshaft bearings.
2. of the roller camshaft design.
3. driven by the crankshaft through the use of the crankshaft gear and the camshaft gear.

The hydraulic valve tappets

1. minimize engine noise.
2. maintain zero valve lash.
3. incorporate camshaft follower guides.
4. incorporate a roller follower design that reduces camshaft wear.

The cylinder heads are designed

1. to incorporate electrohydraulic fuel injectors.
2. to locate the fuel injectors in the center of the combustion chambers between the rocker arms.
3. with external high-pressure oil galleries.

The glow plug system is

1. designed to preheat the cylinders for faster cold weather starts and smoke reduction.
2. controlled by the powertrain control module (PCM) and glow plug control module.
3. mounted directly into the cylinder heads.

The optional block heater is

1. designed to heat the engine coolant and oil for improved cold weather starts.
2. located near the starter.
3. powered by a 120-volt external power source.
4. replaceable, but not repairable.

The fuel injection system used on the engine

1. is controlled by the powertrain control module (PCM) and fuel injector control module.
2. utilizes a frame mounted horizontal fuel conditioning module.
3. circulates fuel through a combination fuel filter, fuel heater and water separator assembly.
4. uses eight electrohydraulic fuel injectors.
5. has a secondary fuel filter mounted on the engine.
6. has a fuel pressure regulator mounted in the secondary fuel filter housing.

The engine lubrication system

1. is divided into two systems: the low-pressure system lubricates the engine, the high-pressure system actuates the fuel injectors.
2. is cooled by an engine oil cooler.
3. utilizes an engine oil pressure (EOP) sensor and an oil pressure regulator.

Scheme 797

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Scheme 801

The lubrication system is pressure regulated, cooled and full flow filtered. In addition to providing engine lubrication, it supplies oil to the high-pressure oil system to control fuel delivery in the fuel injectors.

The following sequence describes lube oil flow through the major oil system components

1. Oil pan (sump).
2. Oil pickup tube and screen.
3. The low pressure oil pump is a gerotor type contained in the front cover. The gerotor assembly consists of an outer and an inner gear. The inner gear is driven by the crankshaft. The pump inlet and outlet passages are through ports in the front cover. Oil pressure regulator (bypass) controls lube oil pressure via a spring-loaded plunger relieving oil back to the inlet of the pump once operating pressure has exceeded 517 kPa (75 psi).
4. The oil cooler cover receives oil from the oil pump and cools it in the oil cooler, which is located underneath the oil cooler housing. The cooler bypass valves open in the event that the oil cooler base and/or cooler becomes restricted.
5. The oil filter housing contains a paper type element. Unfiltered oil flows down and around the outside of the filter and then up through the center standpipe. The oil filter bypass allows oil to pass directly to the main oil gallery should the filter become restricted.
6. Turbocharger and drive gears. Cooled and filtered oil supplied from the oil cooler base lubricates the turbocharger bearings and provides hydraulic pressure for the variable geometry turbocharger control valve. Oil drains from the turbocharger through a drain tube back to the high-pressure hydraulic pump cover.
7. Main galleries. Cooled and filtered oil supplied from the oil cooler base fills the main galleries to distribute oil to the following components via passages machined within the crankcase. Hydraulic cam followers. Camshaft main journals. Crankshaft main journals. Connecting rod bearings receive pressurized oil from the main bearings via drilled passages within the crankshaft. Rocker arms receive lube oil from the hydraulic cam followers via the push rods. Oil drains back to the sump through holes located in the cylinder head. Piston cooling tubes.
8. High-pressure hydraulic pump oil reservoir. This reservoir (below oil cooler) has a constant supply of oil for the pressure hydraulic oil pump. It has an approximate capacity of 0.9 liter (0.95 quart).

Scheme 802

Note. Early build shown, late build similar.

The high pressure oil system is composed of two subsystems

1. Injection control pressure (ICP) system
2. Fuel injector assembly

The hydraulic force necessary to inject fuel into the combustion chamber is provided by the ICP system. The fuel injectors on the engine are hydraulically actuated and electronically controlled.

The ICP system is composed of the following components

1. Oil reservoir
2. Oil pump assembly (high pressure)
3. Oil pump cover
4. High-pressure tubes
5. High-pressure rail assemblies
6. Injection control pressure (ICP) sensor
7. Injection pressure regulator (IPR) valve
8. Check valves

The high-pressure oil pump receives engine lube oil from a reservoir cast into the vee of the crankcase. This reservoir makes available a constant supply of engine oil from the pump. This reservoir is constantly refilled by the low-pressure lube oil system with filtered oil from a passage in the oil cooler housing.

The high-pressure oil pump is mounted at the rear of the crankcase and is driven by the camshaft gear. Oil is drawn from the oil reservoir through a 200-micron screen and into a passage to the pump inlet port. High-pressure oil from the pump is distributed to the injectors through a series of tubes and manifolds.

The high-pressure discharge tube is mounted to the pump and serves to connect the oil flow from the high-pressure oil pump to the rear engine tube assembly. This tube assembly divides oil flow into two tubes or branches, one for each side of the engine. Rigid tubes in each branch direct oil up into the high-pressure oil rail of each cylinder head. Oil from the rails enters the injectors through O-ring sealed ports at the top of each injector. When the injector opening coil is energized, high-pressure oil is used to push fuel into the combustion chamber. After injection is complete, the oil inside the injector is vented through the top portion of the injector and allowed to drain back to the oil sump.

Special Tool(s)

SPECIAL TOOL Adapter, High Pressure Pump Test 303-765

Scheme 803

Powertrain Control/Emissions Diagnosis

For diagnosis and testing of the electronic engine control system, refer to INTRODUCTION -- 6.0L DIESEL .

Scheme 804

1. Verify the customer concern.
2. Visually inspect for obvious signs of damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. If the concern is not visually evident, check the base oil pressure.
5. Remove the engine oil temperature (EOT) sensor. Install the special tool. Tighten to 12 Nm (9 lb-ft).
6. Install a commercially available oil pressure gauge and check the base oil pressure. The minimum engine oil pressure specifications are 82.7 kPa (12 psi) at 700 rpm, 165.5 kPa (24 psi) at 1,200 rpm and 310.3 kPa (45 psi) at 1,800 rpm with the engine at operating temperature.
7. Remove the oil pressure gauge and special tool. Install the EOT sensor. Tighten to 12 Nm (9 lb-ft).
8. If the concern is not evident, verify the symptom. GO to «SYMPTOM CHART»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450__symptom-chart) .

Symptom Chart

ENGINE 6.0L SYMPTOM CHART

SPECIAL TOOL Pins, Piston Groove Gauge 303-D1169

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1. Clean the pistons with liquid soap and water.
2. Break the old compression rings in half, then use the compression rings to clean the piston ring groove areas of the piston.
3. Inspect the piston ring lands, skirts, oil ring slot corners and pin bosses for scoring, scuffing or cracks. Install a new piston if these types of damage appear.
4. Measure keystone piston ring groove wear. Select 2.08 mm (0.082 in) piston gauge pins. Install the gauge pins in the top groove. Using a micrometer, measure the distance between the gauge pins. Install a new piston if not within specification.
5. Measure the piston pin diameter in two directions at the points (Scheme 805) Verify the diameter is within specification. If out of specification, install a new piston pin.
6. Measure the outside diameter of the piston pin and the inside diameter of the piston pin bore. The difference between the two readings is the piston pin-to-bore clearance. Install a new piston pin or piston if not within specification.

Scheme 808

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1. Using a suitable solvent, thoroughly clean the connecting rod and rod cap.
2. Mark each connecting rod and its corresponding rod cap for correct installation.
3. Measure the inside diameter of the piston pin bushing. Install a new connecting rod, if not within specification.
4. Using a suitable micrometer, measure the connecting rod bearing bore. Remove the connecting rod bearings from the connecting rod and the connecting rod cap. Install the connecting rod cap onto the connecting rod and tighten the bolts. Further tighten the connecting rod cap bolts. Measure and record the connecting rod bearing bore as indicated. Install new connecting rods if not within specification.
5. Using a suitable micrometer, inspect the connecting rod bearing bore taper. Measure the bearing bore inside diameter near the large chamfer. Measure the bearing bore inside diameter near the small chamfer. The difference between the two readings is the bore taper. Install new connecting rods if not within specifications.

SPECIAL TOOL Feeler Gauge Set (D81L-4201-A) 303-D027

Scheme 811

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Scheme 813

1. Inspect the oil pump for excessive metal particles.
2. Inspect the oil pump for gouging, cracks or deep scratches.
3. Inspect the oil pump inner and outer gear rotors for damage or excessive wear.
4. Using a straightedge and the Feeler Gauge, measure the height clearance between the oil pump housing and the inner and outer rotors. If the measurement does not meet specifications, install new gerotors as a set.
5. Using the Feeler Gauge, measure the clearance between the outer rotor and the oil pump housing. If the measurement does not meet specifications, install new gerotors as a set.

Material

MATERIAL SPECIFICATION

Scheme 814

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Scheme 816

1. Disassemble the rocker arm from the fulcrum plate. With the rocker arm and fulcrum plate upside down in your palm, push down on the fulcrum plate. Using your palm, move the rocker arm away from the rocker arm ball and off of the fulcrum plate.
2. Move the rocker off the ball, keeping the ball in the detent of the fulcrum plate. Remove the rocker arm ball.
3. Remove and discard the rocker arm clip.
4. Clean all parts with a suitable solvent. Use filtered compressed air to dry the parts. Inspect each rocker arm pivot foot and corresponding valve bridge for pitting and scuffing. Inspect each rocker arm ball and socket for scuffing. Install new rocker arms and valve bridges as required. Inspect the rocker arm post ball socket for excessive wear. Inspect bolts for thread damage, install new components if worn or damaged.
5. Install a new rocker arm clip on the fulcrum plate.
6. Insert the ball in the detent in the fulcrum plate and lubricate with clean engine oil. Hold the rocker arm upside down in your palm.
7. Press the lower part of the rocker arm against the rocker arm clip, push up with your palm and push the upper part of the rocker arm over the rocker arm ball. Check for freedom of movement of the rocker arm on the fulcrum plate.

MATERIAL SPECIFICATION

Scheme 817

1. The most preferred cylinder block cleaning method is the "hot tank" method. All gallery plugs must be removed prior to hot tanking the cylinder block. If a hot tank is not available, soap and water is the approved alternative cleaning method.
2. Remove the gallery plugs. Remove the tappet oil gallery plugs. Remove the main oil gallery plug.
3. Apply a coating of High Strength Threadlocker to the gallery plugs and install.
4. Spray cylinder wall using Penetrating and Lock Lubricant.
5. Insert the hone into a cylinder and begin honing for three seconds at a cycle of two strokes per second. Remove the hone from the cylinder.
6. Wipe a section of the cylinder wall and inspect the Crosshatch pattern, comparing it to the neighboring (untouched) cylinder.
7. Repeat the honing process until the cylinder wall has a satin-like finish, or the maximum 25 strokes are achieved.
8. Clean and preserve the cylinder bores. Clean the cylinder bores using a mild soap and water. Dry the cylinder bores thoroughly using a clean, lint-free cloth. Soak a clean cloth in clean engine oil, and wipe the cylinder bores with the cloth. Drape a clean cloth over the cylinder block to keep contaminants out of the cylinder bores.

Inspection

1. Inspect the cylinder block for cracks not visible to the eye. Coat the suspected area with a mixture of 25 percent kerosene and 75 percent light engine oil. Wipe the area dry, and immediately apply a coating of zinc oxide dissolved in wood alcohol. If cracks are present, the coating will become discolored at the damaged area.

1. With valves installed to protect the valve seats, remove deposits and gasket material from the valve heads and gasket surface with a scraper and wire brush. Be careful not to damage cylinder head gasket surface.
2. Use a suitable solvent to remove dirt, grease and other deposits from the removed parts.
3. Clean all bolt holes and be sure gasket surfaces, oil return holes, and coolant passages are clean. After rinsing thoroughly with hot water, blow them out using filtered compressed air.
4. Wash all bolts (except head bolts, these must be replaced) with a suitable solvent and dry thoroughly.
5. Inspect the cylinder head for cracks, burned valves or seats and scratched or marred gasket mating surfaces.
6. Measure the cylinder head thickness. If the deck-to-deck measurements are not within specifications, install a new cylinder head.

MATERIAL SPECIFICATION

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Scheme 853

1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) . .
3. Remove the turbocharger pedestal. For additional information, refer to «FUEL CHARGING & CONTROLS - TURBOCHARGER»(/ford/cutaway-e350/2004-2007/remont/blowers-superchargers-turbochargers/#fuel-charging-system-turbocharger) .
4. Remove the accessory drive belt.
5. Remove the bolt and the accessory drive belt tensioner.
6. Remove the accessory drive belt.
7. Remove the bolts, bracket and accessory drive belt idler pulley.
8. Remove the bolts and the accessory drive belt tensioner.
9. Disconnect the generator electrical connector and the B+ wire.
10. Remove the bolts and the generator with mounting bracket.
11. Remove the accessory drive belt.
12. Remove the bolt and position the ground wire aside. Disconnect the electrical connector pushpin.
13. Remove the bolt and position the manifold absolute pressure (MAP) assembly aside. Disconnect the pushpin.
14. Remove the bolts and position the wiring aside.
15. Remove the bolts for the charge air cooler tube and oil fill tube.
16. Disconnect the oil fill tube at the valve cover.
17. Remove the retaining nuts, charge air cooler tube, oil fill tube and bracket.
18. Disconnect the generator electrical connector and the B+ wire. Disconnect the wiring pushpin.
19. Remove the retaining nut for the transmission fluid indicator and tube.
20. Disconnect the pushpin retainer. Remove the retaining nut and position the transmission fluid indicator and tube aside.
21. Remove the three bolts, ground wire and the generator.
22. Remove the bolts and position the heater hose tube aside. Remove and discard the O-ring seal.
23. Remove the retaining nut and disconnect the wiring retainer and the injection pressure regulator valve electrical connector.
24. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
25. Disconnect the engine oil pressure (EOP) sensor electrical connector.
26. Disconnect the engine oil temperature (EOT) sensor electrical connector.
27. Disconnect the pin-type retainer and engine coolant temperature (ECT) sensor.
28. Remove the ECT sensor. Plug or cap the opening as needed.
29. Disconnect the intake air temperature (IAT2) sensor electrical connector.
30. Remove the IAT2 sensor. Plug or cap the opening as needed.
31. Disconnect the eight fuel injector electrical connectors.
32. Disconnect the harness retainers. Position the engine wiring harness as needed for intake manifold removal.
33. Disconnect the manifold absolute pressure (MAP) sensor hose.
34. Disconnect the engine coolant vent hose.
35. Remove the secondary fuel filter and remove all fuel from the filter housing.
36. Disconnect the fuel tube fittings at the secondary fuel filter. Remove and discard the copper sealing washers.
37. Disconnect the fuel tube at the fuel filter housing. Remove the retaining nut.
38. Remove the RH banjo bolt and fuel tube. Discard the copper sealing washers.
39. Remove the bolts and the secondary fuel filter assembly.
40. If equipped, remove the nuts and turbocharger heat shield.
41. Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.
42. Remove the bolts and the intake manifold.
43. Remove the intake manifold gaskets. Clean and inspect the gaskets and front module O-ring seal. Install new gaskets or O-ring seal if necessary. Clean and inspect the sealing surfaces.

Scheme 854

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Scheme 872

1. Install the intake manifold gaskets and front module O-ring seal.
2. Install the intake manifold and bolts and tighten in the following sequence, in three stages: Stage 1: Loosely install bolts 1-8. Stage 2: Tighten bolts 9-16 to 11 Nm (8 lb-ft). Stage 3: Tighten all bolts to 11 Nm (8 lb-ft).
3. Slide the EGR cooler hose forward and rotate the flat to lock.
4. If equipped, install the turbocharger heat shield and nuts.
5. Install the secondary fuel filter assembly and bolts.
6. Install the RH fuel line and banjo bolt.
7. Install the retaining nut and connect the fuel tube at the fuel filter assembly.
8. Reposition and connect the fuel tubes at the fuel filter housing.
9. Install the secondary fuel filter and cover.
10. Connect the engine coolant vent hose.
11. Connect the MAP sensor hose.
12. Position back the engine wiring harness as needed. Connect the harness retainers.
13. Connect the eight fuel injector electrical connectors.
14. Remove the plug or cap. Install the IAT2 sensor.
15. Connect the IAT2 sensor electrical connector.
16. Remove the plug or cap. Install the ECT sensor.
17. Connect the ECT sensor electrical connector and the pin-type retainer.
18. Connect the EOT sensor electrical connector.
19. Connect the EOP sensor electrical connector.
20. Connect the EGR valve electrical connector.
21. Connect the injector pressure regulator valve electrical connector and position back the heat insulating wrap. Install the wiring retainer and retaining nut.
22. Install the heater tube and bolts.
23. Install the generator, ground wire and the three bolts.
24. Position back the transmission fluid indicator and tube and install the retaining nut. Connect the pushpin retainer.
25. Install the retaining nut for the transmission fluid indicator and tube.
26. Connect the generator B+ wire and electrical connector. Position back the boot. Connect the wiring pushpin.
27. Position the charge-air-cooler tube, oil fill tube and bracket. Install the retaining nuts.
28. Connect the oil fill tube at the valve cover.
29. Install the bolts for the charge-air-cooler tube and oil fill tube.
30. Position the conduit and install the bolts.
31. Connect the push pin. Position back the MAP sensor assembly and install the bolt.
32. Connect the electrical connector pushpin. Position back the ground wire and install the bolt.
33. Install the accessory drive belt.
34. Install the generator with mounting bracket and bolts.
35. Connect the generator B+ wire and electrical connector. Position the boot.
36. Install the accessory drive belt tensioner and bolts.
37. Position the accessory drive belt idler pulley. Install the bracket and bolts.
38. Install the accessory drive belt.
39. Install the accessory drive belt tensioner and bolt.
40. Install the accessory drive belt.
41. Install the turbocharger pedestal and turbocharger. For additional information, refer to «FUEL CHARGING & CONTROLS - TURBOCHARGER»(/ford/cutaway-e350/2004-2007/remont/blowers-superchargers-turbochargers/#fuel-charging-system-turbocharger) .
42. Install the cooling fan stator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
43. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .

SPECIAL TOOLS Heavy Duty Floor Crane 014-00071 Adapter for 303-D043 303-D043-01

Scheme 873

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Scheme 890

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
4. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
5. Remove the accessory drive belt.
6. Remove the bolt and the accessory drive belt tensioner.
7. Remove the accessory drive belt.
8. Remove the bolts, bracket and accessory drive belt idler pulley.
9. Remove the bolts and the accessory drive belt tensioner.
10. Disconnect the generator electrical connector and the B+ wire.
11. Remove the bolts and the generator with mounting bracket.
12. Remove the accessory drive belt.
13. Remove the LH fan stator stand-off.
14. Remove the 4 power steering pump bolts and position the power steering pump aside.
15. Install the engine lifting bracket.
16. Remove the turbocharger outlet clamp.
17. Loosen the retaining nuts and position the exhaust pipe aside.
18. Loosen the RH motor mount retaining nuts.
19. Loosen the four LH motor mount bolts.
20. Remove the LH motor mount retaining nuts.
21. Remove the removable stud.
22. Connect a suitable lifting crane and lifting chain to the engine lifting bracket and raise the engine as needed to remove the motor mount.
23. Remove the four bolts and the LH motor mount. Carefully lower the engine.
24. Remove the bolt and position the manifold absolute pressure (MAP) sensor aside.
25. Remove the bolts for the charge air cooler (CAC) pipe and oil fill tube.
26. Remove the retaining nut and disconnect the pushpin retainer for the transmission fluid indicator and tube.
27. Remove the retaining nut for the transmission fluid level indicator and tube. Position the tube aside.
28. Loosen the clamp at the turbocharger outlet hose. Disconnect the CAC pipe from the turbocharger.
29. Disconnect the oil fill tube at the valve cover.
30. Disconnect the injection control pressure (ICP) sensor electrical connector and wire retainers.
31. Remove the ICP sensor. Plug or cap the opening as needed.
32. Position the wiring away from the valve cover as needed.
33. Remove the 11 retainers and the valve cover. Clean and inspect the valve cover gasket.
34. Remove the high pressure oil rail-to-valve cover gasket.
35. To install, reverse the removal procedure. Tighten the top retaining nuts on the motor mount first.

Scheme 891

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
3. Remove the turbocharger inlet tube. For additional information, refer to «FUEL CHARGING & CONTROLS - TURBOCHARGER»(/ford/cutaway-e350/2004-2007/remont/blowers-superchargers-turbochargers/#fuel-charging-system-turbocharger) .
4. Loosen the clamps and remove the charge air cooler pipe.
5. Disconnect the oil level indicator and tube from the stator.
6. Disconnect the glow plug wire retainer. Remove the nut and position the oil level indicator and tube aside.
7. Disconnect the glow plug module electrical connectors.
8. Position back the boot and remove the nut. Disconnect the cables.
9. Disconnect the exhaust back pressure electrical connector and pushpin retainer.
10. Disconnect the exhaust back pressure tube at the exhaust manifold.
11. Remove the retaining nuts and glow plug module.
12. Remove the three retaining nuts and the glow plug module mounting bracket.
13. Remove the 11 retainers and the valve cover. Clean and inspect the valve cover gasket.
14. To install, reverse the removal procedure.

SPECIAL TOOLS Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent

Scheme 898

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Scheme 900

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
4. Remove the dual generator accessory drive belt.
5. Remove the bolts and the dual generator pulley.
6. Remove the accessory drive belt.
7. 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. NOTE: Pry the crankshaft forward only to eliminate possible error caused by crankshaft end play. Rotate the crankshaft 90 degrees. Pry the crankshaft forward. Record the measurement. Repeat at each unpainted surface. If the runout exceeds specification, install a new crankshaft vibration damper.
8. Remove the bolts and the crankshaft vibration damper. Discard the bolts.

Scheme 901

Scheme 902

1. Install the crankshaft vibration damper and bolts and tighten in the following sequence, in three stages: Stage 1: Tighten in the sequence shown. Stage 2: Tighten to 68 Nm (50 lb-ft). Stage 3: Tighten an additional 90 degrees.
2. Install the accessory drive belt.
3. Install the dual generator pulley and bolts.
4. Install the dual generator accessory drive belt.
5. Install the cooling fan stator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
6. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .

MATERIAL SPECIFICATION

Scheme 903

Scheme 904

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
3. Prior to removing the exhaust manifold, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and the cylinder head. Record the measurement and compare with the specifications.
4. Remove the LH bolts for the turbocharger adapter pipe.
5. Disconnect the exhaust back pressure tube.
6. Remove the bolts and the LH exhaust manifold.

Scheme 905

1. Install the LH exhaust manifold and bolts. Tighten the bolts in the sequence (Scheme 919)
2. Connect the exhaust back pressure tube at the exhaust manifold.
3. Install the LH bolts for the turbocharger adapter pipe.
4. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation).

MATERIAL REFERENCE

Scheme 906

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
4. Prior to removing the exhaust manifold, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and the cylinder head. Record the measurement and compare with the specifications.
5. Remove the RH bolts for the turbocharger adapter pipe.
6. Remove the bolts and the RH exhaust manifold.

Installation

1. Install the RH exhaust manifold and bolts. Tighten the bolts in the sequence (Scheme 922)
2. Install the RH bolts for the turbocharger adapter pipe.
3. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation).
4. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables).

MATERIAL SPECIFICATION

Scheme 907

Scheme 908

Scheme 909

Scheme 910

Scheme 911

1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
2. Remove the bolts and oil filter adapter. Clean and inspect the gasket. Install a new gasket if necessary. Clean and inspect the sealing surfaces.
3. Remove the bolts and the exhaust gas recirculation (EGR) cooler supply port cover. Clean and inspect the gasket. Install a new gasket if necessary. Clean and inspect the sealing surfaces.
4. Remove the bolts and the oil filter base. Clean and inspect the gasket. Install a new gasket if necessary. Clean and inspect the sealing surfaces.
5. Remove the bolts and the oil cooler assembly. Clean and inspect the gasket. Install a new gasket if necessary. Clean and inspect the sealing surfaces.
6. Remove the oil pump inlet strainer. Clean and inspect the strainer for tears or other signs of damage.

Scheme 912

Scheme 913

Scheme 914

Scheme 915

Scheme 916

1. Install the oil pump inlet strainer.
2. Install the gasket in the oil cooler assembly cover.
3. Install the oil cooler assembly and the bolts.
4. Install the gasket in the oil filter base.
5. Install the oil filter base and the bolts.
6. Install the seal on the EGR cooler coolant supply port cover.
7. Install the EGR cooler coolant supply port cover and the bolts.
8. Install the oil filter adapter and bolts.
9. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .

SPECIAL TOOLS Installer, Crankshaft Front Seal and Wear Ring 303-761 Remover, Crankshaft Front Wear Ring 303-762 Remover, Oil Seal 303-D060

Scheme 917

Scheme 918

MATERIAL SPECIFICATION

Scheme 919

Scheme 920

1. Remove the crankshaft vibration damper. For additional information, refer to «CRANKSHAFT PULLEY»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
2. Punch two holes in the seal.
3. Using the special tool, remove the crankshaft seal.
4. If equipped, using the special tool, remove the crankshaft damper wear sleeve.

1. Thoroughly clean the crankshaft front seal mounting surface.
2. Apply High Strength Threadlocker to the outer circumference of the leading edge of the crankshaft.
3. Using the special tool, install the oil seal and wear sleeve assembly.
4. Install the crankshaft damper. For additional information, refer to «CRANKSHAFT PULLEY»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .

SPECIAL TOOLS Lifting Attachment, Engine 303-D043 (D83T-6000-B) Heavy Duty Floor Crane 014-00071 Adapter for 303-D043 303-D043-01

Scheme 921

MATERIAL SPECIFICATION

Scheme 922

Scheme 923

Scheme 924

Scheme 925

Scheme 926

Scheme 927

Scheme 928

Scheme 929

Scheme 930

Scheme 931

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable, For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
4. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
5. Remove the A/C compressor. For additional information, refer to «AIR CONDITIONING»(/ford/cutaway-e350/2004-2007/remont/manual-hvac-system/#hvac-system-air-conditioning) .
6. Remove the power steering pump upper mounting bolts.
7. Remove the LH fan stator stand-off.
8. Remove the bolts and position the power steering pump aside.
9. Remove the oil pan drain plug.
10. Loosen the exhaust pipe retaining nuts.
11. Remove the motor mount retaining nuts.
12. Remove the RH fan stator stand-off. Remove the bolt and position the cable aside.
13. Install the special tools.
14. Install the engine lifting attachment and floor crane.
15. Raise the engine.
16. Remove the bolts and position back the oil pan until the oil pickup tube bolts are accessible.
17. Remove the bolts and let the oil pickup tube go into the oil pan. Remove the oil pan.
18. Remove and discard the oil pickup tube O-ring seal.
19. Remove the press-in-place gasket and discard. Clean and inspect the sealing surfaces.

Scheme 932

Scheme 933

Scheme 934

Scheme 935

Scheme 936

Scheme 937

Scheme 938

1. Install a new press-in-place gasket into the upper oil pan.
2. Install a new O-ring seal on the oil pickup tube and position the oil pickup tube in the oil pan.
3. Position the oil pan in the vehicle.
4. Install the oil pan pickup tube and bolts.
5. Install the oil pan and bolts. Install the longer oil pan bolts. Install the remaining oil pan bolts. Tighten to 13 Nm (10 lb-ft).
6. Lower the engine.
7. Remove the floor crane and engine lifting attachment.
8. Remove the special tools.
9. Position back the cable and install the bolt. Install the RH fan stator stand-off.
10. Install the motor mount retaining nuts.
11. Tighten the exhaust pipe retaining nuts.
12. Clean and inspect the oil pan drain plug and gasket. Install new, if necessary.
13. Install the oil drain plug.
14. Reposition the power steering pump and install the power steering pump bolts.
15. Install the LH fan stator stand-off.
16. Install the upper power steering mounting bolts.
17. Fill the engine with clean engine oil.
18. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
19. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
20. Install the A/C compressor. For additional information, refer to «AIR CONDITIONING»(/ford/cutaway-e350/2004-2007/remont/manual-hvac-system/#hvac-system-air-conditioning) .
21. Install the cooling fan stator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
22. Run the engine and check for leaks.

Scheme 939

1. Remove the lower oil pan. For additional information, refer to «OIL PAN - LOWER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
2. Remove the bolts and the upper oil pan. Remove and discard the press-in-place gasket. Clean and inspect the sealing surfaces.

1. Install the upper oil pan and bolts.
2. Install the lower oil pan. For additional information, refer to «OIL PAN - LOWER»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .

Scheme 940

1. Remove the crankshaft front oil seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
2. Remove the bolts and the gerotor cover. Remove and discard the O-ring seal.
3. Remove the inner and outer gerotors.
4. Inspect the oil pump components. Install new components, as necessary. Inspect the oil pump for excessive metal particles. Inspect the oil pump for gouges, cracks or deep scratches. Inspect the oil pump inner and outer gear rotors for damage or excessive wear.

1. Lubricate the inner gear with lithium assembly grease and install onto the crankshaft. Lubricate the outer gear with lithium assembly grease and mesh with the inner gear rotor in the oil pump housing. Wipe off the excess assembly grease.
2. Install the gerotor cover and bolts.
3. Install the crankshaft front oil seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .

SPECIAL TOOLS Installer, Crankshaft Rear Seal and Wear Ring 303-770 Remover, Crankshaft Rear Seal and Wear Ring 303-771 Slide Hammer 100-001 (T50T-100-A)

Scheme 941

Scheme 942

MATERIAL SPECIFICATION

Scheme 943

Scheme 944

1. Remove the transmission. For additional information, refer to «TRANSAXLE/TRANSMISSION - TORQSHIFT»(/ford/cutaway-e350/2004-2007/remont/automatic-trans/#automatic-transmission-5r110w-torqshiftr).
2. Remove the bolts and flexplate. Discard the bolts.
3. Remove the flywheel front adapter.
4. Using the appropriate drill bit, drill a hole on the RH side of the seal and another directly across from it on the LH side of the seal see scheme 216
5. Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.
6. If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
7. Clean and inspect the crankshaft sealing surface.

Scheme 945

Scheme 946

Scheme 947

1. Apply a bead of High Strength Threadlocker around the circumference of the outer rear edge of the secondary crankshaft flange.
2. Using the special tool, install the crankshaft rear oil seal.
3. Install the flywheel front adapter.
4. Install the flexplate and new bolts. Snug to 5 Nm (44 lb-in). Tighten to 94 Nm (69 lb-ft) in the sequence (Scheme 964)
5. Install the transmission. For additional information, refer to «TRANSAXLE/TRANSMISSION - TORQSHIFT»(/ford/cutaway-e350/2004-2007/remont/automatic-trans/#automatic-transmission-5r110w-torqshiftr).

MATERIAL SPECIFICATION

Scheme 948

Scheme 949

Scheme 950

Scheme 951

Scheme 952

Scheme 953

Scheme 954

1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
2. Remove the retaining nut and position the fuel line retaining bracket aside.
3. Remove the stud bolts and the thermostat housing. Remove and discard the O-ring seal.
4. Remove the bolts and the accessory drive idler pulleys.
5. Disconnect the engine coolant fill hose from the retaining clip. Loosen the clamp and remove the engine coolant fill hose.
6. Remove the power steering pump upper mounting bolts.
7. Remove the LH fan stator stand-off.
8. Remove the power steering pump bolts and position aside.
9. Disconnect the lower radiator hose.
10. Remove the bolts and the accessory drive belt tensioner.
11. Remove the coolant pump pulley.
12. Remove the bolts and the coolant pump. Remove and discard the O-ring seal.
13. Remove the oil pump. For additional information, refer to «OIL PUMP»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
14. Remove the bolts and the front cover.
15. Use a thin blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove and discard the front cover gasket. Clean and inspect the sealing surfaces.

Scheme 955

Scheme 956

Scheme 957

Scheme 958

Scheme 959

Scheme 960

Scheme 961

1. If removed, install the front cover crankcase dowels into the cylinder block.
2. Install the guide studs.
3. Apply a bead of sealant at the seam where the crankcase and the lower crankcase meet.
4. Install a new engine front cover gasket.
5. Install the engine front cover and bolts.
6. Install the oil pump. For additional information, refer to «OIL PUMP»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
7. If removed, install the coolant pump and bolts.
8. If removed, install the coolant pump pulley and bolts.
9. Install the accessory drive belt tensioner and bolts.
10. Install the lower radiator coolant hose.
11. Position the power steering pump and install the bolts.
12. Install the LH fan stator stand-off.
13. Install the power steering pump upper mounting bolts.
14. Install the engine coolant fill hose and tighten the clamp. Connect the engine fill hose into the retaining clip.
15. Install the accessory drive idler pulleys and bolts, as needed.
16. If removed, install the thermostat housing and stud bolts.
17. Position back the fuel line retaining bracket and install the retaining nut.
18. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .

SPECIAL TOOLS Installer, Crankshaft Rear Seal and Wear Ring 303-770 Remover, Crankcase Rear Seal and Wear Sleeve 303-771 Slide Hammer 100-001

MATERIAL SPECIFICATIONS

Scheme 962

Scheme 963

1. Remove the starter. For additional information, refer to «STARTING SYSTEM - DIESEL ENGINE»(/ford/cutaway-e350/2004-2007/remont/starter/#starting-system-diesel-engine-e350-e450).
2. Remove the transmission. For additional information, refer to «TRANSAXLE/TRANSMISSION - TORQSHIFT»(/ford/cutaway-e350/2004-2007/remont/automatic-trans/#automatic-transmission-5r110w-torqshiftr).
3. Remove the bolts and the flexplate. Discard the bolts.
4. Remove the flywheel front adapter.
5. Using the appropriate drill bit, drill a hole on the RH side of the seal and another directly across from it on the LH side of the seal (Scheme 972)
6. Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.
7. If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
8. Clean and inspect the crankshaft sealing surface.
9. Remove the bolts and the turbocharger heat shield.
10. Remove the 11 bolts from the rear engine cover.
11. Using a thin-blade scraper, cut the sealant at the oil pump cover joint.
12. Using a thin-blade scraper, cut the sealant where the crankcase and the lower crankcase meet.
13. Using a thin-blade scraper, cut the sealant where the crankcase and the lower crankcase meet. Remove the rear cover. Remove and discard the press-in-place gasket. Clean and inspect the sealing surfaces.

Scheme 964

Scheme 965

Scheme 966

Scheme 967

1. Apply a bead of sealant at the back seam of the upper and lower crankcase.
2. Apply a bead of sealant at the oil pump cover joint.
3. Install the rear engine cover. Install the press in place gasket. Install the rear engine cover. Install the bolts.
4. Install the turbocharger heat shield and bolts.
5. Using the special tool, install the crankshaft rear oil seal.
6. Install the front flywheel adapter.
7. Install the flexplate and install the new bolts. Tighten to 5 Nm (44 lb-in). Tighten to 94 Nm (69 lb-ft) in the sequence (Scheme 985)
8. Install the transmission. For additional information, refer to «TRANSAXLE/TRANSMISSION - TORQSHIFT»(/ford/cutaway-e350/2004-2007/remont/automatic-trans/#automatic-transmission-5r110w-torqshiftr).
9. Install the starter. For additional information, refer to «STARTING SYSTEM - DIESEL ENGINE»(/ford/cutaway-e350/2004-2007/remont/starter/#starting-system-diesel-engine-e350-e450).

SPECIAL TOOLS Lifting Attachment, Engine 303-D043 (D83T-6000-B) or equivalent Heavy Duty Floor Crane 014-00071 Adapter for 303-D043 303-D043-01

Scheme 968

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
4. Remove the A/C compressor. For additional information, refer to «HEATING & VENTILATION»(/ford/cutaway-e350/2004-2007/remont/heater/#hvac-system-heating-ventilation) .
5. Remove the power steering pump upper mounting bolt.
6. Remove the LH fan stator stand-off.
7. Remove the bolts and position the power steering pump aside.
8. Remove the RH fan stator stand off. Remove the bolt and position the cable aside.
9. Loosen the exhaust pipe retaining nuts.
10. Remove the motor mount retaining nuts.
11. Remove the upper motor mount studs.
12. Loosen the four motor mount bolts for each motor mount.
13. Install the special tools.
14. Install the lifting attachment and lifting crane.
15. Raise the engine.
16. Remove the bolts and the motor mounts.

1. Install the motor mounts and loosely install the bolts.
2. Lower the engine.
3. Remove the lifting attachment and lifting crane.
4. Remove the special tools.
5. Install the upper motor mount studs.
6. Tighten the motor mount bolts.
7. Install the motor mount retaining nuts.
8. Tighten the exhaust pipe retaining nuts.
9. Position back the cable and install the bolt. Install the RH fan stator stand-off.
10. Position the power steering pump and install the bolts.
11. Install the LH fan stator stand-off.
12. Install the upper power steering bolts.
13. Install the A/C compressor. For additional information, refer to «HEATING & VENTILATION»(/ford/cutaway-e350/2004-2007/remont/heater/#hvac-system-heating-ventilation) .
14. Install the cooling fan stator and radiator. For additional information, refer to «ENGINE COOLING»(/ford/cutaway-e350/2004-2007/remont/cooling-system-mechanical/#engine-cooling) .
15. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .

SPECIAL TOOLS Service Tool, Rocker Arm 303-1170 Release Tool, Injector Connector 303-1115

Scheme 969

MATERIAL SPECIFICATION

Scheme 970

Scheme 971

Scheme 972

Scheme 973

Scheme 974

Scheme 975

Scheme 976

Scheme 977

Scheme 978

Scheme 979

1. Remove the engine from the vehicle. For additional information, refer to «ENGINE»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
2. Remove the RH stud bolts, bolts and valve cover. Clean and inspect the valve cover gasket, replace if necessary.
3. Remove the RH high-pressure oil rail-to-valve cover gasket.
4. If replacing rocker arms on the LH side, remove the protective covering from the LH cylinder head.
5. Locate the dowel hole in the vibration damper. The hole is located between two of the four bolts that attach the damper to the front of the crankshaft.
6. Rotate the crankshaft until the dowel hole is at the 12 o'clock position. The No. 1 piston should be on the compression stroke. Wiggle the rocker on the No. 1 cylinder to verify both intake and exhaust rocker arms are able to move freely. If the intake and exhaust rocker arms do not move freely, rotate the crankshaft one complete revolution. You are now positioned to service the rocker arms for cylinders 1, 2, 7 and 8.
7. If required, skip Step 8 and complete the rest of the procedure, for rocker arms on cylinders 1, 2, 7 and 8.
8. If you are not servicing cylinders 1, 2, 7 and 8 or if service to those cylinders has been completed, rotate the crankshaft one complete revolution to service the rocker arms for cylinders 3, 4, 5 and 6. Complete the rest of this procedure for rocker arms on cylinders 3, 4, 5 and 6.
9. Remove the crankcase-to-head tube. Remove and discard the D-ring seals.
10. Remove the bolts and the high-pressure oil rail.
11. If the crankcase-to-head tube separated, using a pair of soft-jawed pliers, remove the lower crankcase-to-head tube. Remove and discard the D-ring seal.
12. Remove the crankcase-to-head tube assembly. Remove and discard the D-ring seals. All vehicles
13. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
14. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
15. Remove the bolt, the fuel injector hold-down and the fuel injector.
16. Insert the injector hold-down clamp into the special tool base.
17. Install the assembly in between the bridges as if you are installing an injector.
18. Install the special tool plate on top of the bridges with the small point of the plate in between the exhaust rocker and bridge. Install the special tool bolt and compress the valve springs until the plate contacts the top of the tool base.
19. Disengage the rocker arm from the push rod. Then rotate the rocker arm out while compressing down on the rocker arm retaining clip. Remove and discard the rocker arm retaining clip. Repeat the step for the other rocker arm.
20. Remove the push rod. Inspect each push rod for wear and deposits which may restrict the flow of oil into the rocker arm assembly, replace as necessary. Check the push rod for flatness by rolling them on a flat surface if not within specification, replace as necessary.
21. With the rocker arms removed, remove the special tool bolt and the special tool plate to gain access to the valve bridges.
22. Remove and discard the valve bridges.

Scheme 980

Scheme 981

Scheme 982

Scheme 983

Scheme 984

Scheme 985

1. Install new O-ring seals on the crankcase-to-head tube assemblies.
2. Install the new valve bridges.
3. Install the special tool plate and bolt. Tighten the bolt until the plate contacts the top of the tool base.
4. Apply clean engine oil to each end of the push rods. Insert them into their respective positions with the copper-colored end up.
5. Place a dab of multi-purpose grease in the fulcrum socket to hold the ball in place while installing the rocker arms.
6. Insert the rocker arm under the fulcrum and ball, rotate the rocker arm into place and position onto the push rod. Install a new rocker arm retaining clip. Repeat the step for the other rocker arm.
7. Remove the special tool bolt and plate. Make sure the rocker arms remain in place and the fulcrum ball has not fallen out.
8. Remove the shop towels.
9. Remove the injector hold-down and special tool base.
10. Install new O-ring seals and copper washer on the fuel injector.
11. Install the fuel injector, the fuel injector hold-down and bolt.
12. Install the fuel injector electrical connector into the rocker arm carrier.
13. Apply clean engine oil and install the crankcase-to-head tube assembly.
14. Position the high-pressure oil rail on the injectors. Place the high-pressure oil rail on top of the carrier so that the four single ball tubes are engaging the fuel injector lead angle. Insert three guide bolts, two on the ends of the straight side of the high-pressure oil rail and one in the middle of the wavy side of the high pressure oil rail. Install the guide studs six to seven turns. Press the high-pressure oil rail into the fuel injectors. Inspect that the high-pressure oil rail mounting feet are flat against the mounting surface. Loosely install the six bolts.
15. Install the remaining bolts and tighten. Remove the three guide bolts. Loosely install the three remaining bolts. Tighten the nine bolts in the sequence (Scheme 1023)
16. Apply clean engine oil and install the crankcase-to-head tube.
17. If removed, cover the LH cylinder head with an appropriate covering.
18. Install the RH high-pressure oil rail-to-valve cover gasket.
19. Position the RH valve cover gasket. Install the RH valve cover, stud bolts and bolts.
20. Install the engine in the vehicle. For additional information, refer to «Engine»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450).

SPECIAL TOOLS Lifting Attachment, Engine 303-D043 (D83T-6000-B) or equivalent Heavy Duty Floor Crane 014-00071 Adapter for 303-D043 303-D043-02 or equivalent Disconnect Tool, Transmission Cooler Line 307-459 Adapter for 303-D043 303-D043-01 or equivalent Wrench, Fan Clutch Nut 303-591

Scheme 986

MATERIAL SPECIFICATION

Scheme 987

Scheme 988

Scheme 989

Scheme 990

Scheme 991

Scheme 992

Scheme 993

Scheme 994

Scheme 995

Scheme 996

Scheme 997

Scheme 998

Scheme 999

Scheme 1000

Scheme 1001

Scheme 1002

Scheme 1003

Scheme 1004

Scheme 1005

Scheme 1006

Scheme 1007

Scheme 1008

Scheme 1009

Scheme 1010

Scheme 1011

Scheme 1012

Scheme 1013

Scheme 1014

Scheme 1015

Scheme 1016

Scheme 1017

Scheme 1018

Scheme 1019

Scheme 1020

Scheme 1021

Scheme 1022

Scheme 1023

Scheme 1024

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
3. Remove the A/C condenser assembly. For additional information, refer to «AIR CONDITIONING»(/ford/cutaway-e350/2004-2007/remont/manual-hvac-system/#hvac-system-air-conditioning) .
4. Remove the front bumper. For additional information, refer to «BUMPERS»(/ford/cutaway-e350/2004-2007/remont/exterior-body-panels/#bumpers) .
5. Remove the radiator grille support. For additional information, refer to «FRONT END BODY PANELS»(/ford/cutaway-e350/2004-2007/remont/exterior-body-panels/#body-panel-system-front-end-body-panels) .
6. Remove the bolts, disconnect and remove the air bag sensor. Position the headlamp wiring harness aside.
7. Remove the bolts and hood latch.
8. Remove the eight bolts and the upper radiator support.
9. Remove the 12 bolts and lower radiator support.
10. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
11. Remove the RH fan stator stand-off. Remove the bolt and position the cable aside.
12. Disconnect the A/C electrical connector.
13. Disconnect the A/C pressure switch and remove the A/C manifold from the tee block. Remove and discard the O-ring seals. Cap or plug the A/C openings as needed.
14. Remove the bolts and A/C compressor.
15. Disconnect the heater hose. Position the heater hose and tube aside.
16. Remove the bolt and idler pulley.
17. Disconnect the engine coolant fill hose from the retaining clip. Loosen the clamp and remove the engine coolant fill hose.
18. Disconnect the vacuum pump hose and remove the engine coolant fill hose clip.
19. Remove the bolts and the vacuum pump.
20. Remove the power steering upper mounting bolts.
21. Remove the LH fan stator stand-off.
22. Remove the bolts and position the power steering pump aside.
23. Remove the lower radiator hose.
24. Disconnect the fuel lines. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/fuel-system/#fuel-system-general-information) .
25. Disconnect the crankshaft position (CKP) sensor electrical connector and retaining clips.
26. Disconnect the injection control pressure (ICP) sensor electrical connector. Disconnect the glow plug electrical connector and wire retainers.
27. Disconnect the camshaft position (CMP) sensor electrical connector and retaining clips.
28. Disconnect the electrical connector and wire retainers at the transmission.
29. Disconnect the glow plug module electrical connectors.
30. If equipped, position back the boot and disconnect the B+ wire.
31. Disconnect the exhaust back pressure sensor electrical connector and pushpin retainer.
32. Disconnect the LH glow plug electrical connector.
33. Disconnect the two engine-to-vehicle electrical connectors.
34. Disconnect the two powertrain control module (PCM) electrical connectors and position the engine wiring harness aside.
35. Remove the bolts and the oil filter assembly.
36. Remove the retaining nut and remove the transmission cooling tubes off the stud.
37. Remove the retaining clips from the transmission tubes.
38. Using the special tool, disconnect transmission cooler tubes.
39. Remove the torque converter cover.
40. Remove and discard the torque converter nuts.
41. Disconnect the block heater electrical connector.
42. Remove the retaining nut. Disconnect the battery cable bracket at the starter and position aside.
43. Remove the starter solenoid protective cap.
44. Disconnect the starter motor electrical connections.
45. Remove the bolts and the starter motor.
46. Remove the cylinder block drain plugs and drain the coolant from the block.
47. Install the cylinder block drain plugs.
48. Remove the motor mount nuts.
49. Remove the lower engine-to-transmission bolts.
50. Remove the mounting bolts from the lifting bracket and remove the tubes.
51. Disconnect the glow plug wire retainer. Remove the retaining nut and the oil indicator and tube. Remove and discard the O-ring seal.
52. Disconnect the exhaust back pressure tube at the exhaust manifold.
53. Remove the retaining nuts and glow plug module.
54. Remove the retaining nuts and the glow plug module mounting bracket.
55. Remove the bolts and the LH valve cover. Remove the valve cover gasket. Cover the cylinder head after the valve cover is removed.
56. Remove the ICP sensor. Plug or cap the opening as needed.
57. Install the special tools.
58. Remove the turbocharger exhaust pipe.
59. Remove the factory-installed engine lifting bracket.
60. Install the special tool.
61. Install the engine lifting attachment and lifting crane.
62. Remove the oil pan drain plug and drain the engine oil.
63. Remove the bolts and position back the oil pan until the oil pickup tube bolts are accessible.
64. Remove the bolts and let the oil pickup tube go into the oil pan. Remove the oil pan.
65. Remove the press-in-place gasket and discard.
66. Remove and discard the oil pickup tube O-ring seal.
67. Position a suitable transmission jack under the transmission.
68. Remove the upper engine-to-transmission bolts.
69. Raise the engine. Remove the four bolts and LH motor mount.
70. Remove the bolts and the RH motor mount.
71. Remove the engine from the vehicle.

SPECIAL TOOLS Lifting Bracket, Cylinder Head 303-759 Heavy Duty Floor Crane 014-00071 Adapter for 303-D043 303-D043-01 Adapter for 303-D043 303-D043-02 Remover/Installer, Glow Plug Connector 303-1114 Release Tool, Injector Connector 303-1115

Scheme 1025

MATERIAL SPECIFICATION

Scheme 1026

Scheme 1027

Scheme 1028

Scheme 1029

Scheme 1030

Scheme 1031

Scheme 1032

Scheme 1033

1. Remove the engine. For additional information, refer to «Engine»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
2. Remove the bolts and flexplate. Discard the bolts.
3. Mount the engine on an engine stand.
4. Remove the rear lifting eye adapter.
5. Remove the special tools.
6. Using the special tool, remove the glow plug harness.
7. Remove the eight glow plugs.
8. Prior to removing the exhaust manifolds, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and cylinder head. Record the measurement and compare with the specification.
9. Remove the bolts and the exhaust manifolds.
10. Remove the left cylinder head banjo fitting and fuel line. Discard the sealing washers.
11. Remove the bolts and turbocharger heat shield.
12. Remove the protective covering from the LH cylinder head.
13. Remove the RH valve cover. Remove the stud bolts, bolts and valve cover. Clean and inspect the gaskets. Install a new gasket if necessary. Clean and inspect the sealing surfaces.
14. Remove the RH high-pressure oil rail-to-valve cover gasket.
15. If equipped with a two-piece tube, remove the crankcase-to-head tube assembly. Remove and discard the D-ring seals.
16. Remove the bolts and the high-pressure oil rail.
17. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
18. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
19. Remove the bolt, the fuel injector hold down and the fuel injector.
20. Remove the shop towels.
21. Remove the crankcase-to-head tube assembly. Remove and discard the D-ring seals.
22. If the crankcase-to-head tube separated, using a pair of soft-jawed pliers, remove the lower crankcase-to-head tube. Remove and discard the D-ring seal.
23. Remove and discard the 20 inner cylinder head bolts.
24. Remove the 16 bolts and the rocker arm assemblies.
25. Remove the bolts and rocker arm carrier. Clean and inspect the gasket. Install new gaskets if necessary. Clean and inspect the sealing surfaces.
26. Mark the 16 valve bridges with a permanent marker and remove.
27. Mark the location and remove the 16 push rods.
28. Remove the outer cylinder head bolts.
29. Remove the cylinder heads. Install the special tool. Install the bolts. Remove the cylinder head.
30. Remove and discard the cylinder head gasket and dowels. Clean and inspect the gasket sealing surfaces.

SPECIAL TOOLS Lifting Bracket, Cylinder Head 303-759 Remover, Crankshaft Front Wear Ring 303-762 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Adapter for 303-D043 303-D043 Adapter for 303-D043 303-D043 Remover, Oil Seal 303-D060 (D86-6701-B) Heavy Duty Floor Crane 014-00072 Service Set, Camshaft 303-017 (T65L-6250-A) or equivalent Remover, Crankshaft Rear Wear Ring 303-771 Slide Hammer 100-001 (T50T-100-A) Remover/Installer, Glow Plug Connector 303-1114 Socket, Injection Pressure Regulator (IPR) Valve 303-1112 Release Tool, Injector Connector 303-1115 Disconnect Tool, Quick Release Tool 303-755

Scheme 1034

Scheme 1035

Scheme 1036

MATERIAL SPECIFICATION

Scheme 1037

Scheme 1038

Scheme 1039

Scheme 1040

Scheme 1041

Scheme 1042

Scheme 1043

Scheme 1044

Scheme 1045

Scheme 1046

Scheme 1047

Scheme 1048

Scheme 1049

Scheme 1050

Scheme 1051

Scheme 1052

Scheme 1053

Scheme 1054

Scheme 1055

Scheme 1056

Scheme 1057

Scheme 1058

Scheme 1059

Scheme 1060

Scheme 1061

Scheme 1062

Scheme 1063

Scheme 1064

Scheme 1065

Scheme 1066

Scheme 1067

Scheme 1068

Scheme 1069

1. Remove the bolts and the flexplate. Discard the bolts.
2. Mount the engine on an engine stand.
3. Remove the rear lifting eye adapter.
4. Remove the special tools.
5. Remove the bolts and RH motor mount plate.
6. Remove the retaining nut and position the fuel line bracket aside.
7. Remove the stud bolts and thermostat housing. Remove and discard the O-ring seal.
8. Remove the left cylinder head banjo fitting and fuel line. Discard the sealing washers.
9. Remove the bolt and serpentine belt idler.
10. If equipped, remove the bolts and serpentine belt tensioner.
11. Remove the bolts and oil filter adapter.
12. Remove and discard the O-ring seals from the oil filter base.
13. Remove the exhaust gas recirculation (EGR) cooler coolant supply port cover. Remove the bolts. Clean and inspect the gaskets. Install new gaskets if necessary. Clean and inspect the sealing surfaces.
14. Remove the oil filter base. Remove the bolts. Clean and inspect the gaskets. Install new gaskets if necessary. Clean and inspect the sealing surfaces.
15. Remove the oil cooler assembly. Remove the bolts. Clean and inspect the gaskets. Install a new gasket, if necessary. Clean and inspect the sealing surfaces.
16. Remove the oil pump inlet strainer. Clean and inspect for tears and other damage.
17. Remove the bolts and the turbocharger heat shield.
18. Unsnap and remove the heat insulating wrap.
19. Using the special tool, remove the injection pressure regulator (IPR) valve.
20. Remove the eight bolts from the high-pressure oil pump cover.
21. Use a thin gasket scraper to separate the cover from the crankcase at the rear cover seam.
22. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
23. Loosen the bolts on the high-pressure tube assembly.
24. Remove the bolts and the high-pressure oil pump.
25. Remove and discard the lower O-ring seals.
26. Using the special tool, disconnect and remove the high-pressure tube assembly.
27. Remove and discard the high-pressure oil pump O-ring seal.
28. Using the special tool, remove the glow plug harness.
29. Remove the eight glow plugs.
30. Remove the protective covering from the LH cylinder head.
31. Remove the RH valve cover. Remove the stud bolts, bolts and valve cover. Clean and inspect the gaskets. Install a new gasket, if necessary. Clean and inspect the sealing surfaces.
32. Remove the RH high-pressure oil rail-to-valve cover gasket.
33. Remove the bolts and the coolant pump pulley.
34. Remove the coolant pump. Remove the bolts. Remove and discard the O-ring seal.
35. If equipped, remove the bolts and the dual generator pulley.
36. 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. NOTE: Pry the crankshaft forward at the same point to eliminate possible error caused by crankshaft end play. Rotate the crankshaft 90 degrees. Pry the crankshaft forward. Record the measurement. Repeat at each unpainted surface. If the runout exceeds specification, install a new crankshaft vibration damper.
37. Remove the bolts and the crankcase vibration damper. Discard the bolts.
38. Punch two holes in the seal.
39. Using the special tool, remove the crankshaft seal.
40. If equipped, remove the crankshaft seal wear sleeve with the special tool.
41. Remove the oil pump body. Remove the bolts. Remove and discard the O-ring seal.
42. Remove the inner and outer oil pump drive rotors.
43. Remove the bolts and engine front cover.
44. Use a thin-blade scraper to cut the sealant where the crankcase and the lower crankcase meet. Remove and discard the front cover gasket.
45. Remove the flywheel adapter.
46. Using the appropriate drill bit, drill a hole on the RH side of the seal and another directly across from it on the LH side of the seal, as shown.
47. Using the special tool and a commercially available body dent puller attachment, remove and discard the rear main seal.
48. If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
49. Clean and inspect the crankshaft sealing surface.
50. Remove the 11 bolts from the rear engine cover.
51. Using a thin-blade scraper, cut the sealant where the crankcase and the lower crankcase meet.
52. Using a thin-blade scraper, cut the sealant where the crankcase and the lower crankcase meet.
53. Prior to removing the exhaust manifolds, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and cylinder head. Record the measurement and compare with the specification.
54. Remove the bolts and the RH exhaust manifold.
55. Remove the bolts and the LH exhaust manifold.
56. Remove the crankcase-to-head tube assembly. Remove and discard the D-ring seals.
57. Remove the bolts and the high-pressure oil rail.
58. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
59. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
60. Remove the bolt, the fuel injector hold down and the fuel injector.
61. Remove the shop towels.
62. Remove the crankcase-to-head tube assembly. Remove and discard the D-ring seals.
63. If the crankcase-to-head tube separated, using a pair of soft-jawed pliers, remove the lower crankcase-to-head tube. Remove the discard the D-ring seal.
64. Remove and discard the 20 head bolts from both cylinder heads.
65. Remove the 16 bolts and the rocker arm assemblies.
66. Remove the rocker arm carrier from the cylinder head. Remove the bolts. Clean and inspect the gaskets. Install new gaskets if necessary. Clean and inspect the sealing surfaces.
67. Remove the 16 valve bridges.
68. Mark and remove the 16 push rods.
69. Remove the 10 outer head bolts.
70. Remove the cylinder heads. Install the special tool. Install the bolts. Remove the cylinder heads.
71. Remove and discard the cylinder head gaskets.
72. Remove and discard the four cylinder head dowel sleeves.
73. Remove the bolts and the rear engine tube assembly.
74. Remove the bolts and the roller follower guides. Remove the hydraulic cam followers.
75. Remove the upper oil pan. Remove the bolts. Clean and inspect the gaskets. Install new gaskets if necessary. Clean and inspect the sealing surfaces.
76. Check the piston protrusion above the crankcase as follows: Zero the dial indicator gauge on the crankcase deck surface. Position the dial indicator 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 tip onto the piston head at the opposite position. Rotate the crankshaft to measure the maximum piston protrusion and record. Average the two readings to see if the maximum piston protrusion is exceeded.
77. Using a feeler gauge, check for the minimum connecting rod side clearance.
78. Remove the bolts and the connecting rod caps.
79. Use a razor knife or emery board to scrape the carbon ridge from the top of the cylinder bore.
80. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.
81. Remove the piston rings. Remove the top compression ring. Remove the intermediate compression ring. Remove the oil control ring.
82. Remove and discard the connecting rod bearings.
83. Install the special tool and measure the camshaft gear backlash. Install a new gear if backlash is not within specification.
84. Install the special tool and measure the camshaft end play. Install a new camshaft thrust plate if end play is not within specification.
85. Install the special tool and measure the crankshaft end play. Record the end play.
86. Remove the bolt and the crankshaft position (CKP) sensor.
87. Remove the bolt and the camshaft position (CMP) sensor.
88. Remove the block heater.
89. Remove the 20 lower case bolts and the eight outside lower crankcase bolts. Remove the lower crankcase assembly.
90. Remove the lower crankcase seals and the lower bearings and discard.
91. Using the appropriate lifting device, remove the crankshaft assembly.
92. Remove and discard the crankshaft upper bearings and crankshaft upper thrust bearing.
93. Remove the thrust plate mounting bolts and remove the camshaft and gear.
94. Remove the bolts and the eight piston cooling tubes.
95. Using the special tool, remove the camshaft bearings and discard.

Scheme 1070

Scheme 1071

Scheme 1072

Scheme 1073

Scheme 1074

Scheme 1075

1. Remove the lifting bracket from the cylinder head.
2. Install the Valve Spring Compressor.
3. Remove the valve spring retainer keys. Remove the valve spring retainer keys. Remove the Valve Spring Compressor.
4. Remove the valve spring rotator.
5. Remove the valve spring.
6. Remove the valve.
7. Remove the valve stem seal.
8. Clean and inspect the valves, valve guides and seats. If they are serviceable, resurface to specification.

Scheme 1076

1. Install the valve stem seal.
2. Install the valve.
3. Install the valve spring.
4. Install the valve spring rotator.
5. Install the valve spring retainer keys. Install the Valve Spring Compressor. Install the valve spring retainer keys.
6. Remove the Valve Spring Compressor.
7. Install the lifting bracket on the cylinder head.

Scheme 1077

1. Remove the piston pin retainers.
2. Remove the connecting rod. Remove the piston pin. Remove the connecting rod.
3. To assemble, reverse the disassembly procedure.

SPECIAL TOOLS Lifting Bracket, Cylinder Head 303-759 Installer, Crankshaft Front Seal and Wear Ring 303-761 Dial Indicator Gauge with Holding Fixture 100-002 (TOOL-4201-C) or equivalent Service Set, Camshaft 303-017 (T65L-6250-A) or equivalent Heavy Duty Floor Crane 014-00072 Alignment Tool, Camshaft 303-772 Installer, Crankshaft Rear Seal and Wear Ring 303-770 Compressor, Piston Ring 303-D032 (D81L-6002-C) or equivalent Adapter for 303-D043 303-D043-01 Adapter for 303-D043 303-D043-02 Remover/Installer, Glow Plug Connector 303-1114 Socket, Injection Pressure Regulator (IPR) Valve 303-1112

Scheme 1078

MATERIAL SPECIFICATIONS

Scheme 1079

Scheme 1080

Scheme 1081

Scheme 1082

Scheme 1083

Scheme 1084

Scheme 1085

Scheme 1086

Scheme 1087

Scheme 1088

Scheme 1089

Scheme 1090

Scheme 1091

Scheme 1092

Scheme 1093

Scheme 1094

Scheme 1095

Scheme 1096

Scheme 1097

Scheme 1098

Scheme 1099

Scheme 1100

Scheme 1101

Scheme 1102

Scheme 1103

Scheme 1104

Scheme 1105

Scheme 1106

Scheme 1107

Scheme 1108

1. Install new D-ring seals on the crankcase-to-head tube assemblies.
2. If removed, install the camshaft bearings.
3. Install the eight piston cooling tubes and bolts.
4. Install the camshaft and gear assembly. Install the thrust plate mounting bolts.
5. Install the crankshaft upper bearings and the crankshaft upper thrust bearing.
6. Using the special tool, align the camshaft timing mark (Scheme 1111)
7. With the timing peg in the special tool over the camshaft timing mark, install the crankshaft.
8. Position commercially available plastigage in the center of each main bearing bolt cap.
9. Install the lower bearings into the lower crankcase.
10. Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in the following sequence, in three stages: Stage 1: Tighten to 122 Nm (90 lb-ft) in numerical sequence. Stage 2: Tighten again to 163 Nm (120 lb-ft) in numerical sequence. Stage 3: Tighten to 231 Nm (170 lb-ft) in numerical sequence.
11. Install eight M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence (Scheme 1112)
12. Remove the 28 bolts and the lower crankcase.
13. Measure the clearances for the main bearings. Remove the plastigage.
14. Install new lower crankcase seals.
15. Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten mounting bolts in the following sequence, in three stages: Stage 1: Tighten to 122 Nm (90 lb-ft) in numerical sequence. Stage 2: Tighten again to 163 Nm (120 lb-ft) in numerical sequence. Stage 3: Tighten to 231 Nm (170 lb-ft) in numerical sequence.
16. Install eight M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence see scheme 526
17. Install the special tool and measure the crankshaft end play.
18. Install the special tool and measure the camshaft end play.
19. Install the special tool and measure the camshaft gear backlash.
20. Install the block heater.
21. Install the camshaft position (CMP) sensor and the bolt.
22. Install the crankshaft position (CKP) sensor and the bolt.
23. Install the connecting rod bearings.
24. Install new piston rings. The top compression ring is identified with one indentation mark and a 15-degree keystone profile. The intermediate compression ring is identified with two indentation marks and a square profile. Install the oil control ring.
25. Install the piston and rod assemblies. Coat the inside diameter of the ring compressor with clean engine oil. Insert the piston into the special tool. Position the piston, connecting rod and special tool into the correct cylinder bore. Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.
26. Position a piece of plastigage across the bearing surface.
27. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence, in two stages: Stage 1: Tighten to 45 Nm (33 lb-ft). Stage 2: Tighten to 68 Nm (50 lb-ft).
28. Remove the bolts and the connecting rod cap.
29. Measure the clearances for the connecting rod cap. Remove the plastigage.
30. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence, in two stages: Stage 1: Tighten to 45 Nm (33 lb-ft). Stage 2: Tighten to 68 Nm (50 lb-ft).
31. Using a feeler gauge, check for the minimum connecting rod side clearance.
32. Install the upper oil pan. Install the upper oil pan gasket. Install the upper oil pan. Install the bolts.
33. Apply clean engine oil to the hydraulic cam followers and install into the roller follower guide. Install the roller follower guide and the bolts.
34. Install the rear engine tube assembly bolts. Position the rear engine tube assembly and install the right side bolt hand tight. Install the left side bolt hand tight. Tighten both rear engine tube assembly bolts.
35. Install the four cylinder head dowels.
36. Place the new cylinder head gaskets over the dowel sleeves and onto the crankcase.
37. Using the special tool, install the cylinder heads. Install the lifting bracket. Install the bolts. Install the cylinder heads.
38. Install the 10 outer head bolts (finger-tight).
39. Apply clean engine oil to each end of the push rods. Insert them into their respective positions with the copper-colored end up.
40. Install the 16 valve bridges.
41. Install the rocker arm carrier to the cylinder head. Install the press-in-place gasket. Install the rocker arm carrier. Install the bolts.
42. Install the rocker arm assemblies and the 16 bolts.
43. Install the new cylinder head retaining bolts finger-tight.
44. Tighten the head bolts in the following sequence, in seven stages: Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 lb-ft). Stage 2: Tighten bolts 1 through 10 to 115 Nm (85 lb-ft). Stage 3: Tighten bolts in sequence 1 through 10, clockwise 90 degrees. Stage 4: Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees. Stage 5: Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees. Stage 6: Tighten bolts 11 through 15 to 24 Nm (18 lb-ft). Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
45. Apply clean engine oil and install a crankcase-to-head tube assembly.
46. Install new O-ring seals and a copper washer on the fuel injector.
47. Install the fuel injector, the fuel injector hold down and bolt.
48. Install the fuel injector electrical connector into the rocker carrier.
49. Position the high-pressure oil rail on the injectors. Place the high-pressure oil rail on top of the carrier so that the four single ball tubes are engaging the fuel injector lead angle. Insert three guide bolts, two on the ends of the straight side of the high-pressure oil rail and one in the middle of the wavy side of the high-pressure rail. Install the guide studs six to seven turns. Press the high-pressure oil rail into the fuel injectors. Inspect that the high-pressure oil rail mounting feet are flat against the mounting surface. Loosely install the six bolts.
50. Install the remaining bolts and tighten. Remove the three guide bolts. Loosely install the three remaining bolts. Tighten the nine bolts in the sequence see scheme 559
51. Install the crankcase-to-head tube assembly.
52. Install the left exhaust manifold and the bolts.
53. Install the right exhaust manifold and the bolts.
54. Apply a bead of sealant at the back seam of the upper and lower crankcase.
55. Install the rear engine cover. Install the press-in-place gasket. Install the rear engine cover. Install the bolts.
56. Using the special tools, install the crankshaft rear oil seal.
57. Install the flywheel adapter.
58. If removed, install the front cover crankcase dowels into the cylinder block.
59. Apply a bead of sealant at the front seam of the upper and lower crankcase.
60. Install the guide studs and the front cover gasket.
61. Install the engine front cover and bolts.
62. Lubricate the inner drive rotor with a suitable lithium assembly grease and install onto the crankshaft. Lubricate the outer drive rotor with lithium assembly grease and mesh with the inner drive rotor in the oil pump housing. Wipe off excess assembly grease.
63. Install the oil pump body and the bolts.
64. Using the special tool, install the oil seal and wear sleeve assembly.
65. Install the crankshaft vibration damper and bolts. Tighten the bolts in the sequence shown, in two stages: Stage 1: Tighten to 68 Nm (50 lb-ft). Stage 2: Tighten an additional 90 degrees.
66. If equipped, install the dual generator pulley and bolts.
67. Install the coolant pump and bolts.
68. Install the coolant pump pulley and the bolts.
69. Install the RH high-pressure oil rail-to-valve cover gasket.
70. Install the RH valve cover. Install the gasket. Install the valve cover. Install the bolts and stud bolts.
71. Cover the LH cylinder head with an appropriate covering.
72. Install the eight glow plugs.
73. Using the special tool, install the glow plug harness.
74. Install a new O-ring seal on the high-pressure oil pump.
75. Install the high-pressure tube assembly.
76. Install new lower O-ring seals.
77. Install the high-pressure pump and bolts.
78. Tighten the bolts for the high-pressure tube assembly.
79. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
80. Install a new press-in-place gasket in the high-pressure pump cover.
81. Clean the cover mounting surface and apply sealer at the seams.
82. Install the high-pressure oil pump cover and eight bolts.
83. Install the IPR valve.
84. Install the heat insulating wrap and fasten the snap.
85. Install the turbocharger heat shield and bolts.
86. Install the oil pump inlet strainer.
87. Install the oil cooler assembly. Install the gasket. Install the oil cooler assembly. Install the bolts.
88. Install the oil filter base. Install the gasket. Install the oil filter base. Install the bolts.
89. Install the exhaust gas recirculation (EGR) cooler coolant supply port cover. Install the gasket. Install the EGR cooler coolant supply port cover. Install the bolts.
90. Install a new O-ring seal in the oil filter base.
91. Install the oil filter adapter and bolts.
92. Install the serpentine belt idler and bolt.
93. If equipped, install the belt tensioner and bolts.
94. Install the left cylinder head fuel line.
95. Install the thermostat housing and the stud bolts.
96. Position back the fuel bracket and install the retaining nut.
97. Install the RH motor mount plate and bolts.
98. Install the special tools.
99. Install the special tool.
100. Install the lifting crane and remove the engine from the engine stand.
101. Install the flexplate and the new bolts. Tighten the bolts in the following sequence, in two stages: Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 94 Nm (69 lb-ft) in the sequence see scheme 608

SPECIAL TOOLS Lifting Attachment, Engine 303-D043 (D83T-6000-B) or equivalent Heavy Duty Floor Crane 014-00071 Adapter for 303-D043 303-D043-02 or equivalent Adapter for 303-D043 303-D043-01 or equivalent Wrench, Fan Clutch Nut 303-591

MATERIAL SPECIFICATION

Scheme 1109

Scheme 1110

Scheme 1111

Scheme 1112

Scheme 1113

Scheme 1114

Scheme 1115

Scheme 1116

Scheme 1117

Scheme 1118

Scheme 1119

Scheme 1120

Scheme 1121

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(/ford/cutaway-e350/2004-2007/remont/hoistjack/#jacking-lifting) .
2. Raise the engine high enough to clear the No.1 Crossmember and position the engine into the vehicle.
3. Position the motor mounts in the vehicle.
4. Align the torque converter studs with the holes in the flywheel and push the engine in. Install the top engine-to-transmission bolts.
5. Lower the engine until it is just above the motor mounts. Install the retaining bolts in the RH motor mount.
6. Install the four retaining bolts in the LH motor mount.
7. Remove the transmission jack.
8. Install a new O-ring seal on the oil pickup tube and position the oil pickup tube in the oil pan.
9. Install a new press-in-place gasket into the upper oil pan.
10. Position the oil pan in the vehicle.
11. Install the oil pickup tube and bolts.
12. Position the oil pan and install the bolts. Install the longer oil pan bolts. Install the remaining oil pan bolts. Tighten the bolts to 13 Nm (10 lb-ft).
13. Clean and inspect the oil pan drain plug and gasket. Install new, if necessary.
14. Install the oil pan drain plug.
15. Lower the engine. Remove the lifting crane and the engine lifting attachment.
16. Remove the special tool.
17. Install the factory engine lifting bracket.
18. Loosely install the turbocharger exhaust pipe.
19. Remove the special tools.
20. Install the injection control pressure (ICP) sensor.
21. Install the LH valve cover gasket, valve cover and bolts.
22. Install the glow plug module mounting bracket and retaining nuts.
23. Install the glow plug module and retaining nuts.
24. Connect the exhaust back pressure tube at the exhaust manifold.
25. Install the oil indicator and tube. Install the retaining nut. Connect the glow plug wire retainer.
26. Position the fuel tubes and install the mounting bolts for the fuel tube bracket.
27. Install the lower engine-to-transmission bolts.
28. Install the motor mount nuts.
29. Install the starter motor and bolts.
30. Connect the starter motor electrical connections.
31. Install the starter motor solenoid protective cap.
32. Position the battery cable bracket and install the retaining nut.
33. Connect the block heater electrical connector.
34. Install the new torque converter nuts.
35. Install the torque converter cover.
36. Install the transmission tubes and retaining clips.
37. Position the transmission cooler tubes on the stud and install the retaining nut.
38. Install the oil filter assembly and bolts.
39. Position the engine wiring harness and connect the powertrain control module electrical connectors.
40. Connect the two engine-to-vehicle electrical connectors.
41. Connect the LH glow plug electrical connector.
42. Connect the push pin retainer and exhaust back pressure sensor electrical connector.
43. If equipped, connect the B+ wire and reposition the boot.
44. Connect the electrical connector and wire retainers at the transmission.
45. Connect the glow plug module electrical connectors.
46. Connect the camshaft position sensor electrical connector and retaining clips.
47. Position the wiring and connect the glow plug electrical connector. Connect the ICP sensor electrical connector.
48. Connect the crankshaft position (CKP) sensor electrical connector and retaining clips.
49. Connect the fuel lines and install the retaining clips.
50. Install the lower radiator hose.
51. Position the power steering pump and install the bolts.
52. Install the LH fan stator stand-off.
53. Install the power steering upper mounting bolts.
54. Install the vacuum pump and bolts.
55. Connect the vacuum pump hose and install the engine coolant fill hose clip.
56. Install the engine coolant fill hose and tighten the clamp. Connect the engine fill hose into the retaining clip
57. Install the idler pulley and bolt.
58. Position the heater hose back and connect.
59. Install the A/C compressor and bolts.
60. Install the A/C manifold at the tee block. Connect the high-pressure switch electrical connector.
61. Connect the A/C clutch electrical connector.
62. Position back the cable and install the bolt. Install the RH fan stator stand-off.
63. Install the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450) .
64. Install the lower radiator supports and bolts.
65. Install the upper radiator supports and bolts.
66. Position the hood latch and install the bolts.
67. Position the headlamp wiring harness and connect the air bag sensor. Install the bolts for the air bag sensor.
68. Install the valance panel, radiator grille support and grille opening panel reinforcement. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(/ford/cutaway-e350/2004-2007/remont/exteriorinterior-trim/#interior-trim-and-ornamentation) .
69. Install the front bumper. For additional information, refer to «BODY SYSTEM - GENERAL INFORMATION»(/ford/cutaway-e350/2004-2007/remont/exterior-body-panels/#body-panel-system-body-system-general-information) .
70. Install the A/C condenser assembly. For additional information, refer to «AIR CONDITIONING»(/ford/cutaway-e350/2004-2007/remont/manual-hvac-system/#hvac-system-air-conditioning) .
71. Fill the engine with clean engine oil.
72. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(/ford/cutaway-e350/2004-2007/remont/charging-system/#battery-mounting-and-cables) .
73. Check and top off the transmission fluid level.

SPECIAL TOOLS Lifting Bracket, Cylinder Head 303-759 Heavy Duty Floor Crane 014-00071 Adapter for 303-D043 303-D043-01 Adapter for 303-D043 303-D043-02 Remover/Installer Glow Plug Connector 303-1114

MATERIAL SPECIFICATION

1. Install new D-ring seals on the crankcase-to-head tube assemblies.
2. Install new dowels and the cylinder head gasket.
3. Using the special tools, install the cylinder head on the engine. Install the lifting bracket. Install the bolts. Install the cylinder head.
4. Install the outer cylinder head bolts finger-tight.
5. Apply clean engine oil to each end of the push rods. Insert them into their respective positions, with the copper-colored end up.
6. Install the 16 valve bridges.
7. Install the rocker arm carrier. Install the press-in-place gasket. Install the rocker arm carrier and bolts.
8. Install the rocker arm assemblies and 16 bolts.
9. Install the 20 new inner cylinder head retaining bolts finger-tight.
10. Tighten the head bolts in the following sequence, in seven stages: Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 lb-ft). Stage 2: Tighten bolts 1 through 10 to 115 Nm (85 lb-ft). Stage 3: Tighten bolts in sequence 1 through 10, clockwise 90 degrees. Stage 4: Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees. Stage 5: Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees. Stage 6: Tighten bolts 11 through 15 to 24 Nm (18 lb-ft). Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
11. If equipped with a one-piece tube, apply clean engine oil and install a crankcase-to-head tube assembly.
12. Install new O-ring seals and a copper washer on the fuel injector.
13. Install the fuel injector, the fuel injector hold down and bolt.
14. Install the fuel injector electrical connector into the rocker carrier.
15. Position the high-pressure oil rail on the injectors. Place the high-pressure oil rail on top of the carrier so that the four single ball tubes are engaging the fuel injector lead angle. Insert three guide bolts, two on the ends of the straight side of the high-pressure oil rail and one in the middle of the wavy side of the high-pressure rail. Install the guide studs six to seven turns. Press the high-pressure oil rail into the fuel injectors. Inspect that the high-pressure oil rail mounting feet are flat against the mounting surface. Loosely install the six bolts.
16. Install the remaining bolts and tighten. Remove the three guide bolts. Loosely install the three remaining bolts. Tighten the nine bolts in the sequence shown.
17. If equipped with a two-piece tube, install the crankcase-to-head tube assembly.
18. Install the RH high-pressure oil rail-to-valve cover gasket.
19. Install the RH valve cover.
20. Install the right exhaust manifold and the bolts.
21. Cover the LH cylinder head with an appropriate covering.
22. Install the turbocharger heat shield and bolts.
23. Install the left cylinder head fuel line.
24. Install the left exhaust manifold and the bolts.
25. Install the eight glow plugs.
26. Using the special tool, install the glow plug harness.
27. Install the special tools.
28. Install the special tool.
29. Install the lifting crane and remove the engine from the engine stand.
30. Install the flexplate and the new bolts. Tighten the bolts in the following sequence, in two stages: Stage 1: Tighten to 5 Nm (44 lb-in). Stage 2: Tighten to 94 Nm (69 lb-ft) in the sequence see scheme 697
31. Install the engine. For additional information, refer to «Engine»(/ford/cutaway-e350/2004-2007/remont/mechanical/#engine-60l-diesel-e350-e450).

See also:
• INTRODUCTION -- 6.0L DIESEL
• BATTERY, MOUNTING AND CABLES
• ENGINE COOLING
• FUEL CHARGING & CONTROLS - TURBOCHARGER
• JACKING & LIFTING
• INTERIOR TRIM AND ORNAMENTATION
• AIR CONDITIONING
• TRANSAXLE/TRANSMISSION - TORQSHIFT
• STARTING SYSTEM - DIESEL ENGINE
• HEATING & VENTILATION
• BUMPERS
• FRONT END BODY PANELS
• FUEL SYSTEM-GENERAL INFORMATION
• FUEL CHARGING & CONTROLS - 6.0L DIESEL
• BODY SYSTEM - GENERAL INFORMATION
• GENERAL PROCEDURES
• SYMPTOM CHART