Part 1 of 2
Engine
Special Tool(s)
All vehicles
1. Index-mark the clutch pressure plate and the flywheel, if reinstalling these parts.
2. Remove the bolts, the clutch pressure plate and the clutch disc.
3. Remove the flywheel.
1 Remove the bolts. Install the guide studs.
2 Remove the bolts.
3 Remove the reinforcing ring (7.3L) and flywheel, and the ring gear assembly.
4 Remove the guide studs.
Vehicles equipped with automatic transmission
4. Remove the bolts, spacers and flexplate.
5. NOTE: Use extreme care when removing the flywheel front adapter to prevent damage to the alignment dowel pins.
Remove the flywheel front adapter.
All vehicles
6. Remove the crankshaft rear oil seal retaining bolts and the crankshaft rear oil seal.
7. Inspect the crankshaft rear seal, wear sleeve, and alignment dowel pins for damage. Install new components as necessary.
8. If equipped with a crankshaft wear sleeve, use the special tools to remove the crankshaft wear sleeve.
9. Remove the engine adapter plate.
1 Remove the retainer.
2 Remove the adapter plate.
10. Mount the engine on a work stand using the engine mounting brackets.
Vehicles with air conditioning
11. Remove the A/C compressor mounting bracket.
1 Remove the mounting bolts.
2 Remove the mounting bracket.
12. Remove the exhaust adapter pipes.
1 Remove the four mounting bolts and nuts.
2 Remove the exhaust adapter pipes.
13. Disconnect the fuel injector/glow plug nine pin connectors.
1 Disconnect the retaining clip.
2 Disconnect the nine pin connector.
14. Disconnect the exhaust back pressure solenoid electrical connector.
15. Disconnect the fuel heater/water sensor electrical connector.
16. Disconnect the injection pressure regulator electrical connector.
17. Disconnect the injection oil pressure sensor electrical connector.
18. Disconnect the engine oil temperature sensor electrical connector.
19. Disconnect the engine oil pressure sensor electrical connector.
20. Disconnect the exhaust back pressure sensor and Engine Coolant Temperature (ECT) sensor electrical connector.
21. Disconnect the Camshaft Position (CMP) sensor electrical connector.
22. If equipped, remove the cover. Label and disconnect the electrical leads. Remove the two nuts and the glow plug relay/intake air heater relay and bracket as an assembly.
23. Remove the engine electrical harness.
1 Disconnect the pushpin retainer.
2 Remove the engine harness.
24. Remove the turbocharger pedestal.
1 Remove the bolts.
2 Remove the pedestal.
25. Remove and discard the two O-ring seals.
26. Remove the air inlet duct tube mounting bracket.
1 Remove the nuts.
2 Remove the bracket.
27. Remove the oil level indicator tube.
1 Remove the nut.
2 Pull upward and remove the oil level indicator tube.
28. NOTE: Both the left side and the right side valve covers are removed the same way. Only the right side valve cover is shown.
Remove the valve covers.
1 Remove the mounting bolts.
2 Remove the valve cover.
29. NOTE: Both the left side and the right side valve cover gaskets are removed the same way. Only the right side valve cover gasket is shown.
Remove the valve cover gaskets.
1 Disconnect the four fuel injector electrical connectors.
2 Disconnect the four glow plug electrical connectors.
3 Remove the valve cover gasket.
30. Using the special tool, remove the two high pressure oil hoses.