Engine 6.0L Diesel: Overhaul Ford Econoline E250

Disassembly and Assembly

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 TOOL(S)

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MATERIAL

MATERIAL CHART

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1. Install new D-ring seals on each end of 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 as shown.
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. Tighten bolts to 149 Nm (110 lb-ft) in numerical sequence. Tighten bolts again to 176 Nm (130 lb-ft) in numerical sequence. Tighten bolts 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 shown.
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. Tighten bolts to 149 Nm (110 lb-ft) in numerical sequence. Tighten bolts again to 176 Nm (130 lb-ft) in numerical sequence. Tighten bolts 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 shown.
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. Tighten to 45 Nm (33 lb-ft). 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. Tighten to 45 Nm (33 lb-ft). 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 and the bolt.
35. Install the rear engine tube assembly bolts.
36. Install the four cylinder head dowels.
37. Place the new cylinder head gaskets over the dowel sleeves and onto the crankcase.
38. Using the special tool, install the cylinder heads. Install the lifting bracket. Install the bolts. Install the cylinder heads.
39. Install the 10 outer head bolts (finger-tight).
40. Apply clean engine oil to each end of the push rods. Insert them into their respective positions with the copper colored end up.
41. Install the 16 valve bridges.
42. Install the rocker arm carrier to the cylinder head. Install the press-in-place gasket. Install the rocker arm carrier. Install the bolts.
43. Install the rocker arm assemblies and the 16 bolts.
44. Install the new cylinder head retaining bolts finger-tight.
45. 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).
46. Apply clean engine oil and install a crankcase-to-head tube assembly.
47. Install new O-ring seals and a copper washer on the fuel injector.
48. Install the fuel injector, the fuel injector hold down and bolt.
49. Install the fuel injector electrical connector into the rocker carrier.
50. 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.
51. 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.
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. Tighten the bolts to 68 Nm (50 lb-ft). Tighten the bolts 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. Install the glow plug harness.
74. Install a new O-ring seal.
75. Install the high-pressure oil pump and the bolts.
76. Install the high-pressure pump O-ring seal.
77. Position the high-pressure discharge pipe and install the bolts.
78. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
79. Install a new D-ring seal on the high-pressure discharge pipe.
80. Clean the cover mounting surface and apply sealant at the seams.
81. Install the high-pressure pump cover. Install the press-in-place gasket. Install the high-pressure pump cover. Install the bolts.
82. Install the turbocharger heat shield and bolts.
83. Install the oil pump inlet strainer.
84. Install the oil cooler assembly. Install the gasket. Install the oil cooler assembly. Install the bolts.
85. Install the oil filter base. Install the gasket. Install the oil filter base. Install the bolts.
86. 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.
87. Install a new O-ring seal in the oil filter base.
88. Install the oil filter adapter and bolts.
89. Install the serpentine belt idler and bolt.
90. If equipped, install the belt tensioner and bolts.
91. Install the left cylinder head fuel line.
92. Install the thermostat housing and the stud bolts.
93. Position back the fuel bracket and install the retaining nut.
94. Install the RH motor mount plate and bolts.
95. Install the special tools.
96. Install the special tool.
97. Install the lifting crane and remove the engine from the engine stand.
98. 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.

SPECIAL TOOL(S)

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MATERIAL

MATERIAL CHART

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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. 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 pick-up tube and position the oil pick-up 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 pick-up tube and bolts.
12. Position the oil pan and install the bolts.
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 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. Position the transmission cooler tubes and install the retaining nut.
37. Position the tube lock and install the retaining bolt.
38. Install the oil filter assembly and bolts.
39. Position the engine wiring harness and connect the powertrain control module (PCM) electrical connectors.
40. Connect the two electrical connectors.
41. Connect the LH glow plug electrical connector.
42. Connect the push pin retainer and exhaust back pressure sensor electrical connector.
43. Connect the B+ wire and reposition the boot.
44. Connect the two electrical connectors 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 bolt.
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. Position the A/C manifold and install the bolt. 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»(ref-213720-S04554148002005123000000) .
64. Install the radiator core supports and bolts.
65. Position the hood latch and install the bolts.
66. Position the headlamp wiring harness and connect the air bag sensor. Install the bolts for the air bag sensor.
67. Install the valance panel, radiator grille support and grille opening panel reinforcement. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-210204) .
68. Install the front bumper. For additional information, refer to «BUMPERS»(ref-210212) .
69. Install the A/C condenser assembly. For additional information, refer to «AIR CONDITIONING»(ref-210171) .
70. Fill the engine with clean engine oil.
71. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-210181) .
72. Check and top off the transmission fluid level.