How To replace 6.0L Diesel Engine on Ford Truck?

The procedure is similar for both ford and Lincoln car models:-----

The procedure is for Ford Model F series Trucks.

And Lincoln Mark LT model vehicles.

F150 1/2 ton P/U 2WD/ 4WD

F250 Super Duty P/U 2WD/4WD

F350 Super Duty P/U 2WD/4WD

F450 Super Duty P/U 2WD/4WD

F550 Super Duty P/U 2WD/4WD

The procedure to replace 6.0L  Diesel engine is as follows:----

Removal & Installation

6.0L Diesel Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in Neutral , position it on a hoist.
3. Disconnect the left and right battery ground cables.

Vehicles with manual transmission

NOTE

On vehicles equipped with manual transmissions, the transmission must be removed before the engine can be removed.

1. Remove the transmission.
2. Remove the clutch.

All vehicles

1. Remove the air cleaner assembly.
2. Remove the radiator.
3. Remove the charge air cooler.

Vehicles with A/C

1. Remove the A/C condenser assembly.

All vehicles

1. Remove the parking lamp and the headlamp assemblies.
2. Remove the radiator grille, the radiator grille opening panel, and the upper radiator core supports.
3. Remove the front bumper.
4. Disconnect the transmission cooler hoses.
5. Remove the bolts and the transmission oil cooler.
6. Remove the bolts and position the power steering cooler out of the way.
7. Remove the intake manifold.
8. Remove the accessory drive idler pulley and bolt.
9. Disconnect the heater hose at the coolant pump.
10. Remove the battery cable cover.
11. Remove the nut and position the cable out of the way.
12. Disconnect the left glow plug electrical connector and wire retainer.
13. Disconnect the camshaft position (CMP) sensor electrical connector.
14. Remove the clips and disconnect the fuel lines.
15. Remove the lower radiator hose clamp and the hose.
16. Remove the power steering upper mounting bolts.
    
    NOTE

    Bolts need to be removed evenly.
17. Remove the bolts and position the power steering pump out of the way.
18. Remove the nut and the battery cable bracket.
19. Remove the ground stud and the ground cable.
20. If equipped, disconnect the injection control pressure (ICP) sensor electrical connector
21. Disconnect the glow plug electrical connectors.
22. Disconnect the right glow plug electrical connector and wire retainer.

Vehicles with A/C

1. Disconnect the A/C high pressure switch and the A/C clutch electrical connectors.
2. Disconnect the air conditioning manifold lines from the A/C compressor.
3. Remove the A/C compressor.

All vehicles

1. Disconnect the crankshaft position (CKP) sensor electrical connector and position the wiring aside.

Vehicles with automatic transmission

1. Remove the automatic transmission fluid indicator and tube.

All vehicles

1. Remove the ground strap at the back of the right head.
2. Remove the solenoid cap and disconnect the starter wiring.
3. Disconnect the block heater electrical connector.
4. Position the block heater and starter wiring harness out of the way.

Vehicles with automatic transmission

1. Remove the torque converter cover.
2. Remove the torque converter nuts.

All vehicles

1. Remove the bolts for the turbocharger adapter pipe.
2. Remove the motor mount nuts.
3. Loosen the nuts at the turbocharger adapter pipe flange.

Vehicles with automatic transmission

1. Remove the nine bell housing bolts.

All vehicles

1. Remove the turbocharger adapter pipe.
2. Remove the nuts and the fuel injector control module bracket.
3. Remove the left rear valve cover stud.
4. Remove the transmission cooler line bracket.
5. Secure the turbocharger outlet pipe.
6. Remove the manufacturer's lifting eye.
7. Install the engine lifting eye on the right cylinder head.
8. Install the front lifting brackets.

Vehicles with automatic transmission

1. Position a suitable jack under the transmission.

All vehicles

1. Install the Heavy Duty Floor Crane and Diesel Engine Lifting Bracket on the engine.
2. Raise the engine high enough to clear the No. 1 crossmember and pull the engine forward and clear of the vehicle.

To install:

All vehicles

1. With the vehicle in Neutral , position it on a hoist.
2. Raise the engine high enough to clear the No. 1 crossmember, then position the engine into the vehicle.

Vehicles with automatic transmission

1. Align the torque converter studs with the holes in the engine flywheel, then lower the engine onto the engine mount towers.

Vehicles with manual transmission

1. Lower the engine onto the engine mount towers.

All vehicles

1. Remove the Heavy Duty Floor Crane and the Diesel Engine Lifting Bracket.

Vehicles with automatic transmission

1. Remove the transmission jack.
2. Install the transmission-to-engine mounting bolts. Torque to 35 ft. lbs. (47 Nm).
3. Install the torque converter-to-flywheel retaining nuts. Torque to 26 ft. lbs. (35 Nm).
4. Install the flywheel housing cover.

All vehicles

1. Install the left and right side engine mount retaining nuts. Torque to 76 ft. lbs. (103 Nm).
2. Remove the engine lifting eye from the right side cylinder head.
3. Install the manufacturer's lifting bracket.
4. Remove the two engine lift adapters.
5. Position the turbocharger outlet pipe.
6. Install the transmission cooler tube bracket and nut.
7. Install the left rear valve cover stud.
8. Install the fuel injector control module bracket and nuts.
9. Position the turbocharger adapter pipe.
   
   NOTE

   Do not tighten bolts at this time.
   
   
   
   NOTE

   Apply anti-seize lubricant to the threads prior to installing the bolts.
10. Install the bolts for the turbocharger adapter pipe.
11. Position back the block heater and starter wiring.
12. Connect the block heater electrical connector.
13. Connect the starter wiring and install the solenoid cap.
14. Connect the ground strap on the right head and install the bolt.

Vehicles with automatic transmission

1. Install the automatic transmission fluid indicator and tube.

All vehicles

1. Position back the wiring and connect the crankshaft position (CKP) sensor electrical connector.

Vehicles with A/C

1. Install the A/C compressor. Torque to 18 ft. lbs. (25 Nm).
2. Position the A/C compressor manifold and install the bolt. Torque to 15 ft. lbs. (21 Nm).
3. Connect the A/C high pressure switch and the clutch electrical connectors.

All vehicles

1. Connect the right glow plug electrical connector and wire retainer.
2. Connect the glow plug module electrical connectors.
3. If equipped, connect the injection control pressure (ICP) sensor electrical connector.
4. Connect the ground cable and the ground stud.
5. Install the battery cable bracket and the nut.
   
   NOTE

   The lower bolts need to be installed evenly.
6. Position the power steering pump and install the lower bolts. Torque to 18 ft. lbs. (25 Nm).
7. Install the power steering pump upper bolts. Torque to 18 ft. lbs. (25 Nm).
8. Install the lower radiator hose and clamp.
9. Connect the fuel lines and install the clips.
10. Connect the camshaft position (CMP) sensor electrical connector.
11. Connect the left glow plug electrical connector and wire retainer.
12. Connect the battery crossover cable.
13. Install the battery cable cover.
14. Connect the heater hose at the coolant pump.
15. Install the accessory drive idler pulley and bolt. Torque to 35 ft. lbs. (47 Nm).
16. Install the intake manifold.
17. Tighten the turbocharger adapter pipe at the flanges. Torque to 20 ft. lbs. (27 Nm).
18. Tighten the nuts at the turbocharger adapter pipe flange. Torque to 35 ft. lbs. (47 Nm).
19. Position and install the power steering cooler and bolts.
20. Install the transmission oil cooler.
21. Connect the transmission cooler hoses.
22. Install the front bumper.
23. Install the upper radiator core support, radiator grill opening panel and the radiator grill.
24. Install the headlamp and the parking lamp assemblies.

Vehicles with A/C

1. Install the A/C condenser assembly.

All vehicles

1. Install the charge air cooler.
2. Install the radiator.
3. Install the air cleaner assembly.

Vehicles with manual transmission

1. Install the clutch assembly.
2. Install the transmission.

All vehicles

1. Fill the motor with clean engine oil.
2. Connect the left and right battery cables.
3. Fill the cooling system.

Vehicles with automatic transmission

1. Check and fill the automatic transmission.

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html