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    Superduty 6.0L Powerstroke Engine: Removal/Installation Service Tips

    Uploaded by

    vixentd
    This document provides service tips for technicians removing and installing the 6.0L Powerstroke diesel engine found in Ford Superduty trucks. The tips aim to save technicians time during the engine removal and installation process. They include repositioning the turbocharger clamp for better access, using a half-moon wrench on the turbo adapter tube fasteners, removing the factory lifting eye since it has an incorrect angle, and using extended sockets to remove the torque converter nuts without raising the vehicle. Proper tool selection is emphasized to efficiently perform each step in the correct order outlined by the shop manual.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd

    Superduty 6.0L Powerstroke Engine: Removal/Installation Service Tips

    Uploaded by

    vixentd
    311 views21 pages
    This document provides service tips for technicians removing and installing the 6.0L Powerstroke diesel engine found in Ford Superduty trucks. The tips aim to save technicians time during the engine removal and installation process. They include repositioning the turbocharger clamp for better access, using a half-moon wrench on the turbo adapter tube fasteners, removing the factory lifting eye since it has an incorrect angle, and using extended sockets to remove the torque converter nuts without raising the vehicle. Proper tool selection is emphasized to efficiently perform each step in the correct order outlined by the shop manual.

    Original Description:

    Ford

    Original Title

    6.0 Removal Tips

    Copyright

    © © All Rights Reserved

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    PDF, TXT or read online from Scribd

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    This document provides service tips for technicians removing and installing the 6.0L Powerstroke diesel engine found in Ford Superduty trucks. The tips aim to save technicians time during the engine removal and installation process. They include repositioning the turbocharger clamp for better access, using a half-moon wrench on the turbo adapter tube fasteners, removing the factory lifting eye since it has an incorrect angle, and using extended sockets to remove the torque converter nuts without raising the vehicle. Proper tool selection is emphasized to efficiently perform each step in the correct order outlined by the shop manual.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    311 views21 pages

    Superduty 6.0L Powerstroke Engine: Removal/Installation Service Tips

    Uploaded by

    vixentd
    This document provides service tips for technicians removing and installing the 6.0L Powerstroke diesel engine found in Ford Superduty trucks. The tips aim to save technicians time during the engine removal and installation process. They include repositioning the turbocharger clamp for better access, using a half-moon wrench on the turbo adapter tube fasteners, removing the factory lifting eye since it has an incorrect angle, and using extended sockets to remove the torque converter nuts without raising the vehicle. Proper tool selection is emphasized to efficiently perform each step in the correct order outlined by the shop manual.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 21
    At a glance
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    The document provides service tips for efficiently removing and installing a 6.0L Powerstroke engine by following the correct order of steps and using recommended tools.

    The main steps involved in removing a 6.0L Powerstroke engine include disconnecting the battery cables, removing the transmission if it's a manual, and then following the shop manual procedure to remove engine sub-assemblies in the correct order.

    The document recommends using a diesel engine lift bracket and engine hoist to remove the engine from the vehicle chassis as it allows lifting the engine straight up and out with controlled movement compared to using a conventional spreader bar and chain.

    Superduty 6.

    0L
    Powerstroke Engine
    Removal/Installation
    Service Tips
    May 2004

    Continue

    TABLE OF CONTENTS
    Shop Manual Procedure
    The procedure steps must be followed in a specific order.

    Turbo Marmon Clamp


    Saves time during assembly to reposition the clamp for better accessibility.

    Turbo Adapter Tube


    Saves time by using a half moon wrench to better access
    the fasteners from the adapter tube to the exhaust.

    Factory Lifting Eye


    Must be removed because it does not have the correct angle to work
    with the engine lift bracket.

    Torque Converter Nuts


    Saves time by not having to raise and lower the vehicle to remove
    or install the torque converter nuts.

    Engine Removal/Installation from Vehicle Chassis


    Calls out the desired tools that will save time by not having
    to remove the vehicles hood.

    Engine Mounted to Stand


    It is not necessary to remove the starter motor, which will save time.

    Bell Housing Bolts


    How to torque the 9 bell housing bolts.

    < Exit

    Shop Manual Procedure (Page 1 of 2)


    SECTION 303-01D: Engine 6.0L Diesel
    REMOVAL

    Engine

    2003 F-Super Duty/Excursion Workshop Manual


    Procedure revision date: 10/02/2002

    Printable View (1009 KB)

    Special Tool(s)
    Diesel Engine Lifting Bracket
    (D83T-6000-B) 303-D043

    Fuel Line Tool


    (T90T-9550-S) 310-5039

    Follow the Shop Manual for


    the correct order to
    REMOVE
    the engine sub-assemblies.

    Heavy Duty Floor Crane


    014-00071

    Adapter For 303-D043


    303-D043-02

    Adapter For 303-D043


    303-D043-01

    Wrench, Fan Clutch Nut


    303-591

    Removal
    All vehicles
    1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .

    Note:
    Not following the workshop
    manual procedure may result
    in removing the engine subassemblies out of the correct
    order. This can result in
    extra time to complete the
    procedure.

    2. Disconnect the LH and RH battery ground cables. For additional information, refer to Section 414-01 .
    Vehicles with manual transmission
    3. NOTE: On vehicles equipped with manual transmissions, the transmission must be removed before the engine
    can be removed.
    Remove the transmission. For additional information, refer to Section 308-03 .

    < Next

    Shop Manual Procedure (Page 2 of 2)


    SECTION 303-01D: Engine 6.0L Diesel
    REMOVAL

    Engine

    2003 F-Super Duty/Excursion Workshop Manual


    Procedure revision date: 10/02/2002

    Printable View (1009 KB)

    Special Tool(s)
    Diesel Engine Lifting Bracket
    (D83T-6000-B) 303-D043

    Adapter For 303-D043


    303-D043-02

    Follow the Shop Manual for


    the correct order to
    INSTALL
    the engine sub-assemblies.

    Adapter For 303-D043


    303-D043-01

    Heavy Duty Floor Crane


    014-00071

    Wrench, Fan Clutch Nut


    303-591

    Material
    Item
    Super Duty SAE 15W-40 Motor Oil
    XO-15W40-QSD or equivalent
    Premium Engine Coolant
    E2FZ-19549-AA
    R-134a Refrigerant
    YN-19

    Specification
    WSS-M2C171-C
    ESE-M97B44-A
    WSH-M17B19-A

    Installation

    Note:
    Not following the workshop
    manual procedure may result
    in installing engine subassemblies out of the correct
    order. This can result in
    extra time to complete the
    procedure.

    All vehicles
    1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02 .
    2. Raise the engine high enough to clear the No. 1 crossmember, then position the engine into the vehicle.

    < TOC

    Turbo Marmon Clamp Service Tip (Page 1 of 2)

    Marmon Clamp
    BEFORE

    Turbo Assembly

    Factory installed position of the


    marmon clamp.

    Marmon Clamp
    AFTER

    Turbo Assembly

    To ease reassembly, reverse clamp and


    position as shown.

    Turbo shown removed from vehicle for clarity

    < Next

    Turbo Marmon Clamp Service Tip (Page 2 of 2)


    Marmon Clamp
    AFTER

    Bulkhead Location

    Turbo Assembly

    Recommended position of the turbo marmon clamp.


    This is the in-vehicle view as the Technician will see it.
    Not having the turbo marmon clamp positioned as shown makes it
    very difficult to see, access or torque the nut on the clamp during reassembly.

    < TOC

    Turbo Adapter Tube Service Tip (Page 1 of 3)


    Left Side
    Exhaust Manifold
    Turbo Adapter Tube

    Bulkhead
    Half Moon Wrench

    View shown from underneath the vehicle raised on a hoist.


    A 13mm half-moon wrench is the best way to access and hold the left
    outer bolt while removing and installing the nut shown. It saves time
    because of the curved shape of the tool.
    Note: This wrench was not used to determine the labor operation time.
    The curve wrench aids in gaining access to the turbo adapter tube bolt.
    Access is possible with a regular straight wrench, but more difficult.

    < Next

    Turbo Adapter Tube Service Tip (Page 2 of 3)


    Half moon Wrench

    Turbo Adapter Tube

    Left Side
    Exhaust Manifold

    Bulkhead

    Recommended tool to torque the outer left nut and bolt to the
    turbo adapter tube.
    The half moon wrench is used to prevent the bolt from turning while using
    the torque wrench to torque the nut.
    The half moon wrench saves time because the curve of the tool makes
    access to the bolt easier.

    < Next

    Turbo Adapter Tube Service Tip (Page 3 of 3)


    Half moon Wrench

    Recommended tool to remove/install the nut and bolt to


    the turbo adapter tube.
    Available thru:
    Snap-On
    Matco
    MAC
    Craftsman

    < TOC

    Factory Lifting Eye Service Tip (Page 1 of 2)


    RH Cylinder Head

    1/4 or 3/8 NonFlexhead Ratchet

    Allen Socket
    Bulkhead

    Recommended tool for removing the two bolts for the factory lifting eye.
    Factory lifting eye is located on the back side of the right cylinder head. Using a straight
    ratchet helps keep the ratchet and allen socket lined up properly to break the bolts loose.
    A flex ratchet may not keep a straight-on angle, and can possibly cause damage to the bolt
    heads or allen socket.
    The factory lifting eye does not have the correct angle to work with the engine lift
    bracket, therefore, it must be removed.
    Note: The installation procedure recommends reinstalling the factory lifting eye.

    < Next

    Factory Lifting Eye Service Tip (Page 2 of 2)

    Non Flexhead Ratchet

    Allen Socket

    Recommended tool for removing loose the two bolts for the
    factory lifting eye.
    Tool is a long 1/4 or 3/8 inch ratchet without a flexhead.

    < TOC

    Torque Converter Nuts Service Tip (Page 1 of 2)


    Steering Gear

    1/2 Drive 3 Ft Extension

    Harmonic Damper
    1/2 Drive Ratchet

    Recommended tool to remove or install the torque converter


    attaching nuts.
    Using this tool combination allows you to remove the torque converter
    nuts from the front of the vehicle without raising it on a hoist.
    This step helps save time by not having to raise and lower the vehicle to
    remove the torque converter attaching nuts.

    < Next

    Torque Converter Nuts Service Tip (Page 2 of 2)

    Recommended tool to remove/install torque converter nuts:

    1/2 inch drive ratchet

    1/2 inch drive extension (Approx. 3 feet in length)

    < TOC

    Engine Removal/Install from Vehicle Chassis Service Tip


    (Page 1 of 2)

    Bulkhead

    2
    1

    Desired tools for removing the engine from the chassis:


    1) Diesel Engine Lifting Bracket (D83T-6000-B)
    2) Adapter for 303-D043 (303-D043-02)
    3) Adapter for 303-D043 (303-D043-01)
    Using the desired tools allows the Technician to lift the engine straight up
    and out with no side-to-side movement. A conventional spreader bar and
    chain requires hood removal and allows more uncontrolled movement that
    the Technician can struggle to control.
    Using the desired tools will save time when performing the engine removal
    and install steps.

    < Next

    Engine Removal/Install from Vehicle Chassis Service Tip


    (Page 2 of 2)

    Engine Hoist

    Diesel Engine
    Lift Bracket

    Shows how engine lift bracket attaches to the


    engine hoist.

    < TOC

    Engine Mounted to Stand Service Tip (Page 1 of 1)

    Flywheel

    Starter
    Motor

    Removal procedure calls for removal of the battery cable


    from the starter motor. Removal of the starter motor is
    not necessary to remove the engine from the chassis.
    The removal of the starter motor is only necessary if additional repairs need to
    be performed. (Example: If coolant is found in the combustion chambers, new
    injector sleeves may need to be installed. If engine disassembly is necessary,
    drain the engine block. The starter needs to be removed to remove RH block
    drain).

    < TOC

    Bell Housing Bolts Service Tip

    (Page 1 of 5)

    The question has been raised, How do you torque the transmission bell
    housing bolts? The following pages show how to torque each
    transmission bell housing bolt and the tools that are used.

    < Next

    Bell Housing Bolts 1-3 Service Tip (Page 2 of 5)


    Transmission
    Oil Pan

    Torquing left side lowest bell housing bolt.

    Front
    Drive
    Shaft

    Transmission
    Oil Pan

    Torquing left side 2nd lowest bell housing bolt.

    Front
    Drive
    Shaft

    Transmission
    Oil Pan

    Torquing left side middle bell housing bolt.

    < Next

    Bell Housing Bolts 4-6 Service Tip (Page 3 of 5)

    Exhaust
    Manifold

    Transmission
    Oil Pan

    Torquing left side upper bell housing bolt.

    Transmission
    Oil Pan

    Starter
    Motor

    Transmission
    Bell Housing

    Torquing left side top bell housing bolt.

    Torquing right side lowest bell housing bolt.

    < Next

    Bell Housing Bolts 7-9 Service Tip (Page 4 of 5)


    Transmission
    Oil Pan
    Starter
    Motor

    Torquing right side 2nd lowest bell housing bolt.


    Transfer Case

    Exhaust

    Transfer Case

    Transmission
    Oil Pan

    Torquing right side upper bell housing bolt.

    Torquing right side top bell housing bolt.

    < Next

    Bell Housing Bolts Service Tip (Page 5 of 5)

    1
    1/2 Drive Extension, Approx. 3 Feet in Length

    3
    13mm Swivel Socket

    1/2 Drive Extension, 10 in. in Length Equipped with Socket Locking Collar

    Recommended tools to torque the Bell Housing bolts:


    1) 1/2 inch Drive Extension, Approx. 3 Feet in Length
    2) 1/2 Drive Extension, 10 in. in Length Equipped with Socket Locking Collar
    3) 13mm Swivel Socket
    Note: An Impact Swivel Socket may be used to torque fasteners but CANNOT
    exceed a 15 degree working angle.

    < TOC

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