2003 F-Super Duty /Excursion Workshop Manual
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1 Page 1 of 16 SECTION C: Engine 7.3L Diesel DISASSEMBLY Procedure revision date: 05/21/2002 Engine Printable View (1761 KB) Special Tool(s) Cylinder Head Lifting Tool (D94T-6000-B) 303-D098 Damper Remover/Replacer Tool (T83T-6316-A) 303-S215 Heavy Duty Floor Crane High Pressure Line Disconnect Tool Injector Remover (T94T-9000-AH1) Part of 303-S490 Oil Suction Gun (D94T-9000-A) 303-D104 Service Set, Crankshaft Rear Oil Seal 303-S485 (T94T-6701-H) Remover/Replacer Tube (T77J-7025-B) Forcing Screw (T84T-7025-B) Engine Mounting Bracket 303-D097 (D94T-6000-A) All vehicles 1. Index-mark the clutch pressure plate (7563) and the flywheel (6375), if reinstalling these parts.
2 Page 2 of Remove the bolts, the clutch pressure plate and the clutch disc (7550). 3. Remove the flywheel. 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.
3 Page 3 of 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.
4 Page 4 of 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.
5 Page 5 of 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.
6 Page 6 of 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. 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.
7 Page 7 of 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. 31. Drain the fuel galleries in the cylinder heads. Loosen the fuel gallery plug and drain the fuel. After the fuel has drained, tighten the fuel gallery plug. 32. Drain the cylinder head oil galleries. Remove the two oil gallery plugs. After the oil has drained, tighten the oil gallery plugs.
8 Page 8 of Remove the rocker arms. 2. Remove the rocker arms and the push rods. 34. Remove the oil deflectors. 1. Remove the bolt. 2. Remove the oil deflector. 35. Remove the four fuel injector hold-down mounting bolts. 36. Using the special tool, remove the four fuel injectors. 37. Remove the two fuel tubes from the cylinder heads.
9 Page 9 of Remove the fuel tube and clamp. 1. Remove the nut. 2. Remove the fuel line and clamp from the stud bolt. 39. Disconnect the exhaust back pressure tube. 40. Remove the fuel injector hold-down bolts. 41. Remove the glow plugs. 42. Remove the 18 cylinder head bolts.
10 Page 10 of Remove the cylinder heads. 1. Position the special tool. 2. Install the four bolts. 3. Attach the special tool and remove the cylinder head. 44. Remove the oil cooler. 2. Remove the oil cooler and the gaskets. 45. Remove the bolt from the fuel drain tube retainer clamp. 46. Remove the fuel filter/water separator assembly. 2. Remove the fuel filter/water separator assembly. 47. Remove the plug and, using special tool 303-D104 (D94T-9000-A), draw the oil from the reservoir. 48. Remove the bolts and the access cover.
11 Page 11 of Remove the high pressure oil pump drive gear retaining bolt and washer. 50. Remove the high pressure oil pump. 2. Remove the high pressure oil pump and the gasket. 51. Remove the high pressure oil pump reservoir. 2. Remove the reservoir and the gasket. Remove the high pressure oil pump drive gear. 52. Remove the exhaust back pressure sensor and tube. 1. Remove the nut. 2. Remove the sensor and tube. 53. Remove the camshaft position (CMP) sensor. 1. Remove the bolt. 2. Remove the camshaft position (CMP) sensor.
12 Page 12 of Remove the bolt. Using the special tool, remove the crankshaft vibration damper. 55. Remove the oil pump. 2. Remove the oil pump housing and the O-ring seal. 56. Remove the inner gerotor gear. 57. Remove the engine mounts. 1. Remove the three bolts. 2. Remove the mounts.
13 Page 13 of Drain the engine oil pan. 59. Remove the oil pan bolts. 60. Remove the oil pan. 1. Cut the oil pan sealant all the way around the oil pan. 2. Carefully pry the oil pan up and away from the engine block. 61. Remove the oil pickup tube. 1. Remove the nut. 2. Remove the two bolts. 3. Remove the pickup tube and gasket. 62. Remove the four bolts and the water pump pulley. 63. Remove the six bolts and the water pump. 64. Clean the water pump gasket surfaces. 65. Remove the bolts, the engine front cover and gasket.
14 Page 14 of CAUTION: Do not bend the engine rear cover. If the rear cover is bent, it will not reseal causing engine oil leaks. Remove the engine rear cover. 2. Using a putty knife, carefully cut the sealant between the engine rear cover and the engine. Remove the cover. 67. NOTE: All sixteen lifters are removed the same way. Only two lifters are shown. Remove the lifters. 1. Remove the bolt. 2. Remove the lifter retainer. 3. Remove the lifters. 68. Remove the camshaft. 1. Remove the two retainer bolts. 2. Remove the camshaft and the drive gear. 69. Remove the carbon ridge from the top of the cylinder bores. 70. NOTE: Mark and record all eight piston rods to make sure that they are installed into their correct cylinder bores during assembly. NOTE: All eight pistons and rod assemblies are removed the same way. Only one piston and rod assembly is shown. Remove the piston and rod assemblies. 2. Remove the rod cap and bearing half. 3. Install the rod bolt protector sleeves. 4. Push the rod and piston assembly down and out of the engine block.
15 Page 15 of Remove the crankshaft. 2. Remove the main bearing caps and the bearing halfs. 3. Using a suitable sling and special tool , remove the crankshaft. 72. NOTE: All eight piston oil cooling jets are removed the same way. Only one jet is shown. Remove the piston oil cooling jets. 1. Remove the bolt. 2. Remove the cooling jet. 73. Remove the anti-drainback check ball retainer cap. 74. Remove the spring. 75. Remove the anti-drainback check ball.
16 Page 16 of 16
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