Can You Service 6.6l Van Without Removing The Engine?

The 6.0 engine was offered from 2003 to 2007. The 2003 model yr is somewhat dissimilar from later models, as it was the first year for this engine and, as the twelvemonth models progressed, then did the changes and updates.

Engine removal tin be handled in either of two dissimilar means. Because of the trunk style change (along with changes in engine design), removal of this engine can be challenging. Some technicians adopt to raise the cab to gain access to the components, while others remove the engine to access the necessary fasteners and components in the traditional fashion. While there are pros and cons to each process, I adopt leaving the cab in place. The biggest reason is so the torso is not scratched or damaged in whatsoever fashion. In that location have been many complaints most damage resulting from lifting the cab, and then why take the gamble?

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In order to remove the engine, you need basic hand tools forth with a few specialty tools.

The all-time advice is to take your time and keep track of components as they are removed from the vehicle. The best strategy is to identify the components in the social club they are removed—in the bed of the truck or in a separate clean area. This helps when it is time for reinstallation.

Ford Power Stroke 6.0L Engine Removal and Disassembly u1

Looking nether the hood of the 6.0 tin can be very intimidating. But once several components are removed, the engine will be revealed.

Before the engine is removed from the chassis, I try to remove as many external components every bit possible. This includes the components on the superlative of the engine downward to the intake manifold, forth with all accessories on the front of the engine downward to the front end comprehend. This way, all bolt-on accessories are removed. Final removal of the engine from the chassis so consists of hoisting the long cake upwards and out of the engine compartment.

This method also helps to shed some weight because just the long block weighs effectually 900 pounds. All of the accessories accept to come off anyway, and so when the engine is removed information technology can exist placed on an engine stand (refer to Chapter 2 for more detailed data).

The engine bay of 6.0-equipped trucks is a lilliputian more cramped than in those trucks equipped with the seven.iii-liter. I hope you that some components will exist a challenge to remove, but it tin can be accomplished.

Before you get started, remove the battery cables and bombardment, and drain the antifreeze and oil.

Interior Lights

Pace-1: Remove Air Cleaner

Offset past removing the air cleaner associates. In one case the filter is removed, remove the intake tube associates going to the turbo inlet.

Step-ii: Remove Reservoir

Remove the coolant hoses from the reservoir and remove the reservoir from the firewall past loosening ii screws on top of the reservoir.

Step-iii: Remove Wiring Harness (Professional person Mechanic Tip)

Remove the wiring harness from under the reservoir bracket and forth the cowl of the windshield by removing the "push-in" retainers (left and middle). Fold the plastic shield toward the windshield and secure it to the wiper arms by a zero strap. This gives additional room to access more than components.

Footstep-4: Remove Intercooler Piping

Remove the intercooler piping from the turbo and both sides of the engine. The clamps tin be removed with a 7/xvi-inch socket.

Step-5: Remove Turbo

Adjacent, remove the turbo. From the turbine housing, you need to remove the upwards pipe clamp (1) and the down pipage flange (ii) that is a part of the exhaust system. On the 2004 to 2007 models, in that location is one bolt that supports the turbine housing (3) to the turbo pedestal that needs to be removed. For the 2003 model, the turbo pedestal pattern is different and this bolt comes in from the side instead of from the top equally shown here.

Step-vi: Remove Turbo Bolts

On the driver's side at the rear of the base of the turbo is a bolt that needs to exist removed. Also remove the one on the passenger's side.

Step-7: Remove Turbo

Now the turbo can be removed from the pedestal. Elevator the turbo off the oil drain pipe at the base of the pedestal.

Step-8: Remove Pedestal Bolts

Remove the four bolts that adhere the turbo pedestal to the engine block and remove the pedestal.

Step-9: Remove Engine Fan (Special Tool)

Earlier removing the drive belt, the engine fan must be loosened from the h2o pump. In order to do this you need a special tool to break the fan nut gratis. The special tool comes with ii wrenches. Take the wrench that looks like a hook and concord the slotted water pump pulley while using the other wrench to loosen the fan nut. Remove the upper radiator hose if you lot need more room.

Pace-10: Remove Drive Chugalug

Now the drive chugalug can exist removed. This can be somewhat of a task when using conventional hand tools. This is what the belt tensioner looks similar (left). In the end of the tensioner is a slot for a one/two-inch ratchet. Insert a ratchet in the slot and place a piece of pipe over it for some boosted leverage (middle). When pulling up on the ratchet in the tensioner, the bulldoze belt begins to accept some slack (bottom). At this time the belt can be removed from the alternator.

Step-xi: Disconnect Wiring Harness

Disconnect the wiring harness from the alternator and remove the iii bolts that fasten the alternator to the intake manifold.

At the mouth of the intake appears to be some kind of electronic device. This device was incorporated on early on models with some having a throttle plate and others being without. The electronic throttle device is there but no throttle plate. Navistar originally used the electronic throttle to close off air coming into the intake manifold so the engine would siphon more exhaust gas coming in from the EGR valve. Afterward Navistar discontinued the throttle plate and merely used the electronic device as a spacer. On 2005 to 2007 models, the intake manifold has a spacer and no electronic throttle device.

Step-12: Remove Fuel Filter Handbasket Lines

Remove the fuel supply and return lines from the secondary fuel filter basket.

Stride-thirteen: Remove Oil Filter Housing

At the base of the oil filter housing are four Torx bolts that concur the oil filter housing to the oil libation. Remove the four bolts so the oil and fuel filter housing tin can be removed from the engine.

Step-14: Remove Stand up Pipe

Once the oil filter housing is removed, the oil filter stand up pipage needs to exist removed. Remove the pocket-sized Torx screw at the rear of the stand pipe and twist. The stand pipage but lifts off the oil cooler base.

Front Drive Accessories and Radiator

Step-1: Remove Fan Shroud Bolts

Within the inner fan shroud at the base of the front of the intake manifold are two bolts that need to be removed. These bolts hold the inner fan shroud to the intake manifold.

Step-2: Remove Air Conditioning Condenser

Remove the forepart grille and the headlight associates to gain access to the cooling accessories in the front. At this time the air conditioning system needs to be evacuated. Once the refrigerant is evacuated from the air conditioning organisation, remove the condenser from the front of the vehicle.

Step-iii: Remove Transmission Cooling Lines

If the vehicle is equipped with automatic manual, remove the manual cooling lines from the lower part of the radiator.

Stride-iv: Remove Cooler Bolts

Remove two bolts at the base of operations of the transmission cooler that hold the cooler to the front of the lower radiator back up.

Step-5: Remove Shields

On each side of the radiator at the top of the upper radiator back up are two rubber shields that are held in place with plastic pins. Remove the rubber shields.

Pace-half dozen: Remove Intercooler

In lodge to remove the intercooler and radiator the upper radiator support has to exist removed outset.

Step-7: Remove Radiator

Remove the lower radiator hose and the two bolts in the top of the fan shroud from the radiator. Remove the radiator.

Stride-viii: Remove Outer Fan Shroud

Remove the outer fan shroud, which exposes the engine fan and the inner fan shroud.

Step-ix: Remove Inner Fan Shroud Bolts

Earlier, the inner fan shroud bolts were removed from the tiptop of the intake manifold. In society to remove the fan and inner fan shroud, two more bolts must exist removed from the forepart of the engine on each side.

Footstep-x: Remove Inner Fan Shroud

The fan removes from the water pump pulley in a counterclockwise rotation. Remove the fan and the inner shroud to expose the front of the engine.

Step-11: Remove Air conditioning Compressor

At this time, remove the ac compressor from the engine. This is not like shooting fish in a barrel! The bolts come up through the bottom of the compressor to the engine block. Once the compressor is removed, lay the refrigerant lines to the side and out of the fashion.

Footstep-12: Remove Lower Radiator Hose

Remove the lower radiator hose from the water pump.

Step-13: Remove Power Steering Pump (Professional Mechanic Tip)

To remove the power steering pump, remove the four bolts that concur the pump to the engine block, and fix the pump to the side. There is no need to completely remove the pump from the vehicle engine compartment.

Remaining Accessories

Step-one: Remove Bombardment Cable Support

Remove the battery cable support at the lower passengerside front of the engine cake. In this picture, you tin can get an idea of how the ac compressor is mounted to the engine.

Step-2: Remove Motor Mountain Bolts

Remove the motor mountain bolts inside the frame crossmember. There should be two on each side.

Step-three: Disconnect Fuel Lines

Disconnect the fuel lines from the engine using a special tool. The tool expands the spring inside the fitting that locks the fuel lines together. Fuel line disconnect tools can also be purchased at your local parts supplier.

Step-4: Remove Starter

Remove the cake heater drop cord at the engine block and the bombardment cables at the starter. Remove the starter from the engine.

Pace-five: Remove Up Pipage Assembly

Earlier removing the engine, you lot need to remove the frazzle up pipe assembly from each exhaust manifold and remove the up pipe associates from the engine compartment.

Remove Transmission (Automated)

On the driver's side of the engine just to a higher place the oil pan is a window that is covered by a safe plug in the engine block. This window is used to access the torque converter bolts. Remove the xiv-mm torque converter bolts. Later the torque converter bolts are removed, remove the transmission bolts also.

Remove Engine

Step-1: Attach Engine Hoist

Engine support brackets are located at the front of the driver's side of the engine and at the rear of the passenger'due south side of the engine. Place a chain tightly through both back up brackets and attach to an engine hoist. The engine can now be removed.

Step-two: Remove Engine

It is very important to remove the accessories from the top of the engine before trying to remove the engine. There is not a lot of room to raise the engine motor mounts from the crossmember, but at that place is just plenty to get the oil pan beyond the crossmember.

Transmission Accessories

Step-1: Remove Flywheel

In gild to place the engine on an engine stand, the rear structure of the engine needs to exist removed in order to remove the crankshaft. Start by removing the flywheel.

Step-two: Remove Flywheel Adapter (Important!)

In order to remove the rear structure of the engine, remove the flywheel adaptor at the rear of the crankshaft. This can be washed with a three-finger puller (left). After removing the rear structure, yous will find that there are bolts in the rear of the crankshaft (right). DO Non remove these bolts! This is the rear seal adaptor that is fitted to the crankshaft. If you remove these bolts and remove the rear seal adaptor, the crankshaft cannot be reused!

Injectors and Glow Plugs

Stride-1: Remove Valve Covers

Now the valve covers tin be removed. Make sure to marker the valve cover as to where the bolts and studs are located. I usually scribe the valve covers with small lines.

Step-2: Remove Oil Rails

Next, the high-pressure oil rail tin be removed. This way of rail is for the 2003 model. Observe that the highpressure oil rail is fed past a braided line (above). The braided line needs to be unlocked and removed in guild to remove the oil rails. There is a special tool for this as well. If y'all do not have this special tool, the highpressure oil line tin can be removed by using a screw commuter to push button down on the locking spring (left).

Pace-iii: Remove Injector Connectors (Special Tool)

Before removing the rocker boxes, you demand to remove the injector connectors for each injector that passes through the rocker box. There is a special tool that collapses the locks of the injector connectors. Once the locks of the connectors are compressed by the special tool, push the connector through the rocker box. The special tool (PN 6766) is fabricated past OTC.

Step-four: Remove Injector Hold-Down

Using a number-40 Torx scrap socket, remove the injector hold-down from the cylinder head so the injectors can be removed.

Step-five: Remove Glow Plug Harness

Remove the glow plug harness from the rocker box.

Step-half-dozen: Remove Glow Plugs

Once the glow plug harness is removed, the glow plugs can exist removed from the cylinder head.

Cylinder Heads

Pace-i: Remove Cylinder Head Bolts

The rocker boxes are held by the cylinder head bolts. Remove the cylinder caput bolts then the rocker boxes can be removed. The cylinder head does not come off at this fourth dimension considering there are smaller bolts at the top of the cylinder head that need to exist removed beginning.

Step-2: Remove Exhaust Manifolds

Remove the exhaust manifolds from the cylinder heads.

Stride-3: Remove Cylinder Head

In the top of the cylinder head between the intake ports are minor bolts that spike the cylinder head to the cake. Remove these bolts and so the cylinder head can be removed (left). With the cylinder head removed, y'all can see the amount of damage to the engine. For some unknown reason, the engine dropped both of the exhaust valves causing catastrophic damage (middle and bottom).

Disassemble Reciprocating Assembly

Stride-1: Remove Oil Pan Bolts

Remove the bolts that support the oil pan to the engine block.

Pace-two: Remove Oil Pan

The upper oil pan is really an adaptor used to fit the engine with a larger oil pan. Because a wider oil pan would be needed for oil capacity, an adaptor is used between the engine block and oil pan (left). Remove the upper oil pan and the oil pump pick-upward tube from the bottom of the engine (right).

Stride-3: Remove Pistons and Connecting Rods (Documentation Required)

Remove the pistons and connecting rods. Make certain to postage stamp the connecting rod and the cap to the corresponding cylinder it belongs to. At this time also remove the lifters past removing the lifter holddown assembly. Each lifter concord-downward supports four lifters.

Step-4: Remove Bed Plate

Rotate the engine on the stand then that the crankshaft faces upward. Remove the bed plate, which is the primary webbing of the engine that supports the crankshaft and bearings.

Pace-5: Prep for Machining

Now the camshaft and the remainder of the accessories such as the high-pressure oil pump, high-pressure oil lines ("branches" in the rear of the engine), and oil cooler can be prepped for machining.

Written by Bob McDonald and Republished with Permission of CarTech Inc

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