Engine 6.0L Diesel: Other Ford Econoline E250

Cylinder Bore Honing

MATERIAL

MATERIAL CHART

Scheme 1524

1. The most desired 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 Threadlock 262® 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.

Intake Manifold

MATERIAL

MATERIAL CHART

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
2. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
3. Remove the turbocharger pedestal. For additional information, refer to «FUEL CHARGING & CONTROLS-TURBOCHARGER»(ref-210143) .
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 push pin.
13. Remove the conduit and position the wiring aside. Disconnect the locking tab. Remove the bolts. Disconnect the push pin and remove the wiring harness from the conduit.
14. Remove the bolts for the charge air cooler tube and oil fill tube.
15. Disconnect the oil fill tube at the valve cover.
16. Remove the retaining nuts, charge air cooler tube, oil fill tube and bracket.
17. Disconnect the generator electrical connector and the B+ wire. Disconnect the wiring push pin.
18. Remove the retaining nut for the transmission fluid indicator and tube.
19. Disconnect the push pin retainer. Remove the retaining nut and position the transmission fluid indicator and tube aside.
20. Remove the three bolts, ground wire and the generator.
21. Remove the bolts and position the heater hose tube aside. Remove and discard the O-ring.
22. Remove the retaining nut and disconnect the wiring retainer and the injection pressure regulator valve electrical connector.
23. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
24. Disconnect the engine oil pressure (EOP) sensor electrical connector.
25. Disconnect the engine oil temperature (EOT) sensor electrical connector.
26. Disconnect the EGR throttle position control module electrical connector.
27. Disconnect the EGR throttle position sensor electrical connector.
28. Disconnect the pin-type retainer and engine coolant temperature (ECT) sensor.
29. Remove the ECT sensor. Plug or cap the opening as needed.
30. Disconnect the intake air temperature (IAT2) sensor electrical connector.
31. Remove the IAT2 sensor. Plug or cap the opening as needed.
32. Disconnect the eight fuel injector electrical connectors and wiring connectors.
33. Disconnect the harness retainers. Position the engine wiring harness as needed for intake manifold removal.
34. Disconnect the manifold absolute pressure (MAP) sensor hose.
35. Disconnect the engine coolant vent hose.
36. Remove the secondary fuel filter and remove all fuel from the filter housing.
37. Disconnect the fuel tube fittings at the secondary fuel filter. Remove and discard the copper sealing washers.
38. Disconnect the fuel tube at the fuel filter housing. Remove the retaining nut.
39. Remove the banjo bolt and fuel tube. Discard the copper sealing washers.
40. Remove the bolts and the secondary fuel filter assembly.
41. Remove the nuts and turbocharger heat shield.
42. Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.
43. Remove the bolts and the intake manifold.
44. Remove the intake manifold gaskets. Clean and inspect the gaskets. Install new gaskets if necessary. Clean and inspect the sealing surfaces. Remove and discard the front module O-ring seal.

Scheme 1562

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Scheme 1596

1. Install the intake manifold gaskets. Install a new front module O-ring seal.
2. Install the intake manifold and bolts and tighten in the following sequence. Loosely install bolts 1-8. Tighten bolts 9-16 to 11 Nm (8 lb-ft). Tighten all bolts to 11 Nm (8 lb-ft).
3. Slide the EGR cooler hose forward and rotate the flat to lock.
4. Install the turbocharger heat shield and nuts.
5. Install the secondary fuel filter assembly and bolts.
6. Install the 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 EGR throttle position sensor electrical connector.
19. Connect the EGR throttle position control module electrical connector.
20. Connect the EOT sensor electrical connector.
21. Connect the EOP sensor electrical connector.
22. Connect the EGR valve electrical connector.
23. Connect the injector pressure regulator valve electrical connector and position back the heat insulating wrap. Install the wiring retainer and retaining nut.
24. Install the heater tube and bolts.
25. Install the generator, ground wire and the three bolts.
26. Position back the transmission fluid indicator and tube and install the retaining nut. Connect the push pin retainer.
27. Install the retaining nut for the transmission fluid indicator and tube.
28. Connect the generator B+ wire and electrical connector. Position back the boot. Connect the wiring push pin.
29. Position the charge air cooler (CAC) tube, oil fill tube and bracket. Install the retaining nuts.
30. Connect the oil fill tube at the valve cover.
31. Install the bolts for the charge air cooler tube and oil fill tube.
32. Install the conduit and bolts. Install the wiring harness into the conduit and connect the push pin. Install the bolts. Connect the locking tab.
33. Connect the electrical connector push pin. Position back the ground wire and install the bolt.
34. Install the accessory drive belt.
35. Install the generator with mounting bracket and bolts.
36. Connect the generator B+ wire and electrical connector. Position the boot.
37. Install the accessory drive belt tensioner and bolts.
38. Position the accessory drive belt idler pulley. Install the bracket and bolts.
39. Install the accessory drive belt.
40. Install the accessory drive belt tensioner and bolt.
41. Install the accessory drive belt.
42. Install the turbocharger pedestal and turbocharger. For additional information, refer to «FUEL CHARGING & CONTROLS-TURBOCHARGER»(ref-210143) .
43. Install the cooling fan stator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
44. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .

Valve Cover RH

SPECIAL TOOL(S)

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
4. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
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 power steering pump upper mounting bolt.
14. Remove the LH fan stator stand-off.
15. Remove the power steering pump bolts and position the power steering pump aside.
16. Install the engine lifting bracket.
17. Loosen the RH motor mount retaining nuts.
18. Loosen the four LH motor mount bolts.
19. Remove the LH motor mount retaining nuts.
20. Remove the removable stud.
21. Connect a suitable lifting crane and lifting chain to the engine lifting bracket and raise the engine as needed to remove the motor mount.
22. Remove the four bolts and the LH motor mount. Carefully lower the engine.
23. Remove the retaining nut and disconnect the push pin retainer.
24. Remove the retaining nut for the transmission fluid level indicator and tube. Position the tube aside.
25. Remove the bolt for the oil fill tube.
26. Disconnect the oil fill tube.
27. Disconnect the injection control pressure (ICP) sensor electrical connector and wire retainers.
28. Remove the ICP sensor. Plug or cap the opening as needed.
29. Position the wiring away from the valve cover as needed.
30. Remove the 11 retainers and the valve cover. Clean and inspect the valve cover gasket.
31. Remove the high pressure oil rail-to-valve cover gasket.
32. To install, reverse the removal procedure. Tighten the top retaining nuts on the motor mount first.

Scheme 1623

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1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
3. Remove the turbocharger inlet tube. For additional information, refer to «FUEL CHARGING & CONTROLS-TURBOCHARGER»(ref-210143) .
4. Loosen the clamps and remove the charge air cooler pipe.
5. Disconnect the glow plug wire retainer. Remove the nut and position the oil level indicator and tube aside.
6. Disconnect the glow plug module electrical connectors.
7. Position back the boot and remove the nut. Disconnect the cables.
8. Disconnect the exhaust back pressure electrical connector and pushpin retainer.
9. Disconnect the exhaust back pressure tube at the exhaust manifold.
10. Remove the retaining nuts and glow plug module.
11. Remove the three retaining nuts and the glow plug module mounting bracket.
12. Remove the 11 retainers and the valve cover. Clean and inspect the valve cover gasket.
13. To install, reverse the removal procedure.

Crankshaft Pulley

SPECIAL TOOL(S)

Scheme 1628

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Scheme 1632

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
3. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
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 1633

Scheme 1634

Scheme 1635

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»(ref-210139) .
6. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .

Exhaust Manifold LH

MATERIAL

MATERIAL CHART

Scheme 1636

Scheme 1637

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
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 1638

1. Install the LH exhaust manifold and bolts. Tighten the bolts in the sequence shown.
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»(ref-210204) .

Exhaust Manifold RH

MATERIAL

MATERIAL CHART

Scheme 1639

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
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.

Oil Cooler

MATERIAL

MATERIAL CHART

Scheme 1640

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1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-213720-S04554148002005123000000) .
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 1644

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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»(ref-213720-S04554148002005123000000) .

Crankshaft Front Seal

SPECIAL TOOL(S)

Scheme 1651

MATERIAL

MATERIAL CHART

Scheme 1652

Scheme 1653

1. Remove the crankshaft vibration damper. For additional information, refer to «CRANKSHAFT PULLEY»(ref-213720-S11145631682005123000000) .
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.

Oil Pan

SPECIAL TOOL(S)

Scheme 1654

MATERIAL

MATERIAL CHART

Scheme 1655

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Disconnect the battery ground cable, For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
4. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
5. Remove the A/C compressor. For additional information, refer to «HEATING & VENTILATION»(ref-210170) .
6. Remove the power steering pump upper mounting bolt.
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 pick up tube bolts are accessible.
17. Remove the bolts and let the oil pick-up tube go into the oil pan. Remove the oil pan.
18. Remove and discard the oil pick-up tube O-ring seal.
19. Remove the press-in-place gasket and discard. Clean and inspect the sealing surfaces.

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1. Install a new press-in-place gasket into the upper oil pan.
2. Install a new O-ring seal on the oil pick-up tube and position the oil pick-up tube in the oil pan.
3. Position the oil pan in the vehicle.
4. Install the oil pan pick-up tube and bolts.
5. Install the oil pan and bolts.
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 bolt.
17. Fill the engine with clean engine oil.
18. Install the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
19. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
20. Install the A/C compressor. For additional information, refer to «HEATING & VENTILATION»(ref-210170) .
21. Install the cooling fan stator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
22. Run the engine and check for leaks.

Scheme 1678

1. Remove the crankshaft front oil seal. For additional information, refer to «CRANKSHAFT FRONT SEAL»(ref-213720-S27124982132005123000000) .
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 gouging cracks or deep scratches. Inspect the oil pump inner and outer gear rotors for damage or excessive wear.

Crankshaft Rear Seal

SPECIAL TOOL(S)

Scheme 1679

MATERIAL

MATERIAL CHART

Scheme 1680

Scheme 1681

Scheme 1682

1. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSMISSION - TORQSHIFT»(ref-213722) .
2. Remove the bolts and flexplate.
3. Remove the flywheel front adapter.
4. Punch two holes in the rear main seal, across from each other.
5. Using the special tool, remove 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 1683

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Scheme 1685

1. Apply a bead of Threadlock 262® 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 bolts. Snug all bolts to 5 Nm (44 lb-in) Tighten all bolts to 94 Nm (69 lb-ft) in the sequence shown.
5. Install the transmission. For additional information, refer to «AUTOMATIC TRANSMISSION - TORQSHIFT»(ref-213722) .

Engine Front Cover

MATERIAL

MATERIAL CHART

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1. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-213720-S04554148002005123000000) .
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 mounting bolt.
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»(ref-213720-S12526311372005123000000) .
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.

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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»(ref-213720-S12526311372005123000000) .
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 bolt.
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»(ref-213720-S04554148002005123000000) .

Engine Rear Cover

SPECIAL TOOL(S)

Scheme 1706

MATERIAL

MATERIAL CHART

Scheme 1707

Scheme 1708

Scheme 1709

Scheme 1710

1. Remove the starter. For additional information, refer to «STARTERS - DIESEL»(ref-168260) .
2. Remove the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION-4R100»(ref-210155) .
3. Remove the bolts and the flexplate.
4. Remove the flywheel front adapter.
5. Punch two holes in the rear main seal, across from each other.
6. Using the special tool, remove 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 1711

Scheme 1712

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Scheme 1716

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. Install the bolts. Tighten the bolts to 5 Nm (44 lb-in). Tighten all bolts to 94 Nm (69 lb-ft) in the sequence shown.
8. Install the transmission. For additional information, refer to «AUTOMATIC TRANSAXLE/TRANSMISSION-4R100»(ref-210155) .
9. Install the starter. For additional information, refer to «STARTERS - DIESEL»(ref-168260) .

Engine Mount

SPECIAL TOOL(S)

Scheme 1717

Scheme 1718

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Scheme 1725

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
3. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
4. Remove the A/C compressor. For additional information, refer to «HEATING & VENTILATION»(ref-210170) .
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.

Scheme 1726

Scheme 1727

Scheme 1728

Scheme 1729

Scheme 1730

Scheme 1731

Scheme 1732

Scheme 1733

Scheme 1734

Scheme 1735

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 bolt.
13. Install the A/C compressor. For additional information, refer to «HEATING & VENTILATION»(ref-210170) .
14. Install the cooling fan stator and radiator. For additional information, refer to «ENGINE COOLING»(ref-210139) .
15. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .

SPECIAL TOOL(S)

Scheme 1736

MATERIAL

MATERIAL CHART

Scheme 1737

Scheme 1738

Scheme 1739

Scheme 1740

Scheme 1741

Scheme 1742

Scheme 1743

Scheme 1744

Scheme 1745

Scheme 1746

Scheme 1747

Scheme 1748

Scheme 1749

Scheme 1750

Scheme 1751

Scheme 1752

Scheme 1753

Scheme 1754

Scheme 1755

Scheme 1756

Scheme 1757

Scheme 1758

Scheme 1759

Scheme 1760

Scheme 1761

Scheme 1762

Scheme 1763

Scheme 1764

Scheme 1765

Scheme 1766

Scheme 1767

Scheme 1768

Scheme 1769

Scheme 1770

Scheme 1771

Scheme 1772

Scheme 1773

Scheme 1774

Scheme 1775

Scheme 1776

Scheme 1777

Scheme 1778

Scheme 1779

Scheme 1780

Scheme 1781

Scheme 1782

Scheme 1783

Scheme 1784

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-210109) .
2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
3. Remove the A/C condenser assembly. For additional information, refer to «AIR CONDITIONING»(ref-210171) .
4. Remove the front bumper. For additional information, refer to «BUMPERS»(ref-210212) .
5. Remove the radiator grille support. For additional information, refer to «FRONT END BODY PANELS»(ref-210201) .
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 bolts and the radiator core supports.
9. Remove the intake manifold. For additional information, refer to «INTAKE MANIFOLD»(ref-213720-S04554148002005123000000) .
10. Remove the RH fan stator stand-off. Remove the bolt and position the cable aside.
11. Remove the bolt and disconnect the A/C manifold. Disconnect the A/C electrical connector. Remove and discard the O-ring seals. Cap or plug the A/C openings as needed.
12. 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.
13. Remove the bolts and A/C compressor.
14. Disconnect the heater hose. Position the heater hose and tube aside.
15. Remove the bolt and idler pulley.
16. Disconnect the engine coolant fill hose from the retaining clip. Loosen the clamp and remove the engine coolant fill hose.
17. Disconnect the vacuum pump hose and remove the engine coolant fill hose clip.
18. Remove the bolts and the vacuum pump.
19. Remove the power steering upper mounting bolt.
20. Remove the LH fan stator stand-off.
21. Remove the bolts and position the power steering pump aside.
22. Remove the lower radiator hose.
23. Disconnect the fuel lines. For additional information, refer to «FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL»(ref-210160) .
24. Disconnect the crankshaft position (CKP) sensor electrical connector and retaining clips.
25. Disconnect the injection control pressure (ICP) sensor electrical connector. Disconnect the glow plug electrical connector and wire retainers.
26. Disconnect the camshaft position sensor electrical connector and retaining clips.
27. Disconnect the two electrical connectors and wire retainers at the transmission.
28. Disconnect the glow plug module electrical connectors.
29. Position back the boot and disconnect the B+ wire.
30. Disconnect the exhaust back pressure sensor electrical connector and pushpin retainer.
31. Disconnect the LH glow plug electrical connector.
32. Disconnect the two electrical connectors.
33. Disconnect the two powertrain control module (PCM) electrical connectors and position the engine wiring harness aside.
34. Remove the bolts and the oil filter assembly.
35. Remove the bolt at the transmission filter housing.
36. Remove the retaining nut and remove the transmission cooling tubes.
37. Remove the torque converter cover.
38. Remove and discard the torque converter nuts.
39. Disconnect the block heater electrical connector.
40. Remove the retaining nut and position the cable bracket aside.
41. Remove the starter solenoid protective cap.
42. Disconnect the starter motor electrical connections.
43. Remove the bolts and the starter motor.
44. Remove the cylinder block drain plugs and drain the coolant from the block.
45. Install the cylinder block drain plugs.
46. Remove the motor mount nuts.
47. Remove the lower engine-to-transmission bolts.
48. Remove the mounting bolts from the lifting bracket and remove the tubes.
49. Disconnect the glow plug wire retainer. Remove the retaining nut and the oil indicator and tube. Remove and discard the O-ring seal.
50. Disconnect the exhaust back pressure tube at the exhaust manifold.
51. Remove the retaining nuts and glow plug module.
52. Remove the retaining nuts and the glow plug module mounting bracket.
53. Remove the bolts and the LH valve cover. Remove the valve cover gasket. Cover the cylinder head after the valve cover is removed.
54. Remove the ICP sensor. Plug or cap the opening as needed.
55. Install the special tools.
56. Remove the turbocharger exhaust pipe.
57. Remove the factory installed engine lifting bracket.
58. Install the special tool.
59. Install the engine lifting attachment and lifting crane.
60. Remove the oil pan drain plug and drain the engine oil.
61. Remove the bolts and position back the oil pan until the oil pick up tube bolts are accessible.
62. Remove the bolts and let the oil pick-up tube go into the oil pan. Remove the oil pan.
63. Remove the press-in-place gasket and discard.
64. Remove and discard the oil pick-up tube O-ring seal.
65. Position a suitable transmission jack under the transmission.
66. Remove the upper engine-to-transmission bolts.
67. Raise the engine. Remove the four bolts and LH motor mount.
68. Remove the bolts and the RH motor mount.
69. Remove the engine from the vehicle.

Cylinder Heads

SPECIAL TOOL(S)

Scheme 1785

Scheme 1786

Scheme 1787

Scheme 1788

Scheme 1789

Scheme 1790

Scheme 1791

Scheme 1792

Scheme 1793

Scheme 1794

Scheme 1795

Scheme 1796

Scheme 1797

Scheme 1798

1. Remove the engine. For additional information, refer to «ENGINE»(ref-213720-S34049428252005123000000) .
2. Remove the bolts and flexplate.
3. Mount the engine on an engine stand.
4. Remove the rear lifting eye.
5. Remove the special tools.
6. 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 specifications.
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. RH 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. Remove the bolts and the high pressure oil rail.
16. Using a 19 mm (0.74 in) socket, push the fuel injector electrical connector out of the rocker arm carrier.
17. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
18. Remove the bolt, the fuel injector hold down and the fuel injector.
19. Remove the shop towels.
20. Remove the crankcase-to-head tube assembly. Remove and discard the O-ring seals.
21. Remove and discard the 20 inner cylinder head bolts.
22. Remove the 16 bolts and the rocker arm assemblies.
23. Remove the bolts and rocker arm carrier. Clean and inspect the gasket. Install new gaskets if necessary. Clean and inspect the sealing surfaces.
24. Mark the 16 valve bridges with a permanent marker and remove.
25. Mark the location and remove the 16 push rods.
26. Remove the outer cylinder head bolts.
27. Remove the cylinder heads. Install the special tool. Install the bolts. Remove the cylinder head.
28. Remove and discard the cylinder head gasket and dowels. Clean and inspect the gasket sealing surfaces.

SPECIAL TOOL(S)

Scheme 1799

Scheme 1800

Scheme 1801

Scheme 1802

Scheme 1803

Scheme 1804

Scheme 1805

Scheme 1806

Scheme 1807

Scheme 1808

Scheme 1809

Scheme 1810

Scheme 1811

Scheme 1812

Scheme 1813

Scheme 1814

Scheme 1815

Scheme 1816

Scheme 1817

Scheme 1818

Scheme 1819

Scheme 1820

Scheme 1821

Scheme 1822

Scheme 1823

Scheme 1824

Scheme 1825

Scheme 1826

Scheme 1827

Scheme 1828

Scheme 1829

Scheme 1830

Scheme 1831

Scheme 1832

Scheme 1833

Scheme 1834

Scheme 1835

Scheme 1836

Scheme 1837

Scheme 1838

Scheme 1839

Scheme 1840

Scheme 1841

Scheme 1842

Scheme 1843

Scheme 1844

Scheme 1845

Scheme 1846

Scheme 1847

Scheme 1848

Scheme 1849

Scheme 1850

Scheme 1851

Scheme 1852

Scheme 1853

Scheme 1854

Scheme 1855

Scheme 1856

Scheme 1857

Scheme 1858

Scheme 1859

Scheme 1860

1. Remove the bolts and the flexplate.
2. Mount the engine on an engine stand.
3. Remove the rear lifting eye.
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. Remove the high-pressure oil pump cover. Remove the bolts. Use a thin gasket scraper to separate the cover from the crankcase. Clean and inspect the gaskets. Install a new gasket if necessary. Clean and inspect the sealing surfaces.
19. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
20. Remove the bolts from the high-pressure oil pump discharge pipe. Position the high-pressure discharge pipe aside.
21. Remove and discard the high-pressure pump O-ring seal.
22. Remove the bolts and the high-pressure oil pump.
23. Remove and discard the lower O-ring seal.
24. Remove the glow plug harness.
25. Remove the eight glow plugs.
26. Remove the protective covering from the LH cylinder head.
27. 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.
28. Remove the RH high pressure oil rail-to-valve cover gasket.
29. Remove the bolts and the coolant pump pulley.
30. Remove the coolant pump. Remove the bolts. Remove and discard the O-ring seal.
31. If equipped, remove the bolts and the dual generator pulley.
32. 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.
33. Remove the bolts and the crankcase vibration damper. Discard the bolts.
34. Punch two holes in the seal.
35. Using the special tool, remove the crankshaft seal.
36. If equipped, remove the crankshaft damper wear sleeve with the special tool.
37. Remove the oil pump body. Remove the bolts. Remove and discard the O-ring seal.
38. Remove the inner and outer oil pump drive rotors.
39. Remove the engine front cover. Remove the bolts. Clean and inspect the gaskets. Install new gaskets if necessary. Clean and inspect the sealing surfaces.
40. Remove the flywheel adapter.
41. Punch two holes across from each other in the rear main seal.
42. Using the special tool, remove the rear main seal.
43. If equipped with a crankshaft wear sleeve, use the special tool to remove the crankshaft rear wear sleeve.
44. Clean and inspect the crankshaft sealing surface.
45. Remove the rear engine cover. Remove the bolts. Clean and inspect the gaskets. Install a new gasket if necessary. Clean and inspect the sealing surfaces.
46. 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 specifications.
47. Remove the bolts and the RH exhaust manifold.
48. Remove the bolts and the LH exhaust manifold.
49. Remove the bolts and the high pressure oil rail.
50. Using a 19 mm (0.74 in) socket, push the fuel injector electrical connector out of the rocker arm carrier.
51. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
52. Remove the bolt, the fuel injector hold down and the fuel injector.
53. Remove the shop towels.
54. Remove the crankcase-to-head tube assembly. Remove and discard the O-ring seals.
55. Remove and discard the 20 head bolts from both cylinder heads.
56. Remove the 16 bolts and the rocker arm assemblies.
57. 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.
58. Remove the 16 valve bridges.
59. Mark and remove the 16 push rods.
60. Remove the 10 outer head bolts.
61. Remove the cylinder heads. Install the special tool. Install the bolts. Remove the cylinder heads.
62. Remove and discard the cylinder head gaskets.
63. Remove and discard the four cylinder head dowel sleeves.
64. Remove the bolts from the rear engine tube assembly.
65. Remove the bolt and the rear engine tube assembly.
66. Remove the bolts and the roller follower guides. Remove the hydraulic cam followers.
67. Remove the upper oil pan. Remove the bolts. Clean and inspect the gaskets. Install new gaskets if necessary. Clean and inspect the sealing surfaces.
68. 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 crank shaft to measure the maximum piston protrusion and record. Average the two readings to see if the maximum piston protrusion is exceeded.
69. Using a feeler gauge, check for the minimum connecting rod side clearance.
70. Remove the bolts and the connecting rod caps.
71. Use a razor knife or emery board to scrape the carbon ridge from the top of the cylinder bore.
72. Using a wood or plastic hammer handle, push the connecting rod and piston assembly out of the cylinder bore.
73. Remove the piston rings. Remove the top compression ring. Remove the intermediate compression ring. Remove the oil control ring.
74. Remove and discard the connecting rod bearings.
75. Install the special tool and measure the camshaft gear backlash. Install a new gear if backlash is not within specification.
76. Install the special tool and measure the camshaft end play. Install a new camshaft thrust plate if end play is not within specification.
77. Install the special tool and measure the crankshaft end play. Record the end play.
78. Remove the bolt and the crankshaft position (CKP) sensor.
79. Remove the bolt and the camshaft position (CMP) sensor.
80. Remove the block heater.
81. Remove the 20 lower case bolts and the 8 outside lower crankcase bolts. Remove the lower crankcase assembly.
82. Remove the lower crankcase seals and the lower bearings and discard.
83. Using the appropriate lifting device, remove the crankshaft assembly.
84. Remove and discard the crankshaft upper bearings and crankshaft upper thrust bearing.
85. Remove the thrust plate mounting bolts and remove the camshaft and gear.
86. Remove the bolts and the eight piston cooling tubes.
87. Using the special tool, remove the camshaft bearings and discard.

Scheme 1861

Scheme 1862

Scheme 1863

Scheme 1864

Scheme 1865

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 1866

Scheme 1867

Scheme 1868

Scheme 1869

Scheme 1870

Scheme 1871

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.

SPECIAL TOOL(S)

Scheme 1872

MATERIAL

MATERIAL CHART

Scheme 1873

Scheme 1874

Scheme 1875

Scheme 1876

Scheme 1877

Scheme 1878

Scheme 1879

Scheme 1880

Scheme 1881

Scheme 1882

Scheme 1883

1. Install new D-ring seals on each end of 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 rod. 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. Tighten bolts 1 through 10 to 88 Nm (65 lb-ft). Tighten bolts 1, 3, 5, 7 and 9 to 115 Nm (85 lb-ft). Tighten bolts in sequence 1 through 10, clockwise 90 degrees. Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees. Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees. Tighten bolts 11 through 15 to 24 Nm (18 lb-ft). Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
11. 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. Install the RH high-pressure oil rail-to-valve cover gasket.
18. Install the RH valve cover.
19. Install the right exhaust manifold and the bolts.
20. Cover the LH cylinder head with an appropriate covering.
21. Install the turbocharger heat shield and bolts.
22. Install the left cylinder head fuel line.
23. Install the left exhaust manifold and the bolts.
24. Install the eight glow plugs.
25. Install the glow plug harness.
26. Install the special tools.
27. Install the special tool.
28. Install the lifting crane and remove the engine from the engine stand.
29. Install the flexplate and the bolts. Tighten the bolts in the following sequence. Tighten all bolts to 5 Nm (44 lb-in). Tighten all bolts to 94 Nm (69 lb-ft) in the sequence shown.
30. Install the engine. For additional information, refer to «ENGINE»(ref-213720-S35595260392005123000000) .