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Home >> Ford >> 2010 >> F 250 4WD Super Duty V8-6.4L DSL Turbo >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Removal and Replacement >> Engine - Removal - Body On >> Steps 101-154

Steps 101-154




Engine - Body On









Removal

101. If equipped, disconnect the block heater electrical connector.





102. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

Disconnect the fuel hoses.





Vehicles with automatic transmission

103. Remove the flexplate access cover.





104. Remove and discard the 8 torque converter nuts.





105. Loosen the 2 retaining nuts for the transmission mount.





All vehicles

106. NOTE: Do not remove the LH engine mount retaining nuts, they are used to keep the engine stable for the remainder of the procedure.

Loosen the 3 retaining nuts for the LH engine mount.





107. Remove and discard the 4 retaining nuts for the RH engine mount.





108. Remove and discard the 2 studs for the RH engine mount.





109. NOTICE: The engine mount bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. The bolts are a torque-to-yield design and cannot be reused.

NOTE: The bolt is hidden at the approximate location shown.

Remove the LH upper engine bracket bolt.





110. NOTE: LH side shown, RH side similar.

Remove the 6 lower turbocharger inlet pipe nuts.

- Discard the nuts.





111. Remove the 3 studs for the LH turbocharger inlet pipe.
- Remove the LH turbocharger inlet pipe.

- Discard the gasket and studs.





112. NOTE: The RH turbocharger up pipe is removed from the top of the engine.

Remove the 3 studs for the RH turbocharger inlet pipe.

- Discard the gasket and studs.





113. Remove the 3 pushnuts and the glow plug module heat shield.
- Discard the pushnuts.





114. NOTE: Engine removed from the vehicle for clarity.

Remove the bolt and 5 retaining nuts for the fuel pump heat shield. Remove the fuel tube bracket and ground strap from the high-pressure fuel injection pump heat shield.





115. Remove the remaining 2 bolts and the high-pressure fuel injection pump heat shield.





116. Position back and secure the turbocharger exhaust downpipe.

117. Remove the EGR-OC pipe and the RH turbocharger inlet pipe.
- In order to remove the RH turbocharger inlet pipe, roll it to the left side of the vehicle and then remove the turbocharger inlet pipe.





118. Disconnect the PCM and wiring retainer. Disconnect the engine harness electrical connector.





119. Disconnect the heater hose and position aside.





120. Disconnect the glow plug module electrical connectors and high-pressure fuel pump electrical connector.





121. Disconnect the retainers for the EGRT sensor electrical connector and high-pressure fuel pump electrical connector from the glow plug module mounting bracket. Disconnect the pushpin retainer.





122. Disconnect the Intake Air Temperature 2 (IAT2) and the Manifold Absolute Pressure (MAP) sensor electrical connectors. Disconnect the RH fuel charging wiring harness electrical connector and wire retainer.





123. Disconnect the ECT sensor electrical connector and wiring retainer.





124. Disconnect the Engine Oil Temperature (EOT) sensor and the Engine Oil Pressure (EOP) switch electrical connectors.





125. Remove the bolt and position the engine wiring harness aside.





126. Disconnect the high-pressure fuel injection pump electrical connector and the pushpin retainer, and remove the harness.





127. Remove the 2 bolts, 1 stud bolt and the glow plug module bracket.





128. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

Disconnect the fuel injector return tube at the check valve.





129. Remove the 2 retaining nuts for the fuel injection pump supply tube.





130. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in Fuel Delivery and Air Induction.

NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.

Remove the 2 nuts and the sealing washers for the high-pressure fuel injection pump. Remove the fuel return tube and the fuel supply tube.
- Discard the sealing washers.





131. Remove the 2 bolts from the retainers for the 2 fuel rail supply tubes.





132. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in Fuel Delivery and Air Induction.

NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.

NOTE: LH shown, RH similar.

Remove and discard the 2 fuel rail supply tubes.





133. NOTICE: Do not bend or flex the heater supply tube or damage to the tube may occur.

Remove the nut, bolt and heater supply tube.

- Remove and discard the O-ring seal.





134. Remove the nut for the fuel return tube retainer.





135. Remove the 2 bolts for the fuel return tube retainers.





136. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components. Always install Fuel System Caps to any open orifices or tubes.

NOTE: RH side shown, LH side similar.

NOTE: The fuel return tube will be removed with the intake manifold.

Remove the fuel return tube LH and RH banjo bolts and sealing washers.

- Discard the sealing washers.





137. NOTICE: Clean the area between the engine block and the intake manifold thoroughly before removing the intake manifold. The slope of the block will cause any foreign material not removed to fall into the engine.

NOTE: Mark the location of the fasteners prior to removing.

Remove the 16 bolts. Remove the intake manifold and the fuel return tube.





138. Remove the intake manifold gaskets.
- Clean and inspect the gaskets. Install new gaskets if necessary.

- Clean and inspect the sealing surfaces.





139. NOTE: Mark the location of the 5 longer bolts.

Remove as many of the 5 long and 17 short oil pan bolts as possible.





Vehicles with automatic transmission

140. Remove the 5 lower engine-to-transmission bolts.





All vehicles

141. Install the Adapter for 303-D043 on the back of the cylinder head.





142. Disconnect the retainer for the power steering tube.





143. Remove the bolt for the crankcase vent oil separator tube.





144. Install the Adapter for 303-D043.





145. Install the Engine Lifting Attachment.





146. Install the Heavy Duty Floor Crane.

Vehicles with automatic transmission

147. Position a suitable jack under the transmission.

All vehicles

148. Remove and discard the 3 retaining nuts for the LH engine mount.





149. NOTICE: The engine mount bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. The bolts are a torque-to-yield design and cannot be reused.

Remove the 3 LH engine mount bracket bolts.





150. With the help of an assistant, raise the Heavy Duty Floor Crane and the transmission jack (automatic transmission vehicles only) as needed to gain enough clearance to remove the oil pan.

151. NOTE: The oil pan will not come out until the oil pick-up tube is removed.

Remove the remaining bolts for the oil pan and position it as needed for oil pick-up tube access.





152. Remove the 2 bolts for the oil pick-up tube and allow it to drop into the oil pan. Remove the oil pan from the vehicle.
- Discard the O-ring seal.





Vehicles with automatic transmission

153. Remove the 4 upper engine-to-transmission bolts.





All vehicles

154. NOTICE: During removal, the engine will pass very close to brake lines and other body-mounted components. Remove the engine slowly and continually check that engine parts do not snag on body-mounted parts, or component damage may occur.

NOTICE: After the engine is removed, position the engine close to the floor in case of lifting crane failure. Failure to lower the engine may result in engine damage.

With the help of an assistant, using the Heavy Duty Floor Crane and the Engine Lifting Attachment, remove the engine from the vehicle. During the removal of the engine, it will be necessary to remove the LH engine mount.





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