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Engine - 6.0L Diesel -- E350 & E450: Component Locations Ford Econoline E350 Super Duty

Mechanical 53 illustrations ~1914 words

Special Tool(s)

SPECIAL TOOL Adapter, High Pressure Pump Test 303-765

Scheme 805

Scheme 805: Special Tool(s)
Scheme 805: Special Tool(s)

SPECIAL TOOL Pins, Piston Groove Gauge 303-D1169

Scheme 806

Scheme 806: Inspection
Scheme 806: Inspection

Scheme 807

Scheme 807
Scheme 807

Scheme 808

Scheme 808
Scheme 808
  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 806) 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 809

Scheme 809: Inspection
Scheme 809: Inspection

Scheme 810

Scheme 810
Scheme 810

Scheme 811

Scheme 811
Scheme 811
  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 812

Scheme 812: Special Tool(s)
Scheme 812: Special Tool(s)

Scheme 813

Scheme 813: Clearance Test
Scheme 813: Clearance Test

Scheme 814

Scheme 814
Scheme 814
  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.

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

Scheme 815

Scheme 815: Special Tool(s)
Scheme 815: Special Tool(s)

Scheme 816

Scheme 816
Scheme 816

Scheme 817

Scheme 817
Scheme 817

Scheme 818

Scheme 818
Scheme 818

Scheme 819

Scheme 819
Scheme 819

Scheme 820

Scheme 820
Scheme 820

Scheme 821

Scheme 821
Scheme 821

Scheme 822

Scheme 822
Scheme 822

Scheme 823

Scheme 823
Scheme 823

Scheme 824

Scheme 824
Scheme 824

Scheme 825

Scheme 825
Scheme 825

Scheme 826

Scheme 826
Scheme 826

Scheme 827

Scheme 827
Scheme 827

Scheme 828

Scheme 828
Scheme 828

Scheme 829

Scheme 829
Scheme 829

Scheme 830

Scheme 830
Scheme 830

Scheme 831

Scheme 831
Scheme 831

Scheme 832

Scheme 832
Scheme 832
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
  2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
  3. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379) .
  4. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(ref-231368) .
  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 833

Scheme 833: Removal and Installation
Scheme 833: Removal and Installation

Scheme 834

Scheme 834
Scheme 834

Scheme 835

Scheme 835
Scheme 835

Scheme 836

Scheme 836
Scheme 836

Scheme 837

Scheme 837
Scheme 837

Scheme 838

Scheme 838
Scheme 838

Scheme 839

Scheme 839
Scheme 839
  1. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
  2. Remove the engine cover. For additional information, refer to «INTERIOR TRIM AND ORNAMENTATION»(ref-231379) .
  3. Remove the turbocharger inlet tube. For additional information, refer to «FUEL CHARGING & CONTROLS - TURBOCHARGER»(ref-231372) .
  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 840

Scheme 840
Scheme 840

Scheme 841

Scheme 841
Scheme 841

Scheme 842

Scheme 842
Scheme 842
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
  2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
  3. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(ref-231368) .
  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 843

Scheme 843: Installation
Scheme 843: Installation

Scheme 844

Scheme 844
Scheme 844
  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-231368) .
  6. Connect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .

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

Scheme 845

Scheme 845: Special Tool(s)
Scheme 845: Special Tool(s)

Scheme 846

Scheme 846
Scheme 846

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

Scheme 847

Scheme 847: Special Tool(s)
Scheme 847: Special Tool(s)

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 848

Scheme 848: Special Tool(s)
Scheme 848: Special Tool(s)

Scheme 849

Scheme 849
Scheme 849

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

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 850

Scheme 850
Scheme 850
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to «JACKING & LIFTING»(ref-231335) .
  2. Disconnect the battery ground cable. For additional information, refer to «BATTERY, MOUNTING AND CABLES»(ref-231356) .
  3. Remove the cooling fan stator. For additional information, refer to «ENGINE COOLING»(ref-231368) .
  4. Remove the A/C compressor. For additional information, refer to «HEATING & VENTILATION»(ref-231395) .
  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.

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

Scheme 851

Scheme 851: Special Tool(s)
Scheme 851: Special Tool(s)

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 852

Scheme 852
Scheme 852

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 853

Scheme 853: Special Tool(s)
Scheme 853: Special Tool(s)

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 854

Scheme 854
Scheme 854

Scheme 855

Scheme 855
Scheme 855

Scheme 856

Scheme 856
Scheme 856

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 857

Scheme 857
Scheme 857

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

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

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