303-01C-1 IN-VEHICLE REPAIR Oil Pan Lower Special Tool(s) 3-Bar Engine Support 303-F070 Lifting Eyes 303-D030 303-01C-1 2. Disconnect the LH and RH battery ground cables. For additional information, refer to Section 414-01. Vehicles with manual transmissions 3. Remove the engine rear cover. For additional information, refer to Engine Rear Cover in this section. 4. Remove the cooling fan stator. For additional information, refer to Section 303-03. 5. Remove the air cleaner assembly. For additional information, refer to Section 303-12. Heavy Duty Floor Crane 6. NOTE: Charge air cooler (CAC) side shown, 014-00071 engine side similar. Loosen the clamps and remove the CAC ducts. Wrench, Fan Clutch Nut 303-591 Material Item Specification SAE 15W-40 Super Duty WSS-M2C171-D 7. Remove the oil pan drain plug and drain the Diesel Motor Oil XO-15W40-QSD (US); engine oil. CXO-15W40-LSD12 (Canada); or equivalent Removal 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02. Copyright 2006, Ford Motor Company Last updated: 1/11/2007
303-01C-2 303-01C-2 8. Loosen the exhaust pipe retaining nuts. 11. Remove the bolt and the secondary accessory drive belt tensioner. 9. NOTE: RH shown, LH similar. Remove the engine mount retaining nuts. 12. Remove the primary accessory drive belt. Vehicles with dual generators 10. Remove the secondary accessory drive belt. 13. Remove the bolts, bracket and secondary accessory drive belt idler pulley.
303-01C-3 303-01C-3 14. Remove the bolts and the primary accessory drive belt tensioner. 18. Remove the bolts and the primary accessory drive belt tensioner. 15. Disconnect the wire retainer, secondary generator electrical connector and B+ wire. 19. Remove the 3 bolts and position the generator 16. Remove the bolts and the secondary generator back. with mounting bracket. Vehicles with single generator 17. Remove the primary accessory drive belt.
303-01C-4 303-01C-4 20. Support the hood and disconnect the hood lift 23. Disconnect the heater hose from the front cover assemblies. and position aside. 21. Install 2 lifting eyes on the RH cylinder head. 24. Install one lifting eye on the LH cylinder head. 22. Remove the retaining bolt for the fuel tubes.
303-01C-5 303-01C-5 25. CAUTION: Do not use the special tool to raise the engine. Damage to the special tool or vehicle may occur. NOTE: The ball studs may have to be removed. NOTE: This procedure requires a second bolt hook assembly. The tools are available through Rotunda tools with the following numbers: bolt hook 303-F070-6, handle 303-F070-8, bracket 303-F070-7 and washer 303-F070-12004. Install the special tool. 26. NOTE: The engine must be raised evenly. 28. NOTE: The oil pan bolts must be reinstalled in Using a lifting crane, raise the engine until the their original positions. Mark the location of the turbocharger is almost touching the cowl. longer bolts to aid in installation. Secure the engine with the special tool. Remove the bolts and position back the oil pan until the oil pickup tube bolts are accessible. 27. Remove the transmission cooler tube bracket.
303-01C-6 29. Remove the 2 bolts and position the oil pickup tube into the oil pan. Remove the oil pan. Installation 303-01C-6 1. Install a new O-ring seal on the oil pickup tube and position the oil pickup tube in the oil pan. 30. Remove the press-in-place gasket and discard. Clean and inspect the sealing surfaces. 2. Install a new press-in-place gasket into the upper oil pan. 31. Remove and discard the oil pickup tube O-ring seal. 3. Position the oil pan in the vehicle.
303-01C-7 303-01C-7 4. Install the oil pickup tube and the 2 bolts. 6. Install the transmission cooler tube bracket and Tighten to 13 Nm (10 lb-ft). nut. Tighten to 10 Nm (89 lb-in). 5. Position the oil pan and install the bolts. 1 Install the longer oil pan bolts. 2 Install the remaining oil pan bolts and tighten all to 13 Nm (10 lb-ft).
303-01C-8 303-01C-8 7. Using the special tool, lower the engine. 8. NOTE: RH shown, LH similar. 10. Install the retaining bolt for the fuel tubes. Remove the lifting eyes and the special tool. Tighten to 13 Nm (10 lb-ft). 9. Connect the heater hose at the front cover. 11. If removed, install the ball studs. Connect the hood lifts and remove the hood support.
303-01C-9 12. Position the primary generator and install the 3 bolts. Tighten to 47 Nm (35 lb-ft). Vehicle with dual generators 303-01C-9 15. Install the secondary generator with mounting bracket and bolts. Tighten to 47 Nm (35 lb-ft). Vehicle with single generator 13. Install the primary accessory drive belt 16. Connect the B+ wire, secondary generator tensioner and bolts. electrical connector and wire retainer. Tighten to 25 Nm (18 lb-ft). Tighten to 8 Nm (71 lb-in). 14. Install the primary accessory drive belt. 17. Install the primary accessory drive belt tensioner and bolts. Tighten to 25 Nm (18 lb-ft).
303-01C-10 18. Position the secondary accessory drive belt idler pulley. Install the bracket and bolts. Tighten to 25 Nm (18 lb-ft). 303-01C-10 19. Install the primary accessory drive belt. 22. NOTE: RH shown, LH similar. Install the motor mount retaining nuts. Tighten to 103 Nm (76 lb-ft). 20. Install the secondary accessory drive belt tensioner and bolt. Tighten to 25 Nm (18 lb-ft). 23. Tighten the exhaust pipe retaining nuts. Tighten to 47 Nm (35 lb-ft). 21. Install the secondary accessory drive belt.
303-01C-11 303-01C-11 24. Clean and inspect the oil pan drain plug and 27. Install the metal CAC duct and tighten the gasket. Install new if necessary. clamps. 25. Install the oil pan drain plug. 28. Install the air cleaner assembly For additional Tighten to 44 Nm (32 lb-ft). information refer to Section 303-12. 29. Install the cooling fan stator. For additional information, refer to Section 303-03. Vehicles with manual transmissions 30. Install the engine rear cover. For additional information, refer to Engine Rear Cover in this section. 26. Install the composite CAC duct and tighten the clamps. 31. Connect the LH and RH ground cables. For additional information, refer to Section 414-01. 32. Fill the engine with clean engine oil. 33. Run the engine and check for leaks.