How to Overhaul & Installation - Diesel the Engine Controls - Removal Ford Econoline I

INTRODUCTION

Note. References to Econoline include Cutaway and RV Cutaway. References to Pickup include Cab & Chassis and Super Duty Pickups. For alternate fuel and bi-fuel specific removal, overhaul and installation procedures, see REMOVAL, OVERHAUL & INSTALLATION - CNG/LPG (BI-FUEL) article. For gasoline specific removal, overhaul and installation procedures, see REMOVAL, OVERHAUL & INSTALLATION - TRUCKS - GASOLINE article.

Removal, overhaul, and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

Removal & Installation

Remove the radiator. Loosen the clamps and remove inlet and outlet ducts from charge air cooler. Remove 2 charge air cooler stud bolts and remove charge air cooler. (Scheme 35) To install, reverse removal procedure. Tighten charge air cooler stud bolts to specification. See TORQUE SPECIFICATIONS.

Scheme 35

Removal & Installation (Econoline)

1. Remove engine cover. Remove turbocharger heat shield.
2. Loosen marmon clamp and pull exhaust outlet pipe away from turbocharger. (Scheme 36)
3. Disconnect the control rod from exhaust backpressure valve and remove bolts retaining exhaust backpressure valve to turbocharger.
4. To install, reverse removal procedure. Tighten exhaust backpressure valve bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-diesel-the-engine-controls-removal__torque-specifications). Using the Spring Gauge, adjust the control rod length until 10 lbs. (4.5 kg) of force is required to fully close the exhaust backpressure valve. (Scheme 37)

Scheme 36

Scheme 37

Removal & Installation (Excursion & Pickup)

1. Remove charge air cooler inlet and outlet ducts from compressor manifold. (Scheme 35)
2. Loosen exhaust outlet pipe marmon clamp at turbocharger and pull exhaust pipe away from exhaust backpressure valve. (Scheme 38)
3. Disconnect backpressure valve by sliding the retaining clip toward turbocharger housing and disconnecting exhaust backpressure valve actuator rod from the exhaust backpressure valve. Remove 6 exhaust backpressure valve bolts and remove exhaust backpressure valve.
4. To install, reverse removal procedure. Tighten 6 exhaust backpressure valve bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-diesel-the-engine-controls-removal__torque-specifications). Using the Spring Gauge, adjust the control rod length until 10 lbs. (4.5 kg) of force is required to fully close the exhaust backpressure valve. (Scheme 37)

Scheme 38

TURBOCHARGER

Note. Turbocharger overhaul is not available. Replace turbocharger as a unit if necessary.

Removal (Excursion & Pickup)

1. Disconnect negative battery cable(s). Remove charge air cooler inlet and outlet ducts from compressor manifold. Disconnect pressure lines. Disconnect intake air heater, intake air temperature sensor and manifold absolute pressure sensor electrical connectors. Loosen turbocharger-to-compressor manifold clamp. Remove compressor manifold. Loosen clamp and pull exhaust outlet pipe away from turbocharger.
2. On vehicles with exhaust backpressure system, slide retaining clip away from exhaust backpressure valve actuator lever. Pull actuator rod free of exhaust backpressure valve actuator lever. Loosen clamp and disconnect pressure line. On all vehicles, disconnect wastegate solenoid vacuum and pressure hoses.
3. Remove inlet tube. (Scheme 40) Loosen Marmon clamp. Remove turbocharger-to-cylinder block bolts. Remove turbocharger assembly. Install Turbo Protective Cap Set (T94T-9395-AH). Remove and discard oil gallery "O" rings.

Inspection

1. If still attached, disconnect air intake tube and exhaust pipe from turbocharger. Rotate turbine wheel, shaft assembly and compressor wheel inside turbocharger. Shaft assembly should rotate smoothly. Perform STEP 1. (Scheme 39)
2. Push compressor wheel and shaft assembly as far in one direction as possible while rotating shaft assembly. Ensure compressor wheel does not contact compressor housing while rotating shaft assembly. Push turbine wheel and shaft assembly as far in opposite direction as possible while rotating shaft assembly. Ensure turbine wheel does not contact turbine housing while rotating shaft assembly.
3. If compressor wheel or turbine wheel does not contact housing while rotating shaft assembly, bearings in turbocharger are okay. Go to next step. If compressor wheel or turbine wheel contacts housing while rotating shaft assembly, bearings in turbocharger are defective. Replace turbocharger.
4. Install dial indicator so stem contacts end of shaft assembly at compressor wheel. Perform STEP 2. (Scheme 39) Push shaft assembly as far in one direction as possible and zero dial indicator. Push shaft assembly as far in the opposite direction and note shaft end play. Replace turbocharger if shaft end play is not.0010-.0040" (.025-.102 mm). Check control rod tension. Attach spring scale on control rod. see scheme 6 Adjust control rod length to obtain a reading of 10 lbs. (4.5 kg) on spring scale. Remove spring scale.

1. Install NEW oil gallery "O" rings. Position Marmon clamp on exhaust inlet tube. Connect turbocharger electrical connectors and position turbocharger assembly onto cylinder block. Install turbocharger retaining bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-diesel-the-engine-controls-removal__torque-specifications) .
2. Loosely install right and left turbocharger exhaust inlet pipes-to-turbocharger exhaust inlet adapter. Install compressor manifold onto turbocharger and tighten hose clamps. Install engine lift hook and raise vehicle.
3. Tighten 2 right and left lower turbocharger exhaust inlet pipes-to-turbocharger exhaust inlet adapter bolts to specification. Tighten 4 right and left turbocharger exhaust inlet pipes-to-exhaust manifold bolts and nuts to specification. Install catalytic converter-to-engine charge exhaust pipe bolts.
4. Lower vehicle. Tighten 2 right and left upper turbocharger exhaust inlet pipes-to-turbocharger exhaust inlet adapter bolts to specification. Install turbocharger-to-exhaust outlet clamp. Install air intake tube and hose assembly.

Removal (Econoline)

1. Disconnect negative battery cable(s). Remove engine cover. Remove air cleaner, inlet duct and resonator. Remove heat shield. Remove 4 exhaust crossover pipe-to-turbocharger inlet adapter bolts. Remove turbocharger exhaust outlet clamp. Loosen 2 turbocharger exhaust inlet pipe-to-left exhaust manifold bolts. (Scheme 40)
2. Loosen turbocharger exhaust inlet clamp. Remove inlet hose and position aside. Loosen compressor manifold clamps and position compressor manifold toward front of vehicle. Disconnect back pressure valve actuator. Remove 4 turbocharger-to-cylinder block bolts. Remove turbocharger assembly and disconnect electrical connectors. If turbocharger will not be disassembled, install protective caps. Remove and discard oil gallery "O" rings.

1. Disconnect air intake tube and exhaust pipe from turbocharger. Rotate turbine wheel, shaft assembly and compressor wheel inside turbocharger. Shaft assembly should rotate smoothly. Perform STEP 1. (Scheme 39)
2. Push compressor wheel and shaft assembly as far in one direction as possible while rotating shaft assembly. Ensure compressor wheel does not contact compressor housing while rotating shaft assembly. Push turbine wheel and shaft assembly as far in opposite direction as possible while rotating shaft assembly. Ensure turbine wheel does not contact turbine housing while rotating shaft assembly.
3. If compressor wheel or turbine wheel does not contact housing while rotating shaft assembly, bearings in turbocharger are okay. Go to next step. If compressor wheel or turbine wheel contacts housing while rotating shaft assembly, bearings in turbocharger are defective. Replace turbocharger.
4. Install dial indicator so stem on dial indicator contacts end of shaft assembly at the compressor wheel. Perform STEP 2. (Scheme 39) Push shaft assembly as far in one direction as possible and zero dial indicator. Push shaft assembly as far in the opposite direction and note shaft end play. Replace turbocharger if shaft end play exceeds.0010-.0040" (.025-.102 mm). Check control rod tension. Attach spring scale on control rod. see scheme 6 Adjust control rod length to obtain a reading of 10 lbs. (4.5 kg) on spring scale. Remove spring scale.

1. Install NEW oil gallery "O" rings. Connect turbocharger electrical connectors and position turbocharger assembly onto cylinder block. Install turbocharger retaining bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-diesel-the-engine-controls-removal__torque-specifications) .
2. Loosely install right and left turbocharger exhaust inlet pipes-to-turbocharger exhaust inlet adapter. Install exhaust inlet and outlet clamps. Tighten 2 right and left lower turbocharger exhaust inlet pipes-to-turbocharger exhaust inlet adapter bolts to specification.
3. Tighten 4 right and left turbocharger exhaust inlet pipe-to-exhaust manifold bolts and nuts to specification. Install turbocharger-to-exhaust outlet clamp. To complete installation, reverse removal procedure.

Scheme 39

Scheme 40

COMPUTERIZED ENGINE CONTROLS

Disconnect negative battery cable(s). Disconnect coolant recovery bottle hose. Remove coolant recovery bottle. Remove upper and rear IDM mounting bolts. Loosen lower IDM mounting bolt. Remove IDM. Remove Injector Driver Module (IDM) connector retaining bolt. Unplug harness connector from IDM. To install, reverse removal procedure. Tighten bracket bolts and connector bolt to specification. See TORQUE SPECIFICATIONS .

Raise and support vehicle. Remove driver's side front inner fender splash shield. Remove Injector Driver Module (IDM) connector retaining bolt. Unplug harness connector from IDM. Remove 2 IDM mounting bolts. Remove IDM. To install, reverse removal procedure. Tighten bracket bolts and connector bolt to specification. See TORQUE SPECIFICATIONS .

Disconnect negative battery cable(s). Remove any component(s) necessary to gain access to PCM. PCM is located on driver's side of firewall. Loosen PCM connector retaining bolt (if equipped). Unplug harness connector from PCM. Remove 2 PCM mounting bolts. Remove PCM cover and PCM. On Econoline, PCM connector and mounting bolts are underhood. On Excursion and F250/F350 Super Duty Pickup, PCM connector is underhood, PCM mounting bolts are under instrument panel. To install, reverse removal procedure. Tighten bracket bolts and connector bolt to specification. See TORQUE SPECIFICATIONS .

Disconnect harness connector. Remove bolts and accelerator pedal assembly. To install, reverse removal procedure. Accelerator pedal sensor is nonadjustable.

Disconnect Camshaft Position (CMP) sensor harness connector, located at front of engine above crankshaft pulley. Remove bolt and CMP sensor. To install, reverse removal procedure. Tighten bolt to specification. See TORQUE SPECIFICATIONS .

Turn ignition switch to OFF position. Partially drain cooling system. Disconnect Engine Coolant Temperature (ECT) sensor electrical connector and remove ECT from engine. (Scheme 41) To install, reverse removal procedure. Tighten ECT sensor to specification. See TORQUE SPECIFICATIONS. Fill and bleed cooling system. See COOLING SYSTEM.

Scheme 41

Turn ignition switch to OFF position. Remove air cleaner assembly. Remove drive belt and drive belt pulley. Disconnect exhaust backpressure electrical connector and line. Remove exhaust backpressure sensor. (Scheme 42) To install, reverse removal procedure.

Scheme 42

Turn ignition switch to OFF position. Disconnect exhaust backpressure sensor electrical connector and remove sensor from mounting bracket. (Scheme 43) To install, reverse removal procedure.

Scheme 43

Idle validation switch is part of accelerator pedal assembly. For removal and installation, see ACCELERATOR PEDAL SENSOR .

Turn ignition switch to OFF position. Disconnect Manifold Absolute Pressure (MAP) sensor pressure line and electrical connector. Remove MAP sensor mounting screws and remove sensor. (Scheme 44)or (Scheme 45). Compress pressure hose clamp and remove hose from MAP sensor. To install, reverse removal procedure.

Scheme 44

Scheme 45

Turn ignition switch to OFF position. Remove air cleaner assembly. Remove the plug from the high-pressure oil pump reservoir. (Scheme 46) Using the Oil Suction Gun, draw the oil from the high-pressure oil pump reservoir. Disconnect Engine Oil Temperature (EOT) sensor electrical connector and remove EOT sensor. To install, reverse removal procedure. Fill high pressure oil pump reservoir with clean engine oil before installing plug.

Scheme 46

Remove turbocharger. See TURBOCHARGER under AIR INDUCTION SYSTEMS. Remove exhaust backpressure solenoid electrical connector. Remove bolt and retaining bracket. Remove exhaust backpressure solenoid. (Scheme 47) To install, reverse removal procedure. Lubricate "O" ring seals with clean engine oil prior to installing exhaust backpressure solenoid.

Scheme 47

Disconnect negative battery cable. Remove glow plug relay terminal cover. Remove wiring nuts and wiring from relay. Remove 2 glow plug relay retaining nuts. (Scheme 48) Remove relay and inspect plastic base for cracks. To install, reverse removal procedure. Tighten mounting nuts and cable connections to specification. See TORQUE SPECIFICATIONS.

Scheme 48

Note. High pressure oil pressure regulator may also be referred to as injection pressure regulator.

1. Disconnect negative battery cable. Disconnect charge air cooler inlet and outlet pipes.
2. Disconnect intake air heater element electrical leads. Disconnect Air Charge Temperature (ACT) sensor electrical connector and Manifold Absolute Temperature (MAP) sensor electrical connector and pressure hoses.
3. Loosen compressor manifold clamps and remove compressor manifold. Remove and discard compressor manifold "O" ring seal.
4. Remove fuel filter/water separator. See «FUEL FILTER/WATER SEPARATOR»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-diesel-the-engine-controls-removal) under FUEL SYSTEMS.
5. Disconnect electrical connector from oil pressure regulator. Remove nut, spacer washer and regulator. Remove oil pressure regulator valve from high-pressure oil pump. (Scheme 49)
6. To install, reverse removal procedure. Tighten regulator and nut to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-diesel-the-engine-controls-removal__torque-specifications). Install NEW compressor manifold "O" ring seal.

Scheme 49

Remove turbocharger. See TURBOCHARGER under AIR INDUCTION SYSTEMS. Remove adjustment rod clip and disconnect adjustment rod from wastegate crank. Remove 2 lock nuts and wastegate control solenoid. (Scheme 50) To install, reverse removal procedure.

Scheme 50

Adjustment Procedure

1. Disconnect pressure line from wastegate control solenoid. Install adjustment rod end onto wastegate control solenoid, if removed.
2. Press wastegate crank toward wastegate control solenoid. (Scheme 51) Using a pressure pump, apply 5 psi (34.5 kPa) of pressure to the actuator diaphragm.
3. Turn adjustment rod until the adjustment eye slips over the wastegate crank pin with no resistance and install adjustment rod clip. (Scheme 52)
4. Release and reapply 5 psi (34.5 kPa) of pressure to wastegate control solenoid to verify wastegate operations.
5. Tighten adjustment rod set nut to prevent wastegate control solenoid from loosing its adjustment. Disconnect pressure pump and attach pressure line to wastegate control solenoid.

Scheme 51

Scheme 52

COOLING SYSTEM BLEEDING

1. Turn heater controls to maximum and set air discharge to instrument panel vents. Turn blower to high. Fill cooling system with 50/50 mixture of coolant and water. Pause several minutes for circulation. Start engine and run at 2000 RPM for 5 minutes. Feel for hot air at instrument panel vents. If air discharge remains cool and coolant temperature gauge does not move, coolant level is low.
2. Stop engine and allow it to cool. Top off coolant as necessary. Start engine and allow it to idle until normal operating temperature is reached. Hot air should discharge from instrument panel vents. Coolant temperature gauge should maintain a stable reading in middle of range. Upper radiator hose should feel hot to touch. Stop engine and allow it to cool. Top off coolant as necessary. Check for coolant leaks.

FUEL SYSTEM PRESSURE RELEASE

Note. Diesel fuel can damage asphalt and other surfaces. Always place an appropriate container under the fuel filter water drain under the vehicle and dispose of the waste in accordance with all federal, state and local requirements.

Open hood and place an appropriate container under fuel filter water drain under vehicle. (Scheme 53) To release fuel system pressure, open fuel filter/water separator drain valve. (Scheme 54) After pressure has been released, close drain valve. Properly dispose of drained fuel.

Scheme 53

Scheme 54

FUEL FILTER WATER DRAINING

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Allow to drain for approximately 25 seconds or until clean fuel is observed. Close drain valve by resetting handle to its original position. Close hood and remove container from under vehicle. Dispose of waste fuel properly.

1. Disconnect negative battery cable.
2. Open fuel filter/water separator drain valve to release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-diesel-the-engine-controls-removal__fuel-system-pressure-release). Completely drain fuel filter/water separator assembly.
3. Disconnect fuel supply and fuel return lines at fuel filter/water separator. (Scheme 55)
4. Disconnect 2 cylinder head fuel supply lines. (Scheme 56)
5. Disconnect electrical connector from fuel filter/water separator. (Scheme 57)
6. Disconnect exhaust backpressure sensor electrical connector and remove fuel filter/water separator retaining bolts. (Scheme 58) Remove fuel filter/water separator. To install, reverse removal procedure.

Scheme 55

Scheme 56

Scheme 57

Scheme 58

Remove fuel filter/water separator assembly. See FUEL FILTER/WATER SEPARATOR. Remove fuel filter cap and element. Remove thermostat screws and pull thermostat out of fuel filter/water separator housing. (Scheme 59) Disconnect fuel heater element electrical connector and retaining screws. (Scheme 60) Remove the fuel heater. To install, reverse removal procedure.

Scheme 59

Scheme 60

Removal (E-Series)

SPECIAL TOOLS Impact Slide Hammer 100-001 (T50T-100-A) Injector Protective Sleeve and Holding Rack 303-DS113 (D94T-9000-E) or Equivalent Injector Remover 303-491 (T94T-9000-AH1) Injector Replacer 303-492 (T94T-9000-AH2) Injector Sleeve Brush Set 303-DS110 (D94T-9000-D) or Equivalent Injector Sleeve Remover Set 303-DS105 (D94T-9000-B) or Equivalent Injector Sleeve Replacer 303-D109 (D94T-9000-C) or Equivalent

Scheme 61

Scheme 62

Scheme 63

Scheme 64

Scheme 65

Scheme 66

Scheme 67

Scheme 68

Scheme 69

Scheme 70

Scheme 71

1. Remove the air cleaner assembly and resonator.
2. Drain the fuel from the cylinder heads. Loosen the drain plugs, located at the rear of each cylinder head.
3. If removing injector 3 or 5, carry out the following: Disconnect the A/C compressor clutch wire. Raise the vehicle. Loosen the right hand motor mount nuts. Remove the LH engine mount-to-engine bolts. Raise the engine. Remove the LH engine mount-to-crossmember nuts. Remove the LH engine mount. Lower the engine until the oil pan is resting on the crossmember.
4. Remove the valve cover. For additional information, refer to «ROCKER ARM ASSEMBLY & PUSH ROD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-73l-v8-turbo-diesel-vin-f__rocker-arm-assembly-push-rod) for 1999 models, or refer to «VALVE COVERS»(ref-11824-S40624124662004031700000) for 2000 models.
5. Remove the fuel charging wiring.
6. Remove the oil drain plugs.
7. Remove the bolt and the oil deflector from the fuel injector hold-down plate.
8. Remove the outboard fuel injector hold-down bolts.
9. Using the Injector Remover, remove the fuel injector.
10. Place the fuel injector into the injector protective sleeve.
11. Remove the cylinder heads from the engine. For additional information, refer to «CYLINDER HEAD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-73l-v8-turbo-diesel-vin-f__cylinder-head) for 1999 models, or refer to «CYLINDER HEAD»(ref-11824-S21707318422000113000000) for 2000 models.
12. Insert the injector sleeve tap and injector sleeve tap pilot into the cylinder head fuel injector bore. Tighten injector sleeve tap 1-1/2 to 2 turns. Attach the Impact Slide Hammer to the injector sleeve tap pilot, and remove the fuel injector sleeve from the cylinder head fuel injector bore. Discard the sleeve.
13. Using the special tool, remove sealant residue and all foreign material from the cylinder head fuel injector bore.

Removal (Except E-Series)

SPECIAL TOOLS Impact Slide Hammer 100-001 (T50T-100-A) Injector Protective Sleeve and Holding Rack 303-DS113 (D94T-9000-E) or Equivalent Injector Remover 303-491 (T94T-9000-AH1) Injector Replacer 303-492 (T94T-9000-AH2) Injector Sleeve Brush Set 303-DS110 (D94T-9000-D) or Equivalent Injector Sleeve Remover Set 303-DS105 (D94T-9000-B) or Equivalent Injector Sleeve Replacer 303-D109 (D94T-9000-C) or Equivalent

Scheme 72

1. Remove the valve cover. For additional information, refer to «ROCKER ARM ASSEMBLY & PUSH ROD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-73l-v8-turbo-diesel-vin-f__rocker-arm-assembly-push-rod) for 1999 models, or refer to «VALVE COVERS»(ref-11824-S40624124662004031700000) for 2000 models.
2. Drain the fuel from the cylinder heads. Loosen the drain plugs, located at the rear of each cylinder head.
3. Remove the oil drain plugs.
4. Remove the bolt and the oil deflector from the fuel injector hold-down plate.
5. Remove the fuel injector outboard retaining bolts.
6. Using the Injector Remover, remove the fuel injector.
7. Place the fuel injector into the injector protective sleeve.
8. Place the injector and sleeve into the holding rack.
9. If required, remove the cylinder heads from the engine. For additional information, refer to «CYLINDER HEAD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-73l-v8-turbo-diesel-vin-f__cylinder-head) for 1999 models, or refer to «CYLINDER HEAD»(ref-11824-S21707318422000113000000) for 2000 models.
10. Insert the injector sleeve tap and injector sleeve tap pilot into the cylinder head fuel injector bore. Tighten injector sleeve tap 1-1/2 to 2 turns. Attach the Impact Slide Hammer to the injector sleeve tap pilot, and remove the fuel injector sleeve from the cylinder head fuel injector bore. Discard the sleeve.
11. Remove sealant residue and all foreign material from the cylinder head fuel injector bore, using the injector sleeve brush.

Scheme 73

Scheme 74

Scheme 75

Scheme 76

Scheme 77

Scheme 78

Scheme 79

1. Position the fuel injector sleeve onto the special tool. Apply Threadlock® 620 or equivalent to the fuel injector sleeve.
2. Position the fuel injector sleeve into the cylinder head fuel injector bore. Seat the fuel injector sleeve in the fuel injector bore, using a rubber mallet. Remove Injector Sleeve Replacer tool from the cylinder head fuel injector bore.
3. Clean the fuel injector sleeve and bore, using the fuel injector sleeve brush. Remove any sealant residue from the fuel injector bore.
4. Install new O-rings on the fuel injector. Lubricate the fuel injector and O-rings liberally with clean engine oil.
5. If required, install the cylinder heads. For additional information, refer to «CYLINDER HEAD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-73l-v8-turbo-diesel-vin-f__cylinder-head) for 1999 models, or refer to «CYLINDER HEAD»(ref-11824-S21707318422000113000000) for 2000 models.
6. Install the fuel injector. Insert the fuel injector into the cylinder head fuel injector bore. Using the Injector Replacer, seat the fuel injector into the cylinder head fuel injector bore.
7. Install the outboard fuel injector hold-down bolts.
8. Install the oil deflector on the fuel injector hold-down plate, using the shoulder bolt.
9. Install the oil drain plugs.
10. Tighten the fuel drain plug located at the rear of each cylinder head.
11. Position the valve cover gasket onto the cylinder head.
12. Install the fuel charging wiring.
13. Install the valve covers. For additional information, refer to «ROCKER ARM ASSEMBLY & PUSH ROD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-73l-v8-turbo-diesel-vin-f__rocker-arm-assembly-push-rod) for 1999 models, or refer to «VALVE COVERS»(ref-11824-S40624124662004031700000) for 2000 models.
14. Connect the A/C compressor wire.
15. Install the left motor mount and tighten the right motor mount nuts.
16. Install the resonator and air cleaner assembly.

Scheme 80

1. Position the fuel injector sleeve onto the Injector Sleeve Replacer. Apply Threadlock® 620 or equivalent to the very bottom (smallest diameter) and very top (largest diameter) flat areas.
2. Position the fuel injector sleeve into the cylinder head fuel injector bore. Seat the fuel injector sleeve in the fuel injector bore, using a rubber mallet. Remove Injector Sleeve Replacer tool from the cylinder head fuel injector bore.
3. Clean the fuel injector sleeve and bore, using the fuel injector sleeve brush. Remove any sealant residue from the fuel injector bore.
4. Install new O-rings on the fuel injector. Lubricate the fuel injector and O-rings liberally with clean engine oil.
5. If required, install the cylinder heads. For additional information, refer to «CYLINDER HEAD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-73l-v8-turbo-diesel-vin-f__cylinder-head) for 1999 models, or refer to «CYLINDER HEAD»(ref-11824-S21707318422000113000000) for 2000 models.
6. Using the Injector Replacer, seat the fuel injector into the cylinder head fuel injector bore.
7. Using the Injector Replacer, seat the fuel injector into the cylinder head fuel injector bore.
8. Install the fuel injector outboard retaining bolts.
9. Install the oil deflector on the fuel injector hold-down plate. see scheme 39 Tighten bolt to 12 N.m (9 ft. lbs.).
10. Install the oil drain plugs.
11. Tighten the fuel drain plug located at the rear of each cylinder head.
12. Install the valve covers. For additional information, refer to «ROCKER ARM ASSEMBLY & PUSH ROD»(/ford/econoline/i-1985-2013/remont/mechanical/#engine-73l-v8-turbo-diesel-vin-f__rocker-arm-assembly-push-rod) for 1999 models, or refer to «VALVE COVERS»(ref-11824-S40624124662004031700000) for 2000 models.

Remove engine appearance cover. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE under FUEL SYSTEMS. Remove fuel pressure regulator Torx® screws and cap. Remove "O" ring, spring and poppet valve. see scheme 60 Thoroughly clean fuel pressure regulator bore in the fuel filter/water separator. To install, reverse removal procedure.

Scheme 81

1. Disconnect negative battery cable. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-diesel-the-engine-controls-removal__fuel-system-pressure-release).
2. Raise and support vehicle. Disconnect fuel pump electrical connector located behind fuel pump near frame rail. see scheme 61
3. Remove fuel pump supply line retaining clip, discard clip and remove fuel supply line from fuel pump. Using Fuel Line Disconnect Tool, disconnect fuel delivery line.
4. Unclip brake lines from fuel pump bracket. Remove pump bracket mounting nuts, and remove fuel pump with bracket. see scheme 62 Loosen pinch bolt and remove fuel pump from mounting bracket.
5. To install, reverse removal procedure. Tighten fuel pump mounting bracket nuts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-diesel-the-engine-controls-removal__torque-specifications).

Scheme 82

Scheme 83

GLOW PLUGS

1. Disconnect negative battery cable. Remove right or left valve cover as necessary. To remove right valve cover, remove drive belt, generator mounting bracket and generator. To remove left valve cover, remove intake ducting, crankcase breather and vacuum hose from vacuum pump.
2. Disconnect harness connector from valve cover gasket. Remove valve cover bolts and valve cover. Disconnect wiring from fuel injectors. Remove valve cover gasket.
3. Disconnect wiring from glow plug using a pair of pliers. Unscrew glow plug to remove. If damage is evident, replace glow plug. To install, reverse removal procedure. Tighten glow plug to 14 ft. lbs. (19 N.m). Ensure wiring under valve cover is routed to avoid moving parts.

1. Disconnect negative battery cable(s). Remove charge air cooler inlet and outlet ducts from compressor manifold. Disconnect pressure lines. Disconnect pressure valve electrical connector. Loosen turbocharger-to-compressor manifold clamp. Remove compressor manifold. Remove fuel filter/water separator assembly. Remove access plug. Using suction, remove oil from high pressure oil pump reservoir. Remove necessary hoses from high pressure oil pump. (Scheme 81)
2. Disconnect harness connector from high pressure oil pressure control solenoid. Remove high pressure oil pressure regulator.
3. Remove access cover on front of engine exposing high pressure oil pump drive sprocket bolt. Remove drive sprocket bolt and washer. Remove high pressure oil pump mounting bolts and pump. Remove and discard gasket.

Scheme 84

1. Install high pressure oil pump with gasket. Install mounting bolts and tighten to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-diesel-the-engine-controls-removal__torque-specifications). Install drive sprocket on high pressure oil pump shaft. Before tightening drive sprocket bolt, ensure sprocket is fully seated on pump shaft.
2. To complete installation, reverse removal procedure. Ensure hoses are correctly routed. (Scheme 81) Refill high pressure oil pump reservoir with clean engine oil. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/ford/econoline/i-1985-2013/remont/removal-installation/#how-to-overhaul-installation-diesel-the-engine-controls-removal__torque-specifications).

Remove air inlet duct. Remove turbocharger compressor manifold. Remove fuel/water separator. Disconnect wiring from injector control pressure solenoid. Remove nut securing injection control pressure solenoid to high pressure oil pressure regulator. Remove high pressure oil pressure regulator from high pressure oil pump. (Scheme 82) To install, reverse removal procedure. Tighten pressure high pressure oil pressure regulator to 35 ft. lbs. (47 N.m).

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• ROCKER ARM ASSEMBLY & PUSH ROD
• CYLINDER HEAD
• TORQUE SPECIFICATIONS
• COOLING SYSTEM
• TURBOCHARGER
• FUEL SYSTEM PRESSURE RELEASE