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303-01B Engine - 6.7L Power Stroke Diesel

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Displacement 6.7L Diesel (409 cu in.)
No. of cylinders 8
Bore 3.9 in ( 99 mm)
Stroke 4.3 in ( 108 mm)
Firing order 1-3-7-2-6-5-4-8
Compression ratio 15.8:1
Engine weight - (without accessory drive components) 981.1 lb ( 445 kg)

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Motorcraft® SAE 10W-30 Super Duty Diesel Motor Oil WSS-M2C171-F1

Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil WSS-M2C171-F1
Motorcraft® SAE 15W-40 Super Duty Diesel Motor Oil WSS-M2C171-F1
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Service fill including oil filter 13 qt ( 12.3 L)

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Oil pressure (@ 1200 rpm after 15 seconds with engine at normal operating temperature and transmission in Park.) 20 psi (
approximately 137.9 kPa)
Oil pressure (@ 1200 rpm after 15 seconds with engine at normal operating temperature and transmission in Park. Oil Pressure 45 psi (
Control Solenoid electrical connector disconnected.) approximately 310.3 kPa)
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Cylinder bore diameter
Cylinder bore maximum taper
Cylinder bore maximum out-of-round
Main bearing bore inside diameter
Camshaft bearing bore inside diameter
Head gasket surface flatness (across cylinder
bores)
Head gasket surface flatness (across sealing rail on
valley side around pushrods/ lifters)
3.898 –3.898 in ( 99 –99.018 mm)
0.0063 in ( .16 mm)
0.0063 in ( .16 mm)
3.380 –3.381 in ( 85.863 –85.879 mm)
2.514 –2.515 in ( 63.85 –63.875 mm)
0.025 mm (0.001 in) in any 25 mm (1 in) x 25 mm (1 in) area; 0.05 mm (0.002 in) in any
150 mm (6 in) X 150 mm (6 in) area; 0.1 mm (0.004 in) overall
0.025 mm (0.001 in) in any 25 mm (1 in) x 25 mm (1 in) area; 0.06 mm (0.002 in) in any
150 mm (6 in) X 150 mm (6 in) area; 0.13 mm (0.005 in) overall

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Piston Diameter - standard size (major diameter)
Piston Diameter - 0.50 mm (0.019 in) oversize (major diameter)
Piston-to-cylinder bore clearance
co 3.8954 –3.8966 in ( 98.944 –98.974 mm)
3.9151 –3.9163 in ( 99.444 –99.474 mm)
0.001 –0.003 in ( .026 –.074 mm)
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Piston pin bore diameter 1.183 –1.183 in ( 30.045 –30.06 mm)
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Piston pin diameter 1.1809 –1.1811 in ( 29.994 –30 mm)

Piston pin length 2.272 –2.283 in ( 57.7 –58 mm)
Piston pin-to-piston fit 0.0018 –0.0026 in ( .045 –.066 mm)

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Cylinder head gasket surface
flatness - overall
Valve arrangement (front to rear)
Valve seat width - intake,
maximum service limit
Valve seat width - exhaust,
maximum service limit
Valve seat runout (TIR Max)
0.025 mm (0.001 in) in any 25 mm (1 in) x 25 mm (1 in) area; 0.05 mm (0.002 in) in any 150 mm (6 in) X
150 mm (6 in) area; 0.1 mm (0.004 in) overall
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0.098 in ( 2.5 mm)
0.118 in ( 3 mm)
0.002 in ( .055 mm)
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Valve seat angle - intake (from 30.25 °
deck face)
Valve seat angle - exhaust (from 45.25 °
deck face)
Valve margin - intake (minimum) 0.035 in ( .9 mm)
Valve margin - exhaust (minimum) 0.024 in ( .6 mm)
Valve recession depth - intake 0.063 –0.071 in ( 1.6 –1.8 mm)
Valve recession depth - exhaust 0.071 –0.079 in ( 1.8 –2 mm)
Valve guide bore diameter 0.277 –0.278 in ( 7.035 –7.055 mm)

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Valve stem diameter - intake 0.2746 –0.2754 in ( 6.975 –6.995 mm)

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Valve stem diameter - exhaust 0.274 –0.275 in ( 6.97 –6.99 mm)
Valve stem-to-guide clearance - intake 0.0016 –0.0031 in ( .04 –.08 mm)
Valve stem-to-guide clearance - exhaust
Valve head diameter - intake
co 0.0018 –0.0033 in ( .045 –.085 mm)
1.331 in ( 33.8 mm)
Valve head diameter - exhaust 1.195 in ( 30.35 mm)
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Valve face runout (TIR Max) 0.001 in ( .03 mm)
Valve face angle - intake (relative to top of head) 29.5 degrees +/- 0.25 degrees from stem axis
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Valve face angle - exhaust (relative to top of head) 44.5 degrees +/- 0.25 degrees from stem axis
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Valve spring free length - reference
Valve spring solid height - maximum
Valve spring compression pressure - installed
Valve spring compression pressure - valve open
Valve spring installed height - reference
2.020 in ( 51.3 mm)
0.906 in ( 23 mm)
1.338 in @ 96.6 +/- 4.9 lbft (34.0 mm @ 430 +/- 22 N)
0.964 in @ 153.3 +/- 6.9 lbft (24.5 mm @ 682 +/- 31 N)
1.319 –1.358 in ( 33.5 –34.5 mm)

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Main bearing journal diameter - standard size 3.188 –3.189 in ( 80.977 –80.997 mm)
Main bearing journal diameter - 0.25 mm (0.009 in) undersize 3.178 –3.179 in ( 80.733 –80.753 mm)
Main bearing journal maximum taper 0.0003 in ( .008 mm)
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Main bearing journal maximum out-of-round 0.0002 in ( .005 mm)
Main bearing assembly clearance 0.001 –0.003 in ( .03 –.086 mm)
Connecting rod journal diameter - standard size 2.834 –2.835 in ( 71.983 –72.003 mm)
Connecting rod journal diameter - 0.25 mm (0.009 in) undersize 2.824 –2.825 in ( 71.733 –71.753 mm)
Connecting rod journal maximum taper 0.0003 in ( .008 mm)
Connecting rod journal maximum out-of-round 0.0002 in ( .005 mm)
Crankshaft end play 0.004 –0.012 in ( .1 –.31 mm)

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Piston ring end gap - top compression 0.010 –0.016 in ( .25 –.4 mm)
Piston ring end gap - lower compression 0.035 –0.043 in ( .9 –1.1 mm)

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Piston ring end gap - oil control 0.006 –0.014 in ( .15 –.35 mm)
Top piston ring groove width (measured over 2.4 mm (0.094 in) gauge pins) - upper limit 3.819 –3.841 in ( 96.995 –97.555 mm)
Piston ring-to-groove clearance - lower 0.001 –0.003 in ( .03 –.07 mm)
Piston ring-to-groove clearance — oil control ring
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Diameter 1.173 –1.174 in ( 29.797 –29.812 mm)

Clearance to bore 0.001 –0.003 in ( .019 –.072 mm)
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Collapsed lash adjuster gap - at valve tip 0.028 –0.118 in ( .7 –3 mm)

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Gear backlash - camshaft gear to fuel injection pump 0.001 –0.007 in ( .02 –.19 mm)
Gear backlash - camshaft gear to crankshaft gear 0.001 –0.006 in ( .023 –.154 mm)
Lobe lift - intake 0.2240 in ( 5.69 mm)
Lobe lift - exhaust 0.232 in ( 5.9 mm)
Allowable lobe lift loss 0.002 in ( .05 mm)
Journal diameter 2.361 –2.362 in ( 59.97 –59.998 mm)
Camshaft journal bearing inside diameter 2.364 –2.365 in ( 60.0375 –60.0625 mm)
Camshaft journal-to-bearing clearance 0.001 –0.003 in ( .025 –.075 mm)
Runout (TIR center journals relative to end journals, Max) 0.002 in ( .06 mm)
End play 0.003 –0.007 in ( .07 –.17 mm)
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Connecting rod-to-pin clearance
Connecting rod pin bore diameter
Connecting rod length (center-to-center)
Connecting rod maximum allowed bend
Connecting rod maximum allowed twist
Connecting rod bearing bore diameter
Connecting rod bearing-to-crankshaft clearance
Connecting rod side clearance
0.0009 –0.0017 in ( .024 –.042 mm)
1.182 –1.183 in ( 30.024 –30.036 mm)
7.660 in +/- 0.004 in (194.57 mm +/- 0.125 mm )
0.0008 in ( .02 mm)
0.002 in ( .04 mm)
2.834 +/- 0.0004 in (71.993 +/- 0.01 mm)
0.002 –0.004 in ( .044 –.096 mm)
0.005 –0.019 in ( .125 –.475 mm)

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Exhaust manifold warpage - maximum 0.08 mm (0.003 in) over any individual surface, 0.15 mm (0.005 in) over any 2 consecutive
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allowable clearance (cold) surfaces, 0.25 mm (0.009 in) over 4 surfaces
Upper intake manifold warpage - free state 0.118 in ( 3 mm)
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Upper intake manifold warpage - clamped 0.020 in ( .5 mm)

Vibration damper face runout (Max) 0.010 in ( .25 mm)
Vibration damper rubber bulging (Max) 0.098 in ( 2.5 mm)
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Push rod runout (Max) 0.002 in ( .05 mm)

Piston height above crankcase deck 0.017 –0.024 in ( .42 –.62 mm)
(protrusion)
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CKP sensor air gap - minimum 0.008 in ( .2 mm)

CKP sensor air gap - nominal 0.045 in ( 1.15 mm)
CKP sensor air gap - maximum 0.083 in ( 2.1 mm)
CMP sensor air gap - minimum 0.016 in ( .4 mm)
CMP sensor air gap - nominal 0.047 in ( 1.2 mm)
CMP sensor air gap - maximum 0.079 in ( 2 mm)
Trigger wheel runout - maximum 0.014 in ( .35 mm)
Fuel injection pump drive gear backlash 0.001 –0.007 in ( .02 –.19 mm)
Oil pump drive gear backlash 0.001 –0.007 in ( .02 –.19 mm)
Rocker arm ration (all positions) 1.5:1
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Description and Operation

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The 6.7L Power Stroke Diesel engine has the following features:
Interference design engine
4 valves per cylinder
Aluminum upper intake manifold
Composite lower intake manifold
Aluminum cylinder heads
CGI (compacted graphite iron) cylinder block
Common rail fuel system
Turbocharger
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Always refer to these label when installation of new parts is necessary or when checking engine calibrations. The engine parts often differ within a
CID (cubic inch displacement) family. Verification of the identification codes will make sure the correct parts are obtained. These codes contain all
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the pertinent information relating to the dates, optional equipment and revisions.
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The engine code information label is located on the crankcase ventilation housing and contains the following:
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1 Engine serial number
2 Engine displacement
3 Engine build location
4 QR (quick response) code
5 Engine part number

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1 Cylinder number location of replacement fuel injector
2 IQA (injector quantity adjustment) code of replacement fuel injector

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The 6.7 L diesel engine may be operated over a wide range of operating conditions. It is important to match the viscosity of the engine oil to the
vehicle operating conditions. Use the following statements and chart to make sure the oil viscosity chosen is compatible with the expected vehicle
operating conditions.
Use an engine block heater at temperatures below -23°C (-10°F). The engine coolant reaches maximum temperature after
approximately 3 hours of engine block heater operation.
Use the same engine oil and filter change intervals when using synthetic engine oil.
Use Motorcraft® oil or an equivalent oil conforming to Ford specification WSS-M2C171-F1 or API service category CK-4.
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The following operating conditions are considered severe duty service.
frequent or extended idling (over 10 minutes per hour of normal driving).
low speed operation/stationary use.
if vehicle is operated in sustained ambient temperatures below -23°C (-10°F) or above 38°C (100°F).
frequent low speed operation, consistent heavy traffic less than 40 km/h (25 mph).
operating in severe dust conditions.
operating the vehicle off road.
towing a trailer over 1600 km (1000 miles).
sustained high speed driving at GVW.
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Yellow High pressure oil flow

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Blue Oil return/ low pressure oil flow

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1 9424 Lower intake manifold
2 9424 Upper intake manifold
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3 12B591 EGRT (exhaust gas recirculation temperature) sensor

4 9H449 EGR (exhaust gas recirculation) cooler outlet tube
5 9J444 Intake manifold support
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6 9F479 MAP (manifold absolute pressure) sensor

7 6750 Oil level indicator
8 19A095 Radio frequency interference suppression ground strap assembly
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9 6754 Oil level indicator tube

10 9E926 TB (throttle body)
11 6A785 Crankcase vent oil separator

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1 6K682 Turbocharger

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2 8287 Turbocharger inlet pipe clamp (2 required)
3 9F459 EGR EP (exhaust pressure) tube assembly
4
5
6
12B591
9G437
9G478
EGRT sensor
RH turbocharger inlet pipe
Turbocharger heat shield
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7 6N646 Turbocharger downpipe
8 8287 Turbocharger downpipe clamp
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9 9G437 LH turbocharger inlet pipe

10 6466 Turbocharger gasket
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1 6748 EGR cooler assembly
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2 8A520 Turbocharger coolant outlet tube

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3 9E469 EGR cooler inlet tube

4 9L456 EGR cooler inlet tube bracket
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5 9F454 EGR vacuum control switch

6 18696 Heater water inlet tube
7 12B637 Engine control sensor and fuel charge wiring assembly
8 6K089 LH (left hand) engine noise insulator cover
9 6K089 RH (right hand) engine noise insulator cover
10 9N184 Secondary fuel filter
11 9A335 Secondary fuel filter bracket

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1 9D280 RH (right hand) fuel rail

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2 9E527 Fuel injector (8 required)
3 12A342 Glow plug (8 required)
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6
9A337
9D430
9K022
Vacuum hose connector assembly
Fuel injector return hose assembly
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Fuel injector supply tube (8 required)
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7 9J280 Fuel injection pump supply tube assembly
8 00812 Fuel injector retainer clamp bolt (8 required)
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9 9E964 Fuel rail supply tube assembly

10 9C334 Fuel injector retainer clamp (8 required)
11 9D280 LH (left hand) fuel rail
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1 6582 RH valve cover
2 6584 RH valve cover gasket
3 8C368 Engine coolant crossover
4 8575 Coolant thermostat assembly
5 8592 Coolant outlet connector
6 12A648 Engine coolant temperature sensor
7 6766 Oil fill pipe
8 6C535 Valve cover seal (8 required)
9 6582 LH valve cover
10 6584 LH valve cover gasket
11 8C387 Engine coolant crossover gasket (2 required)

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1 6379 Crankshaft pulley bolt (4 required)
2 6312 Crankshaft pulley
3 00811 Fuel injection pump drive gear nut
4 2A451 Vacuum pump
5 9C493 Vacuum pump outlet manifold hose
6 6578 RH oil spray bar
7 6565 Push rod (32 required)
8 9F589 Fuel injection pump drive gear
9 9A543 Fuel injection pump
10 9N943 Fuel injection pump spacer (3 required)
11 9G290 Fuel rail supply tube bracket
12 6578 LH oil spray bar
13 6A585 Rocker arm assembly (8 required)
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1 6500 Valve tappet (16 required)
2
3
6K564
6051
Valve tappet guide (8 required)
RH cylinder head gasket
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4 6A008 Split hollow dowel (4 required)
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5 6049 RH cylinder head
6 6065 Cylinder head bolt (M8) (8 required)
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7 9448 Exhaust manifold gasket (2 required)

8 9430 RH exhaust manifold
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9 9A462 RH exhaust manifold heat shield

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10 9Y427 LH exhaust manifold heat shield

11 9430 LH exhaust manifold
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12 6065 Cylinder head bolt (M8, LH cylinder head only)

13 6065 Cylinder head bolt (M12) (36 required)
14 6049 LH cylinder head
15 6051 LH cylinder head gasket

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1 7A030 Transmission oil cooler coolant tube

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2 6B288 CMP (camshaft position) sensor
3 7A030 Transmission oil cooler coolant tube
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6700
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Front crankshaft slinger
Front crankshaft seal
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EOP (engine oil pressure) sensor
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7 6881 Oil filter adapter
8 6731 Oil filter
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9 6C880 Oil control solenoid

10 6A715 Oil cooler outlet hose
11 6A642 Oil cooler
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12 6A715 Oil cooler inlet hose

13 6C070 Cylinder block opening cover
14 6C315 CKP (crankshaft position) sensor
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15 12A227 Crankshaft sensor pulse ring

16 6379 Flexplate bolt (10 required)
17 6375 Flexplate

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1 6019 Engine front cover

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2 6U004 Upper oil pan
3 6675 Lower oil pan
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6
6710
6D082
6397
Upper oil pan gasket
Engine rear cover
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Engine rear cover dowel (4 required)
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7 6701 Crankshaft rear seal
8 6D083 Engine rear cover gasket
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1 6279 Camshaft gear bolt
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2 6269 Camshaft thrust plate

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3 6A303 Camshaft gear

4 6250 Camshaft
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5 6K868 Piston cooling tube (8 required)

6 6D309 Upper crankshaft bearing (5 required)
7 6600 Oil pump assembly
8 — Crankshaft main bearing cap (5 required) Part of 6010)
9 6B754 Oil pump support bracket
10 6345 Crankshaft main bearing cap bolt (M15, inner) (10 required)
11 6345 Crankshaft main bearing cap bolt (M12, inner) (10 required)
12 6345 Crankshaft main bearing cap side bolt (M15) (10 required)
13 6K302 Crankshaft main bearing lower thrust washer
14 6D309 Lower crankshaft bearing (5 required)
15 6303 Crankshaft
16 6A341 Crankshaft main bearing upper thrust washer (2 required)
17 6140 Piston pin retaining ring (16 required)
18 6200 Connecting rod (8 required)
19 6211 Connecting rod bearing (8 required)
20 6135 Piston pin (8 required)
21 6108 Piston (8 required)
22 6148 Piston ring set (8 required)

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1 00812 Fuel injection pump mounting bolt (3 required)
2 W525585 Spring steel roll pin (4 required)
3 8592 Oil cooler inlet fitting
4 6010 Cylinder block
5 6397 Engine rear cover dowel (4 required)
6 W701548 3/4 x 14 Socket hex plug
7 9G478 Turbocharger heat shield
8 W706860 Turbocharger alignment dowel (2 required)
9 6A051 Block heater
10 W528208 M27 x 2 x 16 Socket hex plug (without block heater)
11 6026 1/2 x 14 Socket hex plug (2 required)
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Diagnosis and Testing

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Engine
Inspection and Verification - Engine Performance
NOTE: dAkik8Oik8K8WcOarnlmc.8COmAl8mAOm8.Or8Lk8pnTTngkW8WkCkrWcra8nr8mAk8mFCk8np8kracrk8.nr.kirt8sOiiF8n9m8frlCk.mcnr8OrW8:kicpc.Omcnr8-8Bracrk8EkipniJOr.k8ni8frlCk.mcnr8OrW8:kicpc.Omcnr8-8w:(t
1. Verify the customer concern.
2. Visually inspect for obvious signs of mechanical or electrical damage.
3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step.
4. NOTE: DOok8l9ik8mn89lk8mAk8TOmklm8l.Or8mnnT8lnpmgOik8ikTkOlkt
If the cause is not visually evident, connect the scan tool to the DLC.
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If the scan tool does not communicate with the VCM:
check the VCM connection to the vehicle.
check the scan tool connection to the VCM.
check for No Power To The Scan Tool, to diagnose no power to the scan tool,
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

6. If the scan tool does not communicate with the vehicle:

verify the ignition key is in the ON position.
verify the scan tool operation with a known good vehicle.
to diagnose no response from the PCM,
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

7. Carry out the network test.

If the scan tool responds with no communication for one or more modules,
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

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If the network test passes, retrieve and record continuous memory DTCs.
8. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
9. If the DTCs retrieved are related to the concern,
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REFER to: Electronic Engine Controls (303-14B Electronic Engine Controls - 6.7L Power Stroke Diesel, Diagnosis and Testing).

10. If no DTCs related to the concern are retrieved, GO to Symptom Chart - Engine Performance.
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Inspection and Verification - NVH
1. NVH symptoms should be identified using the diagnostic tools and techniques that are available. For a list of these techniques, tools, an explanation of their uses and a glossary of common terms,
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing).
Since it is possible that any one of multiple systems may be the cause of the symptom, it may be necessary to use a process of elimination type of diagnostic approach to pinpoint the responsible system.
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2. Verify the customer concern by operating the engine to duplicate the condition.
3. Inspect the engine for installation of an aftermarket oil filter. Review oil and filter maintenance history to make sure the vehicle has not gone beyond the standard Ford recommended oil change interval.
4. Check the engine oil level and check the oil for contamination. Low engine oil level or contaminated oil are a common cause of engine noise. If the oil is contaminated, the source of the contamination must be identified and repaired
as necessary.
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5. Visually inspect for obvious signs of mechanical damage.

6. If the inspection reveals obvious concerns that can be readily identified, repair as necessary.
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If the cause is not visually evident, connect the scan tool to the DLC.
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If the scan tool does not communicate with the VCM:
check the VCM connection to the vehicle.
check the scan tool connection to the VCM.
check for No Power To The Scan Tool, to diagnose no power to the scan tool,
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

9. If the scan tool does not communicate with the vehicle:

verify the ignition key is in the ON position.
verify the scan tool operation with a known good vehicle.
to diagnose no response from the PCM,
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

10. Carry out the network test.

If the scan tool responds with no communication for one or more modules,
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

If the network test passes, retrieve and record continuous memory DTCs.
11. Clear the continuous DTCs and carry out the self-test diagnostics for the PCM.
12. If the DTCs retrieved are related to the concern,
REFER to: Communications Network (418-00 Module Communications Network, Diagnosis and Testing).

13. If no DTCs related to the concern are retrieved, continue the inspection and verification if a noise concern is related to the engine. For vibration concerns and noise concerns such as powertrain mounts, air intake system and starter
GO to Symptom Chart - NVH.
In some cases, a noise may be a normal characteristic of that engine type. In other cases the noise may require further investigation. Comparing the noise to a similar year/model vehicle equipped with the same engine will aid in determining
if the noise is normal or abnormal.
Once a customer concern has been identified as an abnormal engine noise, it is critical to determine the location of the specific noise. Use the EngineEAR/ChassisEAR or stethoscope (the noise will always be louder closer to the noise
source) to isolate the location of the noise to one of the following areas.
Upper end of engine
Lower end of engine
 Front of engine
Rear of engine
Upper end engine noise
The fuel system, camshaft, timing drive components and valve train are common sources of upper end engine noise (ticking, knocking or rattle). Upper end engine noise can be determined using the EngineEAR/ChassisEAR or
stethoscope on the valve cover bolts. If the noise is loudest from the valve cover bolts, then the noise is upper end. The EngineEAR/ChassisEAR or stethoscope can be used to further isolate the noise to the specific cylinder bank and
cylinder. Removal of the valve covers will be required to pinpoint the source of the noise.
Fuel system noise
A common source of engine ticking noise is the switching of the fuel pressure control valve to fuel volume control valve. After the vehicle is started the high-pressure fuel injection pump switches modes and it makes a louder noise than
when the vehicle was first started. There is an inherent ticking noise that comes from the high-pressure fuel injection pump as it switches to the more fuel efficient mode using fuel volume control valve only. This noise may be characteristic
of the fuel system switching from the fuel pressure control valve to the fuel volume control valve. This noise may be more noticeable as the normal diesel engine noise diminishes. This is normal engine noise that can be verified by listening
to another vehicle. If the noise is excessive or irregular, use the EngineEAR/ChassisEAR or stethoscope to isolate the noise.
Valve train
Hydraulic lash adjusters can make an engine ticking or tapping noise noticeable at any engine rpm or temperature and is audible through the wheel well or an open hood. However, with the hood down, hydraulic lash adjuster noise can be
heard as a light tapping noise through the wheel well and is considered normal. The EngineEAR/ChassisEAR or stethoscope can be used to further isolate the noise to the specific cylinder bank and cylinder, some disassembly of the
engine may be required to inspect for damage or wear.
Turbocharger noise
Some vehicles may exhibit a turbocharger spool-down (hoot) noise on engine throttle tip-out when engine oil temperature is below 65°C (150°F) and/or an oscillating turbocharger whine at idle with engine oil temperature below
10°C (50°F). The 6.7L diesel includes design improvements to reduce overall inherent diesel engine noise. These sound reduction improvements enable certain characteristic noises to be more easily heard. Using the incorrect engine
oil can negatively impact the level of noise.
Lower end engine noise
The crankshaft, connecting rod(s) and bearings are common sources of lower end engine noise (tick/tap or typewriter noise). This noise should be considered characteristic as it is not detrimental to engine durability. The 6.7L diesel
includes design improvements to reduce overall inherent diesel engine noise. These sound reductions improvements enable certain characteristic noises to be more easily heard. Lower end noises can be determined by using the oil pan or
cylinder block lug bosses. If the noise is loudest from these areas then the noise is lower end. If an engine noise is isolated to the lower end, some disassembly of the engine may be required to inspect for damage or wear. Using the
incorrect engine oil can negatively impact the level of noise.
Front of engine noise
A common source of noise from the front of the engine (squeal, chirp, whine or hoot) is the FEAD components. To isolate FEAD noise, carry out the Engine Accessory Test,
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness, Diagnosis and Testing).

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Oil pump noise
The oil pump may whine due to air getting into the lubrication system near the oil pump. One source of an oil pump whine are cut gaskets between the upper oil pan and the engine front cover (the 2 gaskets that seal the oil pump).
Another cause is oil aeration which could be a missing O-ring seal on the oil pick-up tube or a cracked oil pick-up tube. Removal of the upper oil pan may be necessary to inspect internal engine components.

of the engine front cover may be necessary to inspect internal engine components.
Rear of engine noise
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Some other noises from the front of the engine (ticking, tapping or rattle) may be internal to the engine. Use the EngineEAR/ChassisEAR or stethoscope on the engine front cover to determine if the noise is internal to the engine. Removal

A common source of noise from the rear of the engine (knocking) is the flexplate. Inspection of the flexplate will be necessary.
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Follow the steps below to help identify the source of engine noise. Compare the characteristics of the engine noise to those listed in the NVH chart.
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14. Using a stethoscope, try to locate the source of the engine noise. Note the location of any suspected noises heard with the stethoscope.
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Click here to view engine noise diagnosis using a stethoscope.

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15. If the noise is unclear using a stethoscope, attach ChassisEAR to multiple locations of the engine. Attach ChassisEAR to suspected areas of the noise and areas not suspected as the source of the noise for comparison purposes.
ChassisEAR allow up to 6 clamps to locate the source of the noise. Instead of or in addition to using the ChassisEAR, EngineEAR can also be used. Wave or hold the EngineEAR over suspected areas of the engine to help identify
the suspected noise.
Click here to view engine noise diagnosis using ChassisEAR.
 Click here to view engine noise diagnosis using EngineEAR.

16. If the noise is still unclear using the stethoscope, ChassisEAR or EngineEAR, connect the scan tool. Use the VCMM oscilloscope function to view and graph noise. Attach the VCMM accelerometers at the loudest suspected
locations as determined previously by using the stethoscope, Chassis Ears or EngineEAR. Using the scan tool and VCMM accelerometers, graph the noise through the oscilloscope and determine if the noise is an upper or lower
engine noise. For upper engine noise, place the accelerometers at either end of the valve cover. For lower engine noises, place the accelerometers at either end or side to side of the engine block.
Click here to view engine noise diagnosis using VCMM and accelerometers.

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If the noise remains unclear or to verify the suspected noise from the stethoscope ChassisEAR, EngineEAR or graphed accelerometers, using a 3.5mm male to RCA female adapter, attach the ChassisEAR or EngineEAR to the
VCMM. Graph all or some of the noises, as like the accelerometers.
Click here to view engine noise diagnosis using VCMM and ChassisEAR.
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Click here to view engine noise diagnosis using VCMM and EngineEAR.

18. If the suspected noise location still cannot be determined, using the oscilloscope function of the VCMM, graph any combination of the accelerometer(s), ChassisEAR and/or EngineEAR to compare or identify the suspected noise.
 All 4 ports on the VCMM may be utilized for graphing noise.
Click here to view engine noise diagnosis using VCMM and ChassisEAR and accelerometer(s).

Click here to view engine noise diagnosis using VCMM and EngineEAR and accelerometer(s).

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19. After the noise is localized, note the characteristics of the noise, including type of noise, frequency and conditions when the noise occurs and GO to Symptom Chart - NVH.
Symptom Chart - Engine Performance
Symptom Chart - Engine Performance
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Symptom Possible Sources Action

Difficult starting Inoperative or damaged glow plug system Refer to the appropriate section in Group 303 for the procedure. Refer to Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
Inoperative or damaged fuel system
Inoperative or damaged starting system
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Damaged charging system/ battery TEST the system for normal operation after the repair.

Burnt valve INSTALL a new cylinder head.

REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
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or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.

Worn piston INSTALL a new piston. TEST the system for normal operation after the repair.

Worn piston rings INSTALL new piston rings. TEST the system for normal operation after the repair.

Worn cylinder INSTALL a new cylinder block. TEST the system for normal operation after the repair.

Damaged head gasket INSTALL a new cylinder head gasket.

REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.

Poor idling Inoperative or damaged EGR system Refer to the appropriate section in Group 303 for the procedure. Refer to Powertrain Control/Emissions Diagnosis
(PC/ED) manual.

Inoperative or damaged cooling system Refer to the appropriate section in Group 303 for the procedure.
Inoperative or damaged fuel system

Damaged hydraulic lash adjuster INSTALL a new hydraulic lash adjuster. TEST the system for normal operation after the repair.

Incorrect valve-to-valve seat contact INSTALL a new cylinder head.

REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.

Damaged head gasket INSTALL a new cylinder head gasket.

REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
Engine runs rough Inoperative or damaged fuel system
Leaking or damaged CAC, intake manifold or
gaskets
EGR system fault
Inoperative or damaged cooling system
Malfunctioning or damaged air intake system
Damaged hydraulic lash adjuster
Burnt or sticking valve
Weak or broken valve spring
Worn valve guides, valves and seals
Excessive oil Leaking oil
consumption
Turbocharger oil seals leaking
Malfunctioning crankcase vent oil separator
Oil dilution (fuel)
Worn valve stem seal
Worn valve stem or valve guide
Sticking piston rings
Worn piston ring groove
Worn piston or cylinder
Insufficient power Air intake system blockage
Boost leaks or blockage
Inoperative or damaged fuel system
Turbocharger damage
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Damaged exhaust or exhaust leaks at
turbocharger housing or exhaust manifold
Oil level too high
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Incorrect engine oil
Low oil pressure
Excessive accessory drive belt loading
Inoperative or damaged cooling system
Damaged or plugged exhaust system
Incorrect tire size
Dragging brakes
Slipping transmission
Malfunctioning hydraulic lash adjuster
Compression leakage at valve seat
Seized valve stem
Weak or broken valve spring
Worn or damaged camshaft
Refer to the appropriate section in Group 303 for the procedure.
INSTALL a new hydraulic lash adjuster.
REFER to: Hydraulic Lash Adjuster (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
INSTALL a new valve. TEST the system for normal operation after the repair.
INSTALL a new valve spring. TEST the system for normal operation after the repair.
INSTALL a new cylinder head.
REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
REPAIR oil leakage. TEST the system for normal operation after the repair.
REFER to Turbocharger Internal Oil Leak Test.
REFER to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger - 6.7L Power Stroke Diesel, Diagnosis
and Testing).
TEST the system for normal operation after the repair.
REPAIR or INSTALL new components as necessary. TEST the system for normal operation after the repair.
CHANGE oil to correct specification. TEST the system for normal operation after the repair.
INSTALL a new valve stem seal. TEST the system for normal operation after the repair.
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INSTALL a new cylinder head.
REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
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INSTALL new piston rings. TEST the system for normal operation after the repair.
INSTALL a new piston and piston pin. TEST the system for normal operation after the repair.
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INSTALL a new piston or cylinder block. TEST the system for normal operation after the repair.
Refer to the appropriate section in Group 303 for the procedure. Refer to Powertrain Control/Emissions Diagnosis
(PC/ED) manual.
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INSPECT the turbocharger. REFER to the Check for Free Rotation.
REFER to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger - 6.7L Power Stroke Diesel, Diagnosis
and Testing).
TEST the system for normal operation after the repair.
INSPECT for leaks. Leaks can be detected audibility or visually, by a discoloration caused by escaping hot exhaust gases.
REPAIR as necessary. TEST the system for normal operation after the repair.
DRAIN oil to correct level.
INSTALL correct specification engine oil. TEST the system for normal operation after the repair.
CARRY OUT the Oil Pressure Test in this section. Compare to specifications, repair as necessary. TEST the system for
normal operation after the repair.
Refer to the appropriate section in Group 303 for the procedure.
INSPECT exhaust system. TEST the system for normal operation after the repair.
REFER to: Identification Codes (100-01 Identification Codes, Description and Operation).
TEST the system for normal operation after the repair.
REFER to: Brake System (206-00 Brake System - General Information, Diagnosis and Testing).
TEST the system for normal operation after the repair.
Refer to the appropriate section in Group 307 for the procedure.
INSTALL a new hydraulic lash adjuster.
REFER to: Hydraulic Lash Adjuster (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
INSTALL a new cylinder head.
REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
INSTALL a new valve spring. TEST the system for normal operation after the repair.
INSTALL a new camshaft. TEST the system for normal operation after the repair.
 Damaged head gasket INSTALL a new head gasket.
REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.

Cracked or distorted cylinder head INSTALL a new cylinder head.

REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.

Damaged, worn or sticking piston ring(s) INSTALL a new piston ring(s). TEST the system for normal operation after the repair.

Worn or damaged piston INSTALL a new piston and piston pin. TEST the system for normal operation after the repair.

Worn or damaged cylinder INSPECT the cylinder for wear or damage. Repair as necessary. TEST the system for normal operation after the repair.

Low oil pressure Inaccurate gauge reading DIAGNOSE the IPC.

REFER to: Instrumentation, Message Center and Warning Chimes (413-01 Instrumentation, Message Center and Warning
Chimes, Diagnosis and Testing).

Low oil level ADJUST the oil level.

Oil dilution (fuel) INSPECT the fuel injectors.

REFER to: Fuel Injectors LH (303-04B Fuel Charging and Controls - 6.7L Power Stroke Diesel, Removal and
Installation).
or REFER to: Fuel Injectors RH (303-04B Fuel Charging and Controls - 6.7L Power Stroke Diesel, Removal and
Installation).
Repair as necessary. TEST the system for normal operation after the repair.

Stuck open oil pressure regulator INSTALL a new oil pump.

REFER to: Oil Pump (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.

Scored/damaged oil pump INSTALL a new oil pump.

REFER to: Oil Pump (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.

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Broken or damaged piston cooling tubes REMOVE the upper oil pan.
REFER to: Upper Oil Pan (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
INSPECT the piston cooling tubes. REPAIR as necessary. TEST the system for normal operation after the repair.

Front cover gasket leaks

Leaking/missing core plugs

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REMOVE the engine front cover.
REFER to: Engine Front Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
INSPECT the gasket. REPAIR as necessary. TEST the system for normal operation after the repair.

INSPECT for leaking/missing core plugs.

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REFER to: Cylinder Block Core Plug Replacement (303-00 Engine System - General Information, General Procedures).
REPAIR as necessary. TEST the system for normal operation after the repair.

Worn/damaged/missing bearing shell(s) CHECK the crankshaft main bearings and connecting rod bearings. CARRY OUT the
REFER to: Crankshaft Main Bearing Journal Clearance (303-00 Engine System - General Information, General
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Procedures).
and REFER to: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General Information, General
Procedures).
REPAIR as necessary. TEST the system for normal operation after the repair.

Restriction in the pickup tube or oil pan REMOVE the upper oil pan.
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REFER to: Upper Oil Pan (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
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INSPECT the oil pan and pickup tube. REPAIR as necessary. TEST the system for normal operation after the repair.

External oil leaks INSPECT the engine for oil leaks. REPAIR as necessary. TEST the system for normal operation after the repair.

Restriction in the oil pressure feedback tube REMOVE the oil pressure feedback tube.
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REFER to: Oil Pressure Feedback Tube (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
INSPECT the oil pressure feedback tube. REPAIR as necessary. TEST the system for normal operation after the repair.

Engine emits Clogged Air Cleaner (ACL) element INSTALL a new ACL element. TEST the system for normal operation after the repair.
excessive black
smoke

Malfunctioning fuel injection system INSPECT the fuel injection system.

REFER to: Fuel Charging and Controls (303-04B Fuel Charging and Controls - 6.7L Power Stroke Diesel, Diagnosis and
Testing).
TEST the system for normal operation after the repair.

Engine emits Damaged cylinder head INSTALL a new cylinder head.

excessive white REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
smoke or REFER to: Cylinder Head RH (303-01C Engine - 7.3L 2V DEVCT V8 (239kW/320PS) (J0), Removal and
Installation).
TEST the system for normal operation after the repair.

Damaged head gasket INSTALL a new cylinder head gasket.

REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01C Engine - 7.3L 2V DEVCT V8 (239kW/320PS) (J0), Removal and
Installation).
TEST the system for normal operation after the repair.

Cracked engine block INSTALL a new engine. TEST the system for normal operation after the repair.

Condensation build up in exhaust Smoke dissipates after start up and doesn't continue after driving/running. Normal no repair needed.

Overheating engine INSPECT the cooling system.

REFER to: Engine Cooling (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Diagnosis and Testing).
;REFER to: Powertrain Secondary Cooling (303-03C Powertrain Secondary Cooling - 6.7L Power Stroke Diesel,
Diagnosis and Testing).
REPAIR as necessary. TEST the system for normal operation after the repair.
 Engine emits Engine wear (piston rings, valve guides) REPAIR as necessary. TEST the system for normal operation after the repair.
excessive blue
smoke

turbo Install a new turbo.

REFER to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger - 6.7L Power Stroke Diesel, Removal
and Installation).
TEST the system for normal operation after the repair.

Blocked or restricted turbocharger oil drain INSPECT the turbocharger oil drain pipe. REPAIR as necessary. TEST the system for normal operation after the repair.
pipe

Turbocharger oil seals leaking REFER to Turbocharger Internal Oil Leak Test.
REFER to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger - 6.7L Power Stroke Diesel, Diagnosis
and Testing).
TEST the system for normal operation after the repair.

Plugged crankcase ventilation system Visually INSPECT the crankcase ventilation system.

Worn valve seals REPAIR as necessary. TEST the system for normal operation after the repair.

Incorrect type or grade of oil DRAIN and FILL with specified oil.

Engine emits Blocked or restricted turbocharger oil drain INSPECT the turbocharger oil drain pipe.
excessive gray pipe REFER to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger - 6.7L Power Stroke Diesel, Diagnosis
smoke and Testing).
REPAIR as necessary. TEST the system for normal operation after the repair.

Damaged/restricted or leaking turbocharger REPAIR or INSTALL a new CAC assembly as necessary. TEST the system for normal operation after the repair.
CAC assembly

Plugged crankcase ventilation system Visually INSPECT the crankcase ventilation system.

Turbocharger oil seals leaking REFER to Turbocharger Internal Oil Leak Test.
REFER to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger - 6.7L Power Stroke Diesel, Diagnosis
and Testing).

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TEST the system for normal operation after the repair.

Transmission fluid burning on exhaust INSPECT the transmission for a leak. Refer to the appropriate section in Group 307 for the procedure. REPAIR as
necessary. TEST the system for normal operation after the repair.

Black soot

Oil in coolant
Exhaust tailpipe GTDI engines

Damaged cylinder head gasket(s)

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Normal condition from rich air/fuel mixture under low load conditions.

REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
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INSPECT the cylinder head gasket(s). REPAIR as necessary. TEST the system for normal operation after the repair.

Damaged cylinder head(s)

REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
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INSPECT the cylinder head(s). REPAIR as necessary. TEST the system for normal operation after the repair.

Damaged cylinder block

REFER to: Engine (303-01B Engine - 6.7L Power Stroke Diesel, Disassembly).
INSPECT the cylinder block. REPAIR as necessary. TEST the system for normal operation after the repair.
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Leaking oil cooler

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REFER to: Oil Cooler (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
INSPECT the oil cooler and gaskets for damage. INSTALL new components as necessary. TEST the system for normal
operation after the repair.

Coolant in oil Damaged cylinder head gasket(s)

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REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
INSPECT the cylinder head gasket(s). REPAIR as necessary. TEST the system for normal operation after the repair.

Damaged cylinder head(s)

REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
INSPECT the cylinder head(s). REPAIR as necessary. TEST the system for normal operation after the repair.

Damaged cylinder block

REFER to: Engine (303-01B Engine - 6.7L Power Stroke Diesel, Disassembly).
INSPECT the cylinder block. REPAIR as necessary. TEST the system for normal operation after the repair.

Leaking oil cooler

REFER to: Oil Cooler (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
INSPECT the oil cooler and gaskets for damage. INSTALL new components as necessary. TEST the system for normal
operation after the repair.

Leaking turbocharger base gasket.

REFER to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger - 6.7L Power Stroke Diesel, Diagnosis
and Testing).
INSPECT the turbocharger base gasket. REPAIR as necessary. TEST the system for normal operation after the repair.

RH valve cover or gasket.

REFER to: Valve Cover RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
INSPECT the valve cover and the gasket. REPAIR as necessary. TEST the system for normal operation after the repair.

Engine front cover

REFER to: Engine Front Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
INSPECT the engine front cover gaskets. REPAIR as necessary. TEST the system for normal operation after the repair.

Symptom Chart - NVH

Symptom Chart - NVH
Symptom Possible Sources Action
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Rattle - occurs at idle or at light acceleration from a stop Powertrain mount(s)
Whine/moan type noise - pitch increases or changes with Powertrain mount(s)
vehicle speed
Clunk - occurs when shifting from PARK or between Powertrain mounts
REVERSE and DRIVE
Driveshaft universal joint
Drone type noise Powertrain mount(s)
Drivetrain
Drumming noise - occurs inside the vehicle during idle or Engine vibration excites the
high idle, hot or cold. Very low-frequency drumming is body resonances inducing
very rpm dependent interior noise
Engine drumming noise - accompanied by vibration
Drivetrain
Powertrain mount(s)
n.
Rattle Drivetrain
Lower end, excessive
clearance between the
connecting rod bearings and
ag
the crankshaft
Lower end, worn or damaged
crankshaft main bearings
Valvetrain
i
rd
Rattle - occurs at idle or at light acceleration from a stop Powertrain mount(s)
ca
Moaning Drivetrain
Whine/moan type noise - pitch increases or changes with Powertrain mount(s)
vehicle speed
Clunk Drivetrain
Clunk - occurs when shifting from PARK or between Powertrain mounts
REVERSE and DRIVE
Idle speed is too high
Hooting Air induction
CHECK the powertrain mounts for damage. INSTALL new mounts as necessary.
REFER to: Engine Mount LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
REFER to: Engine Mount RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
For transmission, Refer to the appropriate section in Group 307 for the procedure. TEST the system
for normal operation after the repair.
CHECK the powertrain mounts for damage. INSTALL new mounts as necessary.
REFER to: Engine Mount LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
REFER to: Engine Mount RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
For transmission, Refer to the appropriate section in Group 307 for the procedure. TEST the system
for normal operation after the repair.
CHECK the powertrain mounts for damage. INSTALL new mounts as necessary.
REFER to: Engine Mount LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
REFER to: Engine Mount RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
For transmission, Refer to the appropriate section in Group 307 for the procedure. TEST the system
for normal operation after the repair.
INSPECT the driveshaft universal joints. REPAIR as necessary. TEST the system for normal
operation after the repair.
CARRY OUT the Powertrain/Drivetrain Mount Neutralizing procedure.
REFER to: Powertrain/Drivetrain Mount Neutralizing (303-00 Engine System - General Information,
General Procedures).
TEST the system for normal operation after the repair.
Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.
m
CARRY OUT the Powertrain/Drivetrain Mount Neutralizing procedure.
REFER to: Powertrain/Drivetrain Mount Neutralizing (303-00 Engine System - General Information,
General Procedures).
TEST the system for normal operation after the repair.
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Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.
CARRY OUT the Powertrain/Drivetrain Mount Neutralizing procedure. TEST the system for
normal operation after the repair.
Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.
CARRY OUT the Connecting Rod Bearing Journal Clearance procedure.
REFER to: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).
CARRY OUT the Crankshaft Main Bearing Journal Clearance procedure.
REFER to: Crankshaft Main Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).
CARRY OUT the Valve Train Analysis Component Test in this section. INSTALL new parts as
necessary. Refer to the appropriate section in Group 303 for the procedure. TEST the system for
normal operation after the repair.
CHECK the powertrain mounts for damage. INSTALL new mounts as necessary.
REFER to: Engine Mount LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
REFER to: Engine Mount RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
For transaxle, Refer to the appropriate section in Group 307 or Group 308 for the procedure.
TEST the system for normal operation after the repair.
Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.
CHECK the powertrain mounts for damage. INSTALL new mounts as necessary.
REFER to: Engine Mount LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
REFER to: Engine Mount RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
For transaxle, Refer to the appropriate section in Group 307 or Group 308 for the procedure.
TEST the system for normal operation after the repair.
Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.
CHECK the powertrain mounts for damage. INSTALL new mounts as necessary.
REFER to: Engine Mount LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
REFER to: Engine Mount RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
For transaxle, Refer to the appropriate section in Group 307 or Group 308 for the procedure.
TEST the system for normal operation after the repair.
CHECK for the correct idle speed. TEST the system for normal operation after the repair.
CHECK the air intake ducts, air cleaner, throttle body and vacuum hoses for leaks and correct fit.
REPAIR or ADJUST as necessary. CHECK the TC and CAC tubes for leaks, correct alignment
and damage. REPAIR or INSTALL a new tube as necessary. TEST the system for normal
operation after the repair.
 Powertrain mounts
Accessory drive bearing hoot - occurs at idle or high idle Accessory drive idler or
in cold temperatures of approximately 4°C (40°F) or tensioner pulley bearing is
colder at the first start of the day experiencing stick/slip
between ball bearings and the
bearing race
Accessory drive belt noise, squeal or chirping Defective/worn or incorrect
accessory drive belt
Misaligned pulley(s)
Pulley runout
Damaged or worn accessory
drive component or idler
Fluid contamination of the
accessory drive belt or
pulleys
Damaged or worn accessory
drive belt tensioner
Damaged pulley grooves
Damaged or worn coolant
pump pulley
Clunking/moaning/grinding noise Coolant pump has excessive
end play or imbalance
Humming Air Induction
ag
Powertrain mounts
i
rd
Whining FEAD
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Whine or moaning noise Air intake system
Whistling noise - normally accompanied with poor idle Air intake system
condition
Turbocharger intake tube
assembly leaking
Loose connections or damage
to air intake hoses and tubes
Air leaks at turbine housing,
blown joints or damaged
exhaust
Carbon build up in the turbine
housing
Turbocharger imbalance due
to foreign object/damage
Whine or air rush type noise TC
Air Induction
powertrain mounts for damage. INSTALL new mounts as necessary.
REFER to: Engine Mount LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
REFER to: Engine Mount RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
For transaxle, Refer to the appropriate section in Group 307 or Group 308 for the procedure.
TEST the system for normal operation after the repair.
CARRY OUT the Engine Cold Soak procedure.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
PLACE the EngineEAR probe directly on the idler/ tensioner center post or bolt to verify which
bearing is making the noise.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
INSTALL new parts as necessary. REFER to: Accessory Drive Belt (303-05B Accessory Drive -
6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Accessory Drive Belt Tensioner (303-05B Accessory Drive - 6.7L Power Stroke
Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
CARRY OUT the Engine Accessory Test.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
INSPECT components and INSTALL new parts as necessary. REFER to: Accessory Drive Belt
(303-05B Accessory Drive - 6.7L Power Stroke Diesel, Removal and Installation).
or REFER to: Accessory Drive Belt Tensioner (303-05B Accessory Drive - 6.7L Power Stroke
Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
m
co
CHECK the coolant pump for excessive end play. INSPECT the coolant pump for imbalance with
the drive belt off. INSTALL a new coolant pump as necessary.
REFER to: Coolant Pump (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Removal and
Installation).
or REFER to: Coolant Pump (303-03C Powertrain Secondary Cooling - 6.7L Power Stroke
n.
Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
CHECK the air intake ducts, air cleaner, throttle body and vacuum hoses for leaks and correct fit.
REPAIR or ADJUST as necessary. CHECK the TC and CAC tubes for leaks, correct alignment
and damage. REPAIR or INSTALL a new tube as necessary. TEST the system for normal
operation after the repair.
CHECK the powertrain mounts for damage. INSTALL new mounts as necessary.
REFER to: Engine Mount LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
REFER to: Engine Mount RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
For transaxle, Refer to the appropriate section in Group 307 or Group 308 for the procedure.
TEST the system for normal operation after the repair.
CARRY OUT the Engine Accessory Test.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
INSPECT components and INSTALL new parts as necessary. Refer to the appropriate section in
Group 303 for the procedure. TEST the system for normal operation after the repair.
CHECK the air cleaner and ducts for correct fit. INSPECT the air intake system for leaks or
damage. TEST the system for normal operation after the repair.
CHECK the air intake ducts, air cleaner, throttle body and vacuum hoses for leaks and correct fit.
REPAIR or ADJUST as necessary. TEST the system for normal operation after the repair.
REPAIR or INSTALL a new tube as necessary. TEST the system for normal operation after the
repair.
TIGHTEN hose clamps. INSPECT for damage and REPAIR as necessary. TEST the system for
normal operation after the repair.
INSPECT for leaks. Leaks can usually be detected audibility or visually, by a discoloration caused
by escaping hot exhaust gases. REPAIR as necessary. TEST the system for normal operation after
the repair.
INSPECT the TC REFER to the Check for Free Rotation. Refer to the appropriate section in
Group 303 for the procedure. TEST the system for normal operation after the repair.
REPAIR as necessary. TEST the system for normal operation after the repair.
Acceptable condition. Some whine or air noise is common.
CHECK the air intake ducts, air cleaner, throttle body and vacuum hoses for leaks and correct fit.
REPAIR or ADJUST as necessary. CHECK the turbocharger and CAC tubes for leaks, correct
alignment and damage. REPAIR or INSTALL a new tube as necessary. TEST the system for
normal operation after the repair.
Hissing noise
Hissing noise - occurs during idle or high idle that is
apparent with the hood open
Grinding noise - occurs during engine cranking
Engine noise, front of engine - knocking noise from lower
front of engine
Tapping
Engine noise, front of engine - ticking, tapping or rattling
noise from the front of the engine
Engine noise, upper end - ticking noise near the valve
cover
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Engine noise, upper end - ticking, knocking or rattle noise
that occurs during idle or high idle during the first cold
start of the day and may disappear as the engine warms
Engine noise, upper end - rattling noise from the valve
train. Worse when the engine is cold
Air Induction
Boost leak noise
Composite intake manifold
Incorrect starter motor
mounting
Starter motor
Incorrect starter motor drive
engagement
Damage flexplate
Drivetrain
Damaged or separated
crankshaft pulley/damper
Drivetrain
Piston
Timing drive components
Damaged oil pump
ag
i
rd
Fuel injector
Valve train noise
Cam Drive
Low oil level
Thin or diluted oil
Low oil pressure
Worn valve train components
Worn valve guides
CHECK the air intake ducts, air cleaner, throttle body and vacuum hoses for leaks and correct fit.
REPAIR or ADJUST as necessary. CHECK the turbocharger and CAC tubes for leaks, correct
alignment and damage. REPAIR or INSTALL a new tube as necessary. TEST the system for
normal operation after the repair.
Use the Ultrasonic Leak Detector/EngineEAR to locate the source. Scan the air intake system from
the inlet to each cylinder intake port. DISCARD the leaking parts, and INSTALL a new
component. TEST the system for normal operation after the repair.
Acceptable condition. Some composite manifolds exhibit this noise, which is the effect of the
composite manifold.
INSPECT the starter motor for correct mounting. REPAIR as necessary.
REFER to: Starter Motor (303-06B Starting System - 6.7L Power Stroke Diesel, Removal and
Installation).
TEST the system for normal operation after the repair.
CHECK the starter motor. INSTALL a new starter motor as necessary.
REFER to: Starter Motor (303-06B Starting System - 6.7L Power Stroke Diesel, Removal and
Installation).
TEST the system for normal operation after the repair.
INSPECT the starter motor drive for wear or damage. INSTALL a new starter motor as necessary.
REFER to: Starter Motor (303-06B Starting System - 6.7L Power Stroke Diesel, Removal and
Installation).
TEST the system for normal operation after the repair.
INSPECT the flexplate for wear or damage. INSTALL a new flexplate as necessary.
REFER to: Flexplate (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.
CHECK for obvious signs of damage or wobble during operation. INSTALL new as necessary.
TEST the system for normal operation after the repair.
Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.
m
CARRY OUT the Piston Diameter procedure.
REFER to: Piston Diameter (303-00 Engine System - General Information, General Procedures).
Measure the cylinder bore diameter. Subtract the piston diameter from the cylinder bore diameter to
co
find the piston-to-cylinder bore clearance. REFER to the appropriate 303-01 Section for
specifications. MEASURE the piston pin bore and the piston pin in 2 directions on each side.
REFER to the appropriate 303-01 Section for specifications.
REMOVE the accessory drive belt.
REFER to: Accessory Drive Belt (303-05B Accessory Drive - 6.7L Power Stroke Diesel, Removal
n.
and Installation).
USE the EngineEAR to isolate the noise to the engine front cover.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
REMOVE the engine front cover.
REFER to: Engine Front Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
INSPECT the timing drive components. INSTALL new parts as necessary. TEST the system for
normal operation after the repair.
USE the EngineEAR to isolate the noisy injector(s). INSTALL a new injector(s) as necessary.
REFER to: Fuel Injectors LH (303-04B Fuel Charging and Controls - 6.7L Power Stroke Diesel,
Removal and Installation).
or REFER to: Fuel Injectors RH (303-04B Fuel Charging and Controls - 6.7L Power Stroke
Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
CARRY OUT the Valve Train Analysis in this section. INSTALL new parts as necessary. Refer to
the appropriate section in Group 303 for the procedure. TEST the system for normal operation after
the repair.
USE the EngineEAR to isolate the noise to the engine front cover.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
REMOVE the engine front cover and INSPECT the timing drive components.
REFER to: Engine Front Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
INSTALL new parts as necessary. Refer to the appropriate section in Group 303 for the
procedure. TEST the system for normal operation after the repair.
CHECK the oil level. FILL as necessary.
INSPECT the oil for contamination. If the oil is contaminated, CHECK for the source. REPAIR as
necessary. CHANGE the oil and filter. TEST the system for normal operation after the repair.
CARRY OUT the Oil Pressure Test in this section. If not within specifications, REMOVE the engine
oil pan.
REFER to: Upper Oil Pan (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
INSPECT for a blocked oil pickup tube. Inspect the oil pressure feedback tube. REFER to: Oil
Pressure Feedback Tube (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
CARRY OUT the Valve Train Analysis in this section. INSTALL new parts as necessary. Refer to
the appropriate section in Group 303 for the procedure. TEST the system for normal operation after
the repair.
CARRY OUT the Valve Guide Inner Diameter procedure.
REFER to: Valve Guide Inner Diameter (303-00 Engine System - General Information, General
Procedures).

Engine noise, lower end - ticking or knocking noise near
the engine front cover
Engine noise, lower end - light knocking noise, also
described as piston slap. Noise is most noticeable when
the engine is cold with light to medium acceleration. The
noise disappears as the engine warms
Engine noise, lower end - light double knock or sharp rap
sound. Occurs mostly with a warm engine at idle or low
speeds in drive. Increases in relation to engine load.
Associated with a poor lubrication history
Engine noise, lower end - light knocking noise. The noise
is most noticeable when the engine is warm. The noise
tends to decrease when the vehicle is coasting or in neutral
Engine noise, lower end - deep knocking noise. The noise
is most noticeable when the engine is warm, at lower rpm
and under a light load and then at float
Engine noise, rear of engine - knocking noise at rear of
engine
Slapping
Knocking
Engine vibration - vibration felt at all times
Engine vibration - at idle, a low-frequency vibration (5-20
Hz) or mild shake that is felt through the seat/ floorpan
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Engine vibration - is felt with increases and decreases in
engine rpm
Engine vibration - increases intensity as the engine rpm is
increased
Engine vibration - mostly at coast/neutral coast. Condition
improves with vehicle acceleration
Engine vibration or shudder - occurs with light to medium
acceleration above 56 km/h (35 mph)
Excessive runout of the valve
seats on the valve face
Oil pump
Excessive clearance between
the piston and the cylinder
wall
Excessive clearance between
the piston and the piston pin
Excessive clearance between
the connecting rod bearings
and the crankshaft
Worn or damaged crankshaft
main bearings
Damaged flexplate
Drivetrain
Piston
Drivetrain
Excessive engine pulley
runout
Damaged or worn accessory
component
ag
Cylinder misfire
i
Engine or torque converter
rd
out of balance
Powertrain mount(s)
Engine or transmission
grounded to chassis
Engine out-of-balance
Combustion instability
Worn or damaged glow plugs
Plugged fuel injector
INSPECT for abnormalities on the valve face and valve seat. INSTALL a new cylinder head
assembly if abnormalities are found.
USE the EngineEAR to verify the oil pump as the source of the noise at low rpm. REPAIR as
necessary. Refer to the appropriate section in Group 303 for the procedure. TEST the system for
normal operation after the repair.
CARRY OUT the Piston Diameter procedure.
REFER to: Piston Diameter (303-00 Engine System - General Information, General Procedures).
Measure the cylinder bore diameter. Subtract the piston diameter from the cylinder bore diameter to
find the piston-to-cylinder bore clearance. REFER to the appropriate 303-01 Section for
specifications.
MEASURE the piston pin bore and the piston pin in 2 directions on each side. REFER to the
appropriate 303-01 Section for specifications.
CARRY OUT the Connecting Rod Bearing Journal Clearance procedure.
REFER to: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).
CARRY OUT the Crankshaft Main Bearing Journal Clearance procedure.
REFER to: Crankshaft Main Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).
INSPECT the flexplate for wear or damage. INSTALL a new flexplate as necessary.
REFER to: Flexplate (303-01A Engine - 6.2L V8, Removal and Installation).
TEST the system for normal operation after the repair.
Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.
CARRY OUT the Piston Diameter procedure.
REFER to: Piston Diameter (303-00 Engine System - General Information, General Procedures).
Measure the cylinder bore diameter. Subtract the piston diameter from the cylinder bore diameter to
find the piston-to-cylinder bore clearance. REFER to the appropriate 303-01 Section for
m
specifications. MEASURE the piston pin bore and the piston pin in 2 directions on each side.
REFER to the appropriate 303-01 Section for specifications.
Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.
co
CARRY OUT the Engine Accessory Test.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
INSTALL a new engine pulley as necessary. Refer to the appropriate section in Group 303 for the
procedure. TEST the system for normal operation after the repair.
n.
CARRY OUT the Engine Accessory Test.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
REPAIR or INSTALL a new component as necessary. TEST the system for normal operation after
the repair.
Using the scan tool, CARRY OUT the cylinder power balance and the relative compression test.
REPAIR as necessary. Refer to the appropriate section in Group 303 for the procedure. TEST the
system for normal operation after the repair.
VERIFY the torque converter to crankshaft pilot clearance is correct. REPAIR as necessary. RE-
INDEX the torque converter on the flex plate by 120 degrees for a 3- bolt converter or 180
degrees for a 4-bolt converter. Refer to the appropriate section in Group 307 for the procedure.
TEST the system for normal operation after the repair.
CHECK the powertrain mounts for damage. INSTALL new mounts as necessary.
REFER to: Engine Mount LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
REFER to: Engine Mount RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
For transmission, Refer to the appropriate section in Group 307 or Group 308 for the procedure.
TEST the system for normal operation after the repair.
INSPECT the powertrain/ drivetrain for correct clearances. REPAIR as necessary. TEST the
system for normal operation after the repair.
CARRY OUT the NERU Test.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
ROTATE the torque converter, 120 degrees for 3- bolt or 180 degrees for 4- bolt. INSPECT the
torque converter pilot outer diameter-to-crankshaft pilot inner diameter. REPAIR as necessary.
Refer to the appropriate section in Group 307 for the procedure. TEST the system for normal
operation after the repair.
CHECK the ignition system. INSTALL new components as necessary. Refer to the appropriate
section in Group 303 for the procedure. TEST the system for normal operation after the repair.
INSPECT the spark plugs for cracks, high resistance or broken insulators. INSTALL a new glow
plug(s) as necessary.
REFER to: Glow Plugs (303-07C Glow Plug System - 6.7L Power Stroke Diesel, Removal and
Installation).
TEST the system for normal operation after the repair.
REPAIR or INSTALL a new injector as necessary.
REFER to: Fuel Injectors LH (303-04B Fuel Charging and Controls - 6.7L Power Stroke Diesel,
Removal and Installation).
or REFER to: Fuel Injectors RH (303-04B Fuel Charging and Controls - 6.7L Power Stroke
Diesel, Removal and Installation).
TEST the system for normal operation after the repair.
 Contaminated fuel INSPECT the fuel for contamination. DRAIN the fuel system and refill.
REFER to: Fuel Tank Draining (310-00B Fuel System - General Information - 6.7L Power Stroke
Diesel, General Procedures).
TEST the system for normal operation after the repair.

Bongo Balance shaft USE the EngineEAR to isolate the noise to the engine front cover.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
REMOVE the engine front cover and INSPECT the timing drive components.
REFER to: Engine Front Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
INSTALL new parts as necessary. Refer to the appropriate section in Group 303 for the
procedure. TEST the system for normal operation after the repair.

Chatter Valvetrain CARRY OUT the Valve Train Analysis Component Test in this section. INSTALL new parts as
necessary. Refer to the appropriate section in Group 303 for the procedure. TEST the system for
normal operation after the repair.

Chirping FEAD CARRY OUT the Engine Accessory Test.

REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
INSPECT components and INSTALL new parts as necessary. Refer to the appropriate section in
Group 303 for the procedure. TEST the system for normal operation after the repair.

Piston Rings Inspect the piston, piston rings and piston ring area for damage, and excessive wear. Check that the
piston rings move freely.
REFER to: Piston Inspection (303-00 Engine System - General Information, General Procedures).
REFER to: Piston Ring End Gap (303-00 Engine System - General Information, General
Procedures).
Refer to the appropriate section in Group 303 for the procedure. TEST the system for normal
operation after the repair.

Valvetrain CARRY OUT the Valve Train Analysis Component Test in this section. INSTALL new parts as
necessary. Refer to the appropriate section in Group 303 for the procedure. TEST the system for
normal operation after the repair.

m
Clicking Fuel Check for normal condition of fuel injectors used in direct injected engines. CHECK that any noise
insulators are installed correctly in the correct positions.

PCV Acceptable condition for the PCV system. If excessive noise is suspected, REFER to PC/ED for

Valvetrain
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PCV diagnosis.

CARRY OUT the Valve Train Analysis Component Test in this section. INSTALL new parts as
necessary. Refer to the appropriate section in Group 303 for the procedure. TEST the system for
normal operation after the repair.
n.
Clatter Cam Drive USE the EngineEAR to isolate the noise to the engine front cover.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
REMOVE the engine front cover and INSPECT the timing drive components.
ag

REFER to: Engine Front Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
INSTALL new parts as necessary. Refer to the appropriate section in Group 303 for the
procedure. TEST the system for normal operation after the repair.

Piston CARRY OUT the Piston Diameter procedure.

i

REFER to: Piston Diameter (303-00 Engine System - General Information, General Procedures).
rd

Measure the cylinder bore diameter. Subtract the piston diameter from the cylinder bore diameter to
find the piston-to-cylinder bore clearance. REFER to the appropriate 303-01 Section for
specifications. MEASURE the piston pin bore and the piston pin in 2 directions on each side.
REFER to the appropriate 303-01 Section for specifications.
ca

Crickets Cam Drive USE the EngineEAR to isolate the noise to the engine front cover.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
REMOVE the engine front cover and INSPECT the timing drive components.
REFER to: Engine Front Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
INSTALL new parts as necessary. Refer to the appropriate section in Group 303 for the
procedure. TEST the system for normal operation after the repair.

Dieseling Lower end, excessive
clearance between the
connecting rod bearings and
the crankshaft
Lower end, worn or damaged
crankshaft main bearings
CARRY OUT the Connecting Rod Bearing Journal Clearance procedure.
REFER to: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).
CARRY OUT the Crankshaft Main Bearing Journal Clearance procedure.
REFER to: Crankshaft Main Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).

Piston CARRY OUT the Piston Diameter procedure.

REFER to: Piston Diameter (303-00 Engine System - General Information, General Procedures).
Measure the cylinder bore diameter. Subtract the piston diameter from the cylinder bore diameter to
find the piston-to-cylinder bore clearance. REFER to the appropriate 303-01 Section for
specifications. MEASURE the piston pin bore and the piston pin in 2 directions on each side.
REFER to the appropriate 303-01 Section for specifications.

Quacking Cam Drive USE the EngineEAR to isolate the noise to the engine front cover.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
REMOVE the engine front cover and INSPECT the timing drive components.
REFER to: Engine Front Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
INSTALL new parts as necessary. Refer to the appropriate section in Group 303 for the
procedure. TEST the system for normal operation after the repair.
 FEAD CARRY OUT the Engine Accessory Test.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
INSPECT components and INSTALL new parts as necessary. Refer to the appropriate section in
Group 303 for the procedure. TEST the system for normal operation after the repair.

Scratching Cam Drive USE the EngineEAR to isolate the noise to the engine front cover.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
REMOVE the engine front cover and INSPECT the timing drive components.
REFER to: Engine Front Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
INSTALL new parts as necessary. Refer to the appropriate section in Group 303 for the
procedure. TEST the system for normal operation after the repair.

Drivetrain Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.

Lower end, excessive
clearance between the
connecting rod bearings and
the crankshaft
Lower end, worn or damaged
crankshaft main bearings
CARRY OUT the Connecting Rod Bearing Journal Clearance procedure.
REFER to: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).
CARRY OUT the Crankshaft Main Bearing Journal Clearance procedure.
REFER to: Crankshaft Main Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).

Squeaking Cam Drive USE the EngineEAR to isolate the noise to the engine front cover.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
Diagnosis and Testing).
REMOVE the engine front cover and INSPECT the timing drive components.
REFER to: Engine Front Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
INSTALL new parts as necessary. Refer to the appropriate section in Group 303 for the
procedure. TEST the system for normal operation after the repair.

Drivetrain Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.

Lower end, excessive
clearance between the
connecting rod bearings and
the crankshaft
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CARRY OUT the Connecting Rod Bearing Journal Clearance procedure.
REFER to: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).

Squealing
Lower end, worn or damaged
crankshaft main bearings

Cam Drive
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CARRY OUT the Crankshaft Main Bearing Journal Clearance procedure.
REFER to: Crankshaft Main Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).

USE the EngineEAR to isolate the noise to the engine front cover.
REFER to: Noise, Vibration and Harshness (NVH) (100-04 Noise, Vibration and Harshness,
n.
Diagnosis and Testing).
REMOVE the engine front cover and INSPECT the timing drive components.
REFER to: Engine Front Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
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INSTALL new parts as necessary. Refer to the appropriate section in Group 303 for the
procedure. TEST the system for normal operation after the repair.

Drivetrain Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.

Lower end, excessive CARRY OUT the Connecting Rod Bearing Journal Clearance procedure.
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clearance between the REFER to: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General
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connecting rod bearings and Information, General Procedures).

the crankshaft
CARRY OUT the Crankshaft Main Bearing Journal Clearance procedure.
Lower end, worn or damaged REFER to: Crankshaft Main Bearing Journal Clearance (303-00 Engine System - General
crankshaft main bearings Information, General Procedures).
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Thumping Drivetrain Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.

Lower end, excessive
clearance between the
connecting rod bearings and
the crankshaft
Lower end, worn or damaged
crankshaft main bearings
CARRY OUT the Connecting Rod Bearing Journal Clearance procedure.
REFER to: Connecting Rod Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).
CARRY OUT the Crankshaft Main Bearing Journal Clearance procedure.
REFER to: Crankshaft Main Bearing Journal Clearance (303-00 Engine System - General
Information, General Procedures).

Tin-Like Drivetrain Refer to the appropriate section in Group 205, 307 or 308 for drivetrain diagnosis.

Cylinder Head INSPECT the cylinder head components. INSTALL new engine components as necessary.
REFER to: Cylinder Head LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
or REFER to: Cylinder Head RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and
Installation).
TEST the system for normal operation after the repair.

Manifold Acceptable condition from expansion and contraction of exhaust components.

Component Tests
The following component tests are used to diagnose engine concerns.
Engine Oil Leaks
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Prior to carrying out this procedure, clean the cylinder block, cylinder heads, valve covers, oil pan and flexplate with a suitable solvent to remove all traces of oil.
Engine Oil Leaks - Fluorescent Oil Additive Method
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Use the UV Long-Wave W/12-foot Cord & Alligator Clips (164-R3748) or Leak Tracker UV-LED Leak Detection Flashlight (164-TP8695) to carry out the following procedure for oil leak diagnosis.
1. Add 237 ml (8 Fl Oz) of Dye-Lite® Oil-Based Fluid Dye (164-TP33200008) to a minimum of 0.47L (1/2 qt) and a maximum of 0.95L (1 qt) engine oil. Thoroughly premix the oil based fluid dye or it will not have enough time
to reach the crankcase, oil galleries and seal surfaces during this particular 15 minute test. The additive must be added through the oil fill. Check the level on the oil level indicator to determine what amount of oil to premix. If it is in
the middle of the crosshatch area or below the full mark, use 0.95L (1 qt). If it is at the full mark, use 0.47L (1/2 qt).
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Run the engine for 15 minutes. Stop the engine and inspect all seal and gasket areas for leaks using the UV Leak Detector Kit. A fluoresces white area will identify the leak. For extremely small leaks, several hours may be required
for the leak to appear.
3. At the end of test, make sure the oil level is within the upper and lower oil indicator marks. Remove oil as necessary if it registers above the full mark.
Leakage Points - Underhood
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Examine the following areas for oil leakage:
Valve cover gaskets
Cylinder head gaskets
Engine front cover
Oil level indicator tube
Crankcase vent oil separator
Turbocharger pedestal
Turbocharger oil supply tube
Leakage Points - Under Engine, With Vehicle on Hoist
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Examine the following areas for oil leakage:
Oil pan gaskets
Oil pan sealer
Engine front cover gasket
Crankshaft front seal
Crankshaft rear seal
Oil filter adapter
Oil cooler

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Engine oil and pressure sensor
Leakage Points - With Transmission and Flywheel/Flexplate Removed
Examine the following areas for oil leakage:
Crankshaft rear oil seal
Flexplate mounting bolt holes (with flexplate installed)
Pipe plugs at the end of oil passages
Core plugs
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Compression Test
n.
1. Make sure the oil in the crankcase is of the correct viscosity and at the correct level.
2. Operate the engine until it is at normal operating temperature. Turn the ignition switch to the OFF position.
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Remove the glow plugs.
REFER to: Glow Plugs (303-07C Glow Plug System - 6.7L Power Stroke Diesel, Removal and Installation).
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4. Connect a battery charger to the battery.

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5. Install the Compression Test Adapter (303-1515) and a commercially available diesel compression tester.
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6. Install an auxiliary starter switch in the starting circuit. With the ignition switch in the OFF position, crank the engine a consistent number of strokes (minimum of 2 compression strokes to 12 compression strokes). Record the
readings.
7. Repeat the test on each cylinder, cranking the engine the same number of compression strokes, record the readings. Compare the readings of the 8 cylinders.
There must be a minimum cylinder pressure of 2068.4 kpa (300 psi) and have no more than a 20% difference from the average on any given cylinder.
8. Investigate and repair any cylinder(s) that are outside the 20% range.
 9. Remove the Compression Test Adapter (303-1515) and the commercially available diesel compression tester.
10. Disconnect the battery charger from the battery.
11. Install the glow plugs.
REFER to: Glow Plugs (303-07C Glow Plug System - 6.7L Power Stroke Diesel, Removal and Installation).

Cylinder Leakage Detection

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When a cylinder produces a low reading, use of a cylinder leakage tester will be helpful in pinpointing the exact cause.
The leakage tester is inserted in the glow plug hole, the piston is brought up to TDC on the compression stroke, and compressed air is admitted.
Once the combustion chamber is pressurized, the leakage tester gauge will read the percentage of leakage. Leakage exceeding 20% is excessive.

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While the air pressure is retained in the cylinder, listen for the hiss of escaping air. A leak at the intake valve will be heard in the TB (throttle body). A leak at the exhaust valve can be heard at the tailpipe. Leakage past the piston rings will
be audible at the crankcase vent oil separator connection. If air is passing through a blown head gasket to an adjacent cylinder, the noise will be evident at the glow plug hole of the cylinder into which the air is leaking. Cracks in the
cylinder block or gasket leakage into the cooling system may be detected by a stream of bubbles in the radiator.
Excessive Engine Oil Consumption
n.
Nearly all engines consume oil, which is essential for normal lubrication of the cylinder bore walls and pistons and rings. Determining the level of oil consumption may require testing by recording how much oil is being added over a given
set of miles.
Customer driving habits greatly influence oil consumption. Mileage accumulated during towing or heavy loading generates extra heat. Frequent short trips, stop-and-go type traffic or extensive idling, prevent the engine from reaching
normal operating temperature. This prevents component clearances from reaching specified operating ranges.
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The following diagnostic procedure may be utilized to determine internal oil consumption. Make sure that the concern is related to internal oil consumption, and not external leakage, which also consumes oil. Verify there are no leaks
before carrying out the test. Once verified, the rate of internal oil consumption can be tested.
A new engine may require extra oil in the early stages of operation. Internal piston-to-bore clearances and sealing characteristics improve as the engine breaks in. Engines are designed for close tolerances and do not require break-in oils
or additives. Use the oil specified in the Owner's Literature. Ambient temperatures may determine the oil viscosity specification. Verify that the correct oil is being used for the vehicle in the geographic region in which it is driven.
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Basic Pre-checks
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1. For persistent complaints of oil consumption, interview the customer to determine the oil consumption characteristics. If possible, determine the brand and grade of oil currently in the oil pan. Look at the oil filter or oil-change
station tags to determine if Ford-recommended maintenance schedules have been followed. Make sure that the oil has been changed at the specified mileage intervals. If vehicle mileage is past the first recommended drain interval,
the OEM (original equipment manufacturer) production filter should have been changed.
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2. Ask how the most current mileage was accumulated. That is, determine whether the vehicle was driven under the following conditions:
Extended idling or curbside engine operation
Stop-and-go traffic or taxi operation
Towing a trailer or vehicle loaded heavily
Frequent short trips (engine not up to normal operating temperature)
Excessive throttling or high engine-rpm driving
3. Verify that there are no external leaks. If necessary, review the diagnostic procedure under Engine Oil Leaks in the Diagnosis and Testing portion of this section.
4. Inspect the crankcase ventilation system for:
disconnected hoses at the valve cover or ACL (air cleaner).
loose or missing valve cover fill cap.
missing or incorrectly seated engine oil level indicator.
incorrect or damaged crankcase vent oil separator.
5. Inspect for signs of sludge. Sludge affects crankcase vent oil separator performance and can plug or restrict cylinder head drainback wells. It can also increase oil pressure by restricting passages and reducing the drainback
capability of piston oil control rings.
6. Inspect the air filter for dirt, sludge or damage. A hole in the filter element will allow unfiltered air to bypass into the air induction system. This can cause premature internal wear (engine dusting), allowing oil to escape past rings,
pistons, valves and guides.
7. If the engine is hot or was recently shut down, wait at least 20-minutes to allow the oil to drain back. Ask the customer if this requirement has been followed. Adding oil without this wait period can cause an overfill condition,
leading to excessive oil consumption and foaming which may cause engine damage.
8. Make sure the oil level indicator (dipstick) is correctly and fully seated in the indicator tube. Remove the oil level indicator and record the oil level.
Detailed Pre-checks
1. Check the thermostat opening temperature to make sure that the cooling system is operating at the specified temperature. If it is low, internal engine parts are not running at specified internal operating clearances.
Oil Consumption Test
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Drain the engine oil and remove the oil filter. Install a new manufacturer-specified oil filter. Make sure the vehicle is positioned on a level surface. Refill the oil pan to a level one liter (quart) less than the specified fill level, using
manufacturer-specified oil.
2. Run the engine for 3 minutes (if hot) or 10 minutes (if cold). Allow for a minimum 20-minute drainback period and then record the oil level shown on the oil level indicator. Place a mark on the backside of the oil level indicator
noting the oil level location.
3. Add the final one liter (quart) to complete the normal oil fill. Restart the engine and allow it to idle for 2 minutes. Shut the engine down.
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After a 20-minute drainback period, record the location of the oil level again. Mark the oil level indicator with the new oil level location. Demonstrate to the customer that the factory-calibrated marks on the oil level indicator are
where the oil should fall after an oil change with the specified fill amount. Explain however, that this may vary slightly between MIN-MAX or the upper and lower holes on the oil level indicator.
5. Record the vehicle mileage.
6. Advise the customer that oil level indicator readings must be taken every 320 km (200 mi) or weekly, using the revised marks as drawn. Remind the customer that the engine needs a minimum 20-minute drainback for an accurate
reading and that the oil level indicator must be firmly seated in the tube prior to taking the reading.
7. When the subsequent indicator readings demonstrate a full liter (quart) has been used, record the vehicle mileage. The mileage driven should not be less than 1,440 km (900 mi). The drive cycle the vehicle has been operated under
must be considered when making this calculation. It may be necessary to have the customer bring the vehicle in for a periodic oil level indicator reading to closely monitor oil usage.
Post Checks, Evaluation and Corrective Action
1. If test results indicate excessive oil consumption, carry out a Compression Test. The compression test should be carried out with a fully charged battery and all glow plugs removed.
2. Compression should be consistent across all cylinders. If compression tested within the specifications found in this section, the excessive oil consumption may be due to wear on the valve guides, valves or valve seals.
3. A cylinder leak detection test can be carried out using a cylinder leakage detector. This can help identify valves, piston rings, or worn valve guides/valve stems, inoperative valve stem seals or other related areas as the source of oil
consumption.
4. If an internal engine part is isolated as the root cause, determine if the repair will exceed cost limits and proceed with a repair strategy as required.
5. Once corrective action to engine is complete and verifying that all pre-check items were eliminated in the original diagnosis, repeat the Oil Consumption Test as described above and verify consumption results.
Oil Pressure Test
1. NOTICE: Inspect the engine for installation of an aftermarket oil filter. Review oil and filter maintenance history to make sure that the vehicle has not gone beyond the standard Ford recommended oil change
intervals. Check the engine oil level and check the oil for contamination. If the oil is contaminated, engine damage can occur, the source of the contamination must be identified and repaired as necessary.
Run the engine until normal operating temperature is reached.

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2. Disconnect the EOP sensor electrical connector.
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3. Remove the EOP sensor.

4. Connect an commercially available Oil Pressure Gauge to the oil pressure switch port.
5. Record the oil pressure gauge reading at 700 RPM, 1,200 RPM and 1800 RPM.
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6. Compare the oil pressure recordings to the specifications,

REFER to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).

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If the pressure is not within specification, check the following possible sources:
Insufficient oil
Oil leakage
Worn or damaged oil pump
Oil pump screen and pickup tube
Excessive main bearing clearance
Excessive connecting rod bearing clearance
Damaged or missing piston cooling tube
If the concern is not evident, verify the symptom. GO to the Engine Performance Symptom Chart.
8. Remove the commercially available Oil Pressure Gauge from the oil pressure switch port.

9. Install the EOP sensor. Torque: 89 lb.in (10 Nm)

 10. Install the EOP sensor electrical connector.
Valve Train Analysis
The following inspection is used to diagnose valve train concerns.
Valve Train Analysis - Valve Cover Removed
Check for damaged or severely worn parts rocker arm assemblies and push rods.
Valve Train Analysis - Valve Springs
Check for broken or damaged parts.
Valve Train Analysis - Valve Spring Retainer and Valve Spring Retainer Keys
Check for correct seating of the valve spring retainer key on the valve stem and in valve spring retainer.
Check for correct seating on the valve stem.
Valve Train Analysis - Valves and Cylinder Head
Check for plugged oil drain back holes.
Check for worn or damaged valve tips.
Check for missing or damaged guide-mounted valve stem seal.
Check for damaged hydraulic lash adjuster.
Check installed valve spring height.

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Check for missing or worn valve spring seats.
Valve Train Analysis - Camshaft Lobe Lift
1. Preform visual inspection. Check for damaged or severely worn parts and correct assembly.
2. Remove the glow plugs.
REFER to: Glow Plugs (303-07C Glow Plug System - 6.7L Power Stroke Diesel, Removal and Installation).
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3. Remove the rocker arm assemblies for the affected cylinders.
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REFER to: Rocker Arm (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
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4. Install the Dial Indicator Gauge with Holding Fixture so the needle tip of indicator is on top of the push rod.
5. Rotate the crankshaft using a breaker bar and socket attached to the crankshaft pulley retaining bolt. Rotate the crankshaft until the base circle of the camshaft lobe is reached.
6. Zero the Dial Indicator Gauge. Continue to rotate the crankshaft until the high lift point of the rocker arm is in the fully raised position (highest indicator reading).
7. To check the accuracy of the original indicator reading, continue to rotate crankshaft until the base circle is reached. The indicator reading should be zero. If zero reading is not obtained, repeat the measurement.
8. If the lift on any lobe is below specified service limits, install a new camshaft and valve tappets.
REFER to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).

9. Install the rocker arm assemblies.

REFER to: Rocker Arm (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).

10. Install the glow plugs.

REFER to: Glow Plugs (303-07C Glow Plug System - 6.7L Power Stroke Diesel, Removal and Installation).
 m
General Procedures

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Floor Crane
Wooden Block

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upwyR3m RvP0-B ivB B0-10B n1o P0a i12B ivB igsdnLvPs-Bs 1S sB2n5BI csn2 ivB B0-10B: wvB 7PSSP-BS 10 ivB donL/9 onLPiBI g0IBs0BPiv ivB igsdnLvPs-Bs9 PsB
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upw3m For EXPORT ONLY vehicles (outside US/Canada), an Export Supplement is provided and should be referenced to identify differences that can impact
service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US
EPA or CARB Regulations."
1. With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).

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2. Remove the following items:
1. Remove the turbocharger.
Refer to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger - 6.7L Power Stroke Diesel, Removal and Installation).
2. Remove the cooling fan stator.

3. Remove the oil cooler.

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Refer to: Cooling Fan Stator (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Removal and Installation).

Refer to: Oil Cooler (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
3.
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Install Special Service Tool: 303-1518 Bracket, Engine Removal.
Torque: 41 lb.ft (55 Nm)
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4. Disconnect and position aside the wire harness.

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5. upwyR3m hP1ogsB in sB7oPLB ivB isP0S21SS1n0 Sg77nsi 10SgoPins 0giS 2Pa sBSgoi 10 isP0S21SS1n0 Sg77nsi 10SgoPins IP2P-B:
Loosen the transmission support insulator nuts. co
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6. upwyR3m hP1ogsB in sB7oPLB ivB B0-10B 2ng0i LsnSS dnoiS 2Pa sBSgoi 10 B0-10B 2ng0i IP2P-B:
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Remove and discard the RH engine mount cross bolt.

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7. upwyR3m hP1ogsB in sB7oPLB ivB B0-10B 2ng0i LsnSS dnoiS 2Pa sBSgoi 10 B0-10B 2ng0i IP2P-B:
Remove and discard the LH engine mount cross bolt.
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8. upwyR3m hP1ogsB in sB7oPLB ivB B0-10B 2ng0i 0giS 2Pa sBSgoi 10 B0-10B 2ng0i IP2P-B:
Remove and discard the nuts for the LH engine mount.
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upw3m Use care not to damage the PCM and wire harness on the RH side when raising the engine.

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Using a floor crane and the special tool, raise the engine 2 in. (51 mm).
Use Special Service Tool: 303-1518 Bracket, Engine Removal.
Use the General Equipment: Floor Crane

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10. Position wooden blocks between the frame and engine for added safety.

Use the General Equipment: Wooden Block

11. upw3m The engine mount bracket needs to be removed in order to remove the engine mount.
Remove the bolts and the LH engine mount bracket.
Discard the bolts.

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12. Remove the LH engine mount.

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1. Clean the LH engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.
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2. Install the LH engine mount.

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upw3m Place a visible mark on the engine mount bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

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upw3m Verify that the engine mount bracket bushing is position out prior to installing the engine mount bracket.
Install the LH engine mount bracket and the new bolts.
Torque:
Stage 1: 41 lb.ft (55 Nm)
Stage 2: 60 °
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4. Remove the wooden blocks.

Use the General Equipment: Wooden Block

5.
upw3m The engine mount may have to be adjusted during the lowering of the engine.
Using the floor crane and the special tool, lower the engine.
Use Special Service Tool: 303-1518 Bracket, Engine Removal.
Use the General Equipment: Floor Crane

6. upwyR3m hP1ogsB in sB7oPLB ivB B0-10B 2ng0i LsnSS dnoiS 2Pa sBSgoi 10 B0-10B 2ng0i IP2P-B:

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Install the LH engine mount cross bolt.
Torque: 258 lb.ft (350 Nm) co
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7. upwyR3m hP1ogsB in sB7oPLB ivB B0-10B 2ng0i LsnSS dnoiS 2Pa sBSgoi 10 B0-10B 2ng0i IP2P-B:
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Install the RH engine mount cross bolt.
Torque: 258 lb.ft (350 Nm)
 8.
upw3m The engine mount have to be adjusted during the lowering of the engine.
Using the floor crane, raise the engine as needed to get the required lift to equalize the engine mounts.
Use the General Equipment: Floor Crane
Lower the engine and remove the floor crane.
9. upwyR3m hP1ogsB in sB7oPLB ivB B0-10B 2ng0i 0giS 2Pa sBSgoi 10 B0-10B 2ng0i IP2P-B:

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Install the LH engine mount nuts.
Torque: 148 lb.ft (200 Nm) co
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10. upwyR3m hP1ogsB in sB7oPLB ivB isP0S21SS1n0 Sg77nsi 10SgoPins 0giS 2Pa sBSgoi 10 isP0S21SS1n0 Sg77nsi 10SgoPins IP2P-B:
Remove and discard the transmission support insulator nuts.

11. Tighten the transmission support insulator studs.

Torque: 66 lb.ft (90 Nm)

12. upwyR3m hP1ogsB in sB7oPLB ivB isP0S21SS1n0 Sg77nsi 10SgoPins 0giS 2Pa sBSgoi 10 isP0S21SS1n0 Sg77nsi 10SgoPins IP2P-B:
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Install the new transmission support insulator nuts.
Torque: 85 lb.ft (115 Nm)

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13. Position back and connect the wire harness.
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14.
Remove Special Service Tool: 303-1518 Bracket, Engine Removal.
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15. Install the following items:
1. Install the oil cooler.
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Refer to: Oil Cooler (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
2. Install the cooling fan stator.
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Refer to: Cooling Fan Stator (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Removal and Installation).
3. Install the turbocharger.
Refer to: Turbocharger (303-04C Fuel Charging and Controls - Turbocharger - 6.7L Power Stroke Diesel, Removal and Installation).
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal and Installation Procedure revision date: 10/30/2019

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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal and Installation Procedure revision date: 10/30/2019

Engine Rear Cover

Removal
NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket
surfaces that enter the oil passages, coolant passages or the oil pan, may cause engine failure.
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
aemobdl dnA fnstdlldtion ProceAure rebision Adtev 10:30:201/

Exhaust Manifold LH
Removal
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
aemobcl cnd vnstcllction Pro:edure rebision dcte/ 109309201T

Lower InteakMiflndR
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal and Installation Procedure revision date: 10/30/2019

Flexplate
Special Tool(s) / General Equipment

303-103 (T74P-6375-A)
Holding Tool, Flywheel
T74P-77000-A
TKIT-2009TC-F

Removal
1. Remove the transmission.
Refer to: Transmission (307-01B Automatic Transmission, Transfer Case and Power Transfer Unit - 10-Speed Automatic Transmission – 10R140, Removal).
2.
NOTICE: Do not use magnetic screwdrivers or other magnetic tools around the CKP sensor and the crankshaft sensor pulse ring or damage to the
components may occur.
Remove the bolts and the flexplate.
Discard the bolts.

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1. NOTICE: Do not use magnetic screwdrivers or other magnetic tools around the CKP sensor and the crankshaft sensor pulse ring or damage to the
components may occur.
Install the flexplate and the new bolts.
Use Suggested Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel. Tool shown or a commercially available equivalent can be used.
Torque:
Stage 1: 44 lb.in (5 Nm)
Stage 2: 74 lb.ft (100 Nm)
2. Install the transmission.
Refer to: Transmission (307-01B Automatic Transmission, Transfer Case and Power Transfer Unit - 10-Speed Automatic Transmission – 10R140, Installation).

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Hydraulic Lash Adjuster

Removal
1. Remove ane doised cdm.
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal and Installation Procedure revision date: 10/30/2019

Lower Intake Manifold

Removal
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal and Installation Procedure revision date: 10/30/2014

Oil Cooler
Special Tool(s) / General Equipment

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Removal
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Lre NOTICE: In the event of catastrophic engine failure, always install a new oil cooler assembly. Foreign material cannot be removed from the oil cooler and
engine damage may occur.
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engine.
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Oil Level Indicator and Tube

Removal
Upper oil level indicator tube
1. With the vehicle in NEUTRAL, position it on a hoist.
Refer to: Jacking and Lifting - Overview (100-02 Jacking and Lifting, Description and Operation).
2. Remove the oil level indicator.

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From below, remove the oil level indicator tube from the engine rear cover.
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4. Remove and discard the oil level indicator tube O-ring seals.
Lower oil level indicator tube
5. Remove the engine rear cover.
Refer to: Engine Rear Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).

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6. Remove the bolts and the lower oil level indicator tube.

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Installation
Lower oil level indicator tube
1. Install the lower oil level indicator tube and bolts.
6hg7-d: 89 lb.in (10 Nm)
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2. Install the engine rear cover.
Refer to: Engine Rear Cover (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
Upper oil level indicator tube
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3. Install new O-ring seals on the oil level indicator tube and lubricate with clean engine oil.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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Position the oil level indicator tube in the vehicle.
From below, align the oil level indicator tube into the engine rear cover.
Install the oil level indicator tube nut and bolt.
6hg7-d: 89 lb.in (10 Nm)
5. Install the oil level indicator.

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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal and Installation Procedure revision date: 11/14/2019

Oil Pressure Feedback Tube

Removal
Eng ie -hegaceg-dLgoB oglkSeepgTp(godksBogaB)en
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal and Installation Procedure revision date: 10/30/2019

Oil Pump
Removal
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T0- NOTICE: Remove the oil pump evenly or damage to the roll pins may occur.
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal and Installation Procedure revision date: 10/30/2019

Oil Pump Screen and Pickup Tube

Removal
Eng ie -hegacegdLLeog-BlgLkSn
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
aemobdl dnA fnstdlldtion ProceAure rebision Adtev 10:30:201/

Rocker Arm
Removal
Both sides
1. Remove the RH valve cover or LH valve cover.
Refer to: Valve Cover LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
Refer to: Valve Cover RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
LH rocker arm
2. NOTICE: Failure to remove the oil spray bar in steps may result in damage to the studs.
NOTE: 9Ie nuts hor tIe oil sprdy ,dr dre cdptureA nuts dnA remdin on tIe oil sprdy ,dr.
Remove and discard the LH oil spray bar. Loosen the nuts 2 revolutions at a time in the sequence shown until the LH oil spray bar can be removed.

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3. NOTICE: Failure to remove the oil spray bar in steps may result in damage to the studs.
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Remove and discard the RH oil spray bar. Loosen the nuts 2 revolutions at a time in the sequence shown until the RH oil spray bar can be removed.
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Both sides
4. NOTE: Mdrk tIe locdtion oh tIe rocker drm dssem,lies prior to remobing.
NOTE: Lj siAe sIownV aj simildr.
NOTE: Cnly one cylinAer sIown.
Remove the rocker arm assemblies as needed.
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5. NOTICE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
NOTE: Cnly one cylinAer sIown.
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6. NOTE: Do not Aisdssem,le tIe rocker drm dssem,ly. 9Iey dre serbiceA ds dn dssem,ly only.
Looking from the side of the rocker arm assembly, inspect each rocker arm ball for scuffing. Install new rocker arm assemblies as required.
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Inspect each rocker arm pivot foot and cup for pitting and scuffing. Install new rocker arm assemblies as required.
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7.
Inspect each push rod for wear and deposits which may restrict the flow of oil into the rocker arm assembly. Install a new push rod as needed.
Inspect the ball end of the push rod, if the end does not have a polished look, replace the push rod.
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Installation
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Both sides
1. NOTICE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
NOTE: Cnly one cylinAer sIown.
Apply clean engine oil to the ball end of the push rod. Install the push rods and verify the push rod socket is engaged on the hydraulic lash adjuster.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
RH rocker arm, single assembly
2. Rotate the crankshaft clockwise and position cylinder number No. 1 approximately 155 degrees after TDC by observing the crankshaft pulley dowel pin and clocking it
to the 3:40 position (as viewed from the front of the engine).

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3.
NOTE: Uerihy tIdt tIe pusI roA socket is on tIe IyArdulic ldsI dANuster prior to instdlling tIe rocker drm dssem,ly.
Determine which cylinder is actually in the firing position by observing the push rods. No. 1 cylinder exhaust push rods should be raised 1.0 mm (0.039 in) and No.
4 cylinder exhaust push rods should be raised 1.5 mm (0.059 in). If the push rods are not in the correct position, rotate the engine one full revolution clockwise
(360 degrees).
Apply clean engine oil to each rocker arm pivot ball and install the rocker arm assemblies for the RH cylinder head (cylinder numbers 1, 2, 3 and 4).
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Verify that the top of the push rod engages the socket on each rocker arm.
9orTue:
Stage 1: 35 lb.in (4 Nm)
Stage 2: 71 lb.in (8 Nm)
Stage 3: 115 lb.in (13 Nm)
Stage 4: Tighten a second time to : 115 lb.in (13 Nm)
Stage 5: Tighten an additional : 80 °
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4. Apply clean engine oil on the O-ring seal on the RH oil spray bar.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).

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5. NOTICE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.
Install the RH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown until the RH oil spray bar nuts can be tightened.
9orTue:
Stage 1: : 106 lb.in (12 Nm)
Stage 2: Tighten a second time to : 106 lb.in (12 Nm)

RH rocker arm, all assemblies

6. Rotate the crankshaft clockwise and position cylinder number No. 1 approximately 155 degrees after TDC by observing the crankshaft pulley dowel pin and clocking it
to the 3:40 position (as viewed from the front of the engine).
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7.
NOTE: Uerihy tIdt tIe pusI roA socket is on tIe IyArdulic ldsI dANuster prior to instdlling tIe rocker drm dssem,ly.
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Determine which cylinder is actually in the firing position by observing the push rods. No. 1 cylinder exhaust push rods should be raised 1.0 mm (0.039 in) and No.
4 cylinder exhaust push rods should be raised 1.5 mm (0.059 in). If the push rods are not in the correct position, rotate the engine one full revolution clockwise
(360 degrees).
Apply clean engine oil to each rocker arm pivot ball and install the rocker arm assemblies for the RH cylinder head (cylinder numbers 1, 2, 3 and 4).
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Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Verify that the top of the push rod engages the socket on each rocker arm.
9orTue:
Stage 1: 35 lb.in (4 Nm)
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Stage 2: 71 lb.in (8 Nm)

Stage 3: 115 lb.in (13 Nm)
Stage 4: Tighten a second time to : 115 lb.in (13 Nm)
Stage 5: Tighten an additional : 80 °
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8. Apply clean engine oil on the O-ring seal on the RH oil spray bar.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
 9. NOTICE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.
Install the RH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown until the RH oil spray bar nuts can be tightened.
9orTue:
Stage 1: : 106 lb.in (12 Nm)
Stage 2: Tighten a second time to : 106 lb.in (12 Nm)

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LH rocker arm, single assembly

10. Rotate the crankshaft clockwise one full revolution (360 degrees) to 155 degrees after TDC by observing the crankshaft pulley dowel pin and clocking it to the 3:40
position (as viewed from the front of the engine).
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11.
NOTE: Uerihy tIdt tIe pusI roA socket is on tIe IyArdulic ldsI dANuster prior to instdlling tIe rocker drm dssem,ly.
 If installing the LH rocker arm assemblies only, determine which cylinder is actually in the firing position by observing the push rods. No. 6 cylinder exhaust push
rods should be raised 1.0 mm (0.039 in) and No. 7 cylinder exhaust push rods should be raised 1.5 mm (0.059 in). If the push rods are not in the correct position,
rotate the engine one full revolution clockwise (360 degrees).
Apply clean engine oil to each rocker arm pivot ball and install the rocker arm assemblies for the LH cylinder head (cylinder numbers 5, 6, 7 and 8).
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Verify that the top of the push rod engages the socket on each rocker arm.
9orTue:
Stage 1: 35 lb.in (4 Nm)
Stage 2: 71 lb.in (8 Nm)
Stage 3: 115 lb.in (13 Nm)
Stage 4: Tighten a second time to : 115 lb.in (13 Nm)
Stage 5: Tighten an additional : 80 °

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12. Apply clean engine oil on the O-ring seal on the LH oil spray bar.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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13. NOTICE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.
Install the LH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown until the LH oil spray bar nuts can be tightened.
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9orTue:
Stage 1: : 106 lb.in (12 Nm)
Stage 2: Tighten a second time to : 106 lb.in (12 Nm)
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LH rocker arm, all assemblies

14. Rotate the crankshaft clockwise one full revolution (360 degrees) to 155 degrees after TDC by observing the crankshaft pulley dowel pin and clocking it to the 3:40
position (as viewed from the front of the engine).
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NOTE: Uerihy tIdt tIe pusI roA socket is on tIe IyArdulic ldsI dANuster prior to instdlling tIe rocker drm dssem,ly.
If installing the LH rocker arm assemblies only, determine which cylinder is actually in the firing position by observing the push rods. No. 6 cylinder exhaust push
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rods should be raised 1.0 mm (0.039 in) and No. 7 cylinder exhaust push rods should be raised 1.5 mm (0.059 in). If the push rods are not in the correct position,
rotate the engine one full revolution clockwise (360 degrees).
Apply clean engine oil to each rocker arm pivot ball and install the rocker arm assemblies for the LH cylinder head (cylinder numbers 5, 6, 7 and 8).
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Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Verify that the top of the push rod engages the socket on each rocker arm.
9orTue:
Stage 1: 35 lb.in (4 Nm)
Stage 2: 71 lb.in (8 Nm)
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Stage 3: 115 lb.in (13 Nm)

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Stage 4: Tighten a second time to : 115 lb.in (13 Nm)

Stage 5: Tighten an additional : 80 °
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16. Apply clean engine oil on the O-ring seal on the LH oil spray bar.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
 17. NOTICE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.
Install the LH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown until the LH oil spray bar nuts can be tightened.
9orTue:
Stage 1: : 106 lb.in (12 Nm)
Stage 2: Tighten a second time to : 106 lb.in (12 Nm)

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Both sides
18. Install the RH valve cover or LH valve cover.
Refer to: Valve Cover LH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
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Refer to: Valve Cover RH (303-01B Engine - 6.7L Power Stroke Diesel, Removal and Installation).
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal and Installation Procedure revision date: 01/7/2020

Upper Intake Manifold

Removal
NOTE: For EXPORT ONLY vehicles (outside US/Canada) an Export Supplement is provided and should be referenced to identify differences that can impact
service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US
EPA or CARB Regulations".
1. Remove the following items:
1. Remove the Eowl Gcnel grille.
Refer to: xowl acnel urille ()C13C0 -ront 8nB 6oB7 acnelsL Removcl cnB PnstcllctionS.
0. Remove the xkx inlet GiGe.
Refer to: xhcrge kir xooler (xkxS PntcDe aiGe (,C,3106 PntcDe kir distriI2tion cnB -iltering 3 H.jF aower 4troDe dieselL Removcl cnB PnstcllctionS.
,. Remove the xkx o2tlet GiGe.
Refer to: xhcrge kir xooler (xkxS (,C,3106 PntcDe kir distriI2tion cnB -iltering 3 H.jF aower 4troDe dieselL Removcl cnB PnstcllctionS.
p. Remove the kxF (cir ElecnerS o2tlet GiGe.
Refer to: kir xlecner y2tlet aiGe (,C,3106 PntcDe kir distriI2tion cnB -iltering 3 H.jF aower 4troDe dieselL Removcl cnB PnstcllctionS.
0. disEonneEt the Eoolcnt hose retciner from the 2GGer intcDe mcnifolB.

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,. Remove the Iolts cnB the intcDe mcnifolB s2GGort.

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disEonneEt the wiring hcrness retciners.
disEonneEt the bka sensorL 8a (e5hc2st Gress2reS sensorL cnB the 8uRU sensor eleEtriEcl EonneEtors.
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Remove the n2t for the 8a sensor t2Ie.
Remove the 8a sensor t2Ie cssemIl7.
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H. Remove the n2tL the Iolt cnB Gosition csiBe the oil level inBiEctor.
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j. disEonneEt the U6 (throttle IoB7S eleEtriEcl EonneEtor.

q. disEonneEt the 8uRU sensor eleEtriEcl EonneEtor cnB the wire retciner.

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N.
Remove the Iolts cnB the 8uR Eooler o2tlet t2Ie.
Remove cnB BisEcrB the 8uR o2tlet t2Ie gcsDets.
 1C. NOTE: Body removed for clarity.
Foosen the retciners cnB remove the 2GGer intcDe mcnifolB.
xover or tcGe the oGening on the vclve Eovers cnB the lower intcDe mcnifolB.

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11. NOTE: Visually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gasket may be reused.
PnsGeEt the 2GGer intcDe mcnifolB gcsDets. ReGlcEe cs neEesscr7.
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Installation
1. Pf removeBL instcll the new 2GGer intcDe mcnifolB gcsDets.
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0. NOTICE: Do not slide the upper intake manifold across the lower intake manifold during installation. Failure to follow this may result in damage to the
upper intake manifold gaskets.
n.
Remove the Eover or tcGe from the vclve Eovers cnB lower intcDe mcnifolB Grior to instclling the 2GGer intcDe mcnifolB.
Pnstcll the 2GGer intcDe mcnifolB cnB tighten the retciners.
Torque:
4tcge 1: Uighten Iolts 1 thr2 q to: : qN lI.in (1C OmS
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4tcge 0: Uighten Iolts 1 thr2 q to: : Nq 9Â

4tcge ,: Uighten Iolt N to: : 1q lI.ft (0p OmS
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,. °sing new gcsDetsL instcll the 8uR Eooler o2tlet t2Ie cnB the Iolts.
Torque: qN lI.in (1C OmS
p. disEonneEt the 8uRU sensor eleEtriEcl EonneEtor cnB the wire retciner.

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). xonneEt the U6 eleEtriEcl EonneEtor.

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H. aosition IcED the engine oil level inBiEctor t2IeL instcll the n2t cnB the Iolt.
Torque: qN lI.in (1C OmS
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1. Pnstcll the 8a sensor t2Ie cssemIl7 cnB n2t. Uighten the 8a sensor t2Ie cssemIl7.
Torque: 1,, lI.in (1) OmS
0. Uighten the n2t.
Torque: qN lI.in (1C OmS
,. Uighten the 8a sensor t2Ie cssemIl7.
Torque: 1jj lI.in (0C OmS
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q.
xonneEt the bka sensorL 8a sensor cnB the 8uRU sensor eleEtriEcl EonneEtors.
xonneEt the wiring hcrness retciners.
 N. Pnstcll the intcDe mcnifolB s2GGort cnB the Iolts.
Torque: qN lI.in (1C OmS

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1C. xonneEt the Eoolcnt hose retciner to the 2GGer intcDe mcnifolB.
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11. Pnstcll the following items:

1. Pnstcll the kxF (cir ElecnerS o2tlet GiGe.
Refer to: kir xlecner y2tlet aiGe (,C,3106 PntcDe kir distriI2tion cnB -iltering 3 H.jF aower 4troDe dieselL Removcl cnB PnstcllctionS.
0. Pnstcll the xkx o2tlet GiGe.
Refer to: xhcrge kir xooler (xkxS (,C,3106 PntcDe kir distriI2tion cnB -iltering 3 H.jF aower 4troDe dieselL Removcl cnB PnstcllctionS.
,. Pnstcll the xkx inlet GiGe.
Refer to: xhcrge kir xooler (xkxS PntcDe aiGe (,C,3106 PntcDe kir distriI2tion cnB -iltering 3 H.jF aower 4troDe dieselL Removcl cnB PnstcllctionS.
p. Pnstcll the Eowl Gcnel grille.
Refer to: xowl acnel urille ()C13C0 -ront 8nB 6oB7 acnelsL Removcl cnB PnstcllctionS.
303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal and Installation Procedure revision date: 10/30/2019

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F 7tmBThe bead of Motorcraft® High Performance Engine RTV Silicone Sealant should cover the openings of the front and rear engine cover gaskets.
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
aemobdl dnA fnstdlldtion ProceAure rebision Adtev 10:30:201/

Valve Cover LH
Removal
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Ing NOTE: ft will 9e necessdry to position dsiAe tIe oil lebel inAicdtor in orAer to remobe tIe bdlbe cober.
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
aemobcl cnd vnstcllction Pro:edure rebision dcte/ 109309201T

Valve Cover RH
Removal
NOTE: For EhPfaI f,LR beXi:les Ooutside NS9Ycncdc( cn EUport Supplement is probided cnd sXould Ce re)eren:ed to identi)y di))eren:es tXct :cn impc:t
serbi:e pro:edures. xeXi:les :cn Ce identi)ied Cy re)erring to tXe underXood xeXi:le Emission Yontrol vn)ormction OxEYv( lcCel wXi:X stctesV ",ot :erti)ied )or NS
EPA or YAaB aegulctions".
1. Remove the following items:
1. Remove the EGR cooler.
Refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08B Engine Emission Control - 6.7L Power Stroke Diesel, Removal and Installation).
2. Remove the RH fuel injectors
Refer to: Fuel Injectors RH (303-04B Fuel Charging and Controls - 6.7L Power Stroke Diesel, Removal and Installation).
3. Remove the RH fuel rail.
Refer to: Fuel Rail RH (303-04B Fuel Charging and Controls - 6.7L Power Stroke Diesel, Removal and Installation).
4. Remove the RH glow plugs.
Refer to: Glow Plugs (303-07C Glow Plug System - 6.7L Power Stroke Diesel, Removal and Installation).
2.
Remove the bolt and disconnect the engine wire harness retainers.

Pull forward to disconnect the engine wire harness retainer and then pull up to disconnect the other retainer. Position aside the engine wire harness.

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3. Disconnect the retainer from the stud bolt and the fuel return hose from the retainer.
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4. NOTE: Mcrk tXe lo:ction o) tXe )csteners prior to remobing tXe bclbe :ober.
Remove the bolts, the stud bolts and the RH valve cover.
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5. Remove and discard the valve cover gasket.

 6. NOTE: Nse tXe not:X in tXe bclbe :ober to cid in remobing tXe )uel inje:tor-to-bclbe :ober secl.

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Remove and discard the fuel injector-to-valve cover seals.

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Installation
1. NOTE: xeri)y tXct tXe )uel inje:tor-to-bclbe :ober secl is squcrely sected in tXe bclbe :ober.
Using a 22 mm (0.866 in) socket or equivalent, install the new fuel injector-to-valve cover seals.
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2. Install the new valve cover gasket.

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3. NOTICE: Failure to install the fuel injectors during the valve cover installation may result in engine failure.
NOTE: IXe bclbe :ober will Xcbe to Ce tigXtened c se:ond time c)ter tXe )uel inje:tors cre instclled.
Install the RH valve cover, the stud bolts and the bolts.
Iorque: 106 lb.in (12 Nm)
4. NOTE: fnly one )uel inje:tor sXown.

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Remove and discard the O-ring seals and the copper combustion gasket.

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5. NOTE: Do not cpply engine oil to tXe )uel inje:tors.

NOTE: v) tXe )uel inje:tor is Ceing reusedV mcke sure to instcll it in tXe origincl lo:ction.
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Install a new copper combustion gasket, O-ring seal and fuel injector return O-ring seal on the fuel injectors. Position the fuel injectors into the engine.

6. NOTICE: Failure to tighten the fuel injector correctly can lead to engine failure.
Install the hold-down clamps and the new fuel injector bolts.
Iorque:
Stage 1: 22 lb.ft (30 Nm)
Stage 2: 90 °
7. Final tighten the valve cover bolts in the sequence shown.
Iorque: 106 lb.in (12 Nm)

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8. Connect the fuel return hose to the retainer and the retainer to the stud bolt.
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9. Position the engine wire harness and connect the harness retainers. Install the bolt.
Iorque: 106 lb.in (12 Nm)
10. Install the following items:
1. Install the RH glow plugs.
Refer to: Glow Plugs (303-07C Glow Plug System - 6.7L Power Stroke Diesel, Removal and Installation).
2. Install the RH fuel rail.
Refer to: Fuel Rail RH (303-04B Fuel Charging and Controls - 6.7L Power Stroke Diesel, Removal and Installation).
3. Install the EGR cooler.
Refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08B Engine Emission Control - 6.7L Power Stroke Diesel, Removal and Installation).

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Valve Tappets
Removal
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90- NOTICE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original
positions or engine damage may occur.
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Installation
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Removal
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal Procedure revision date: 01/7/2020

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Eig1GmIt is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Engine — Body On in this

Eig1GmDuring the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel openings to prevent the ingress of dirt or
other contamination. Remove caps, tape and other protective materials prior to installation.
n.
Eig1GmFor EXPORT ONLY vehicles (outside US/Canada), an Export Supplement is provided and should be referenced to identify differences that can impact
service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US
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2ad3 Eig1GmVisually inspect the intake manifold gaskets for nicks, cuts and abrasions. If these conditions are not present, the gasket may be reused.
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Removal Procedure revision date: 01/7/2020

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-ip1ymIt is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to Engine — Body Off in this section.
-ip1ymDuring the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel openings to prevent the ingress of dirt or
other contamination. Remove caps, tape and other protective materials prior to installation.
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-ip1ymFor EXPORT ONLY vehicles (outside US/Canada), an Export Supplement is provided and should be referenced to identify differences that can impact
service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US
EPA or CARB Regulations."
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Disassembly Procedure revision date: 01/7/2020

Engine
Special Tool(s) / General Equipment

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NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket
surfaces that enter the oil passages, coolant passages or the oil pan, may cause engine failure.
NOTICE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel opening to prevent the ingress of dirt
or other contamination. Remove caps, tape and other protective materials prior to installation.
NOTE: This procedure assumes that the engine was removed using the recommended body off engine removal procedure. If it was necessary to remove the engine
using the alternate body on engine removal procedure, some of the components in this procedure will have already been removed.
NOTE: Disassembly of the engine requires various inspections/measurements of the engine components. These inspections/measurements will aid in determining if
the engine components will require replacement.
NOTE: Refer to the exploded view under the Engine Component View in the Description and Operation.
NOTE: For EXPORT ONLY vehicles (outside US/Canada) an Export Supplement is provided and should be referenced to identify differences that can impact
service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US
EPA or CARB Regulations".
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rM1 NOTICE: Discard the engine mount bracket bolts and install new bolts or damage to the vehicle may occur. They are a torque-to-yield design and cannot
be reused.
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kM1 NOTICE: Use Rotunda Part Number 209-78203 or equivalent to support the engine on the mounting stand. Failure to correctly support the engine may
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vEM1 NOTE: Only one tube shown.

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aEM1 NOTE: Rotate the fuel filter counter clockwise to remove.

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NOTICE: The center lock of the fuel injector return hose connectors must be pulled completely out before the connector can be removed from the
fuel injector or damage may occur to the connector.
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:rM1 NOTE: Only one shown.

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(rM1 WARNING: Support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft. Failure to follow this
instruction may result in serious personal injury.
NOTICE: To prevent engine damage, always install new bolts when installing the crankshaft pulley.

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(aM1 NOTICE: Do not use magnetic screwdrivers or other magnetic tools around the CKP sensor and the crankshaft sensor pulse ring or damage to the

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components may occur.
O7osx71uA71cwPlIVAPhu1V7lVsw1CpeV71w6l2M1
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(:M1 O7osx71uA71jseu1Pl.1uA71DN/1V7lVswM1
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(YM1 O7osx71uA71jseuV1Pl.1uA71OL175APpVu1oPl6hse.1A7Pu1VA67e.M1
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1
1
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1

Y0M1 O7osx71Pl.1.6VcPw.1uA7175APpVu1oPl6hse.1Vup.VM
 1
1
1
1
1
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Y3M1 NOTE: Mark the location of the spacers before removal.

O7osx71uA71lpuV,1uA71VCPc7wV1Pl.1uA71tL175APpVu1oPl6hse.M

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YrM1
NOTE: Cylinder number 8 will have longer studs.
i

O7osx71Pl.1.6VcPw.1uA7175APpVu1oPl6hse.12PVI7uM
rd

O7CePc71PlH175APpVu1oPl6hse.1Vup.BVg1uAPu1Pw71.PoP27.1sw1w7osx7.1y6uA1uA71lpuM
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1
1
1
1
1
1

YvM1 NOTE: Mark the location of the spacers before removal.

O7osx71uA71lpuV,1uA71VCPc7wV1Pl.1uA71OL175APpVu1oPl6hse.M1

m6VcPw.1uA71lpuVM
 1
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1
1
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YkM1
NOTE: Cylinder number 4 will have longer studs.
O7osx71Pl.1.6VcPw.1uA7175APpVu1oPl6hse.12PVI7uM

O7CePc71PlH175APpVu1oPl6hse.1Vup.BVg1uAPu1Pw71.PoP27.1sw1w7osx7.1y6uA1uA71lpuM

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YEM1 NOTE: The fuel injector hold-down clamp bolts are torque-to-yield and cannot be reused.
O7osx71Pl.1.6VcPw.1uA71hp7e16l)7cusw1jseuVM
ag

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YaM1 NOTE: Mark the location of the fuel injector prior to removal.
ag

blVuPee1uA71VC7c6Pe1usse1us1uA71hp7e16l)7cusw1Pl.1hpeeH1APl.-u62Au7l1uA71VC7c6Pe1usse1osplu6l21jseuM1
'V71iC7c6Pe1i7wx6c71 sseq1v30-rv011O7osx7w,1Fp7e1bl)7cuswM
blVuPee1uA71CpVA1jseu1Pl.1u62Au7l1us1w7osx71uA71hp7e16l)7cuswM1
O7osx71uA71VC7c6Pe1usse1osplu6l21jseu1Pl.1uA71esy7w1Cswu6sl1sh1uA71VC7c6Pe1usseM1O7osx71uA71hp7e16l)7cuswM
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1
1
1
1
1
1

Y:M1 NOTE: Only one fuel injector shown.

O7osx71Pl.1.6VcPw.1uA71S-w6l21V7PeV1Pl.1uA71csCC7w1csojpVu6sl12PVI7uM
 1
1
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1

Y(M1 NOTE: Only one glow plug shown.

O7osx71uA712esy1Cep2VM1

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1
1
1
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300M1 O7osx71Pl.1.6VcPw.1uA71xPex71csx7w12PVI7uM
 1
1
1
1
1
1

303M1 O7osx71uA71jseuV,1uA71Vup.1jseuV1Pl.1uA71OL1xPex71csx7wM1

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30rM1 O7osx71Pl.1.6VcPw.1uA71xPex71csx7w12PVI7uM
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1
1
1
1
1
1

30vM1 NOTE: Use the notch in the valve cover to aid in removing the fuel injector-to-valve cover seal.
O7osx71Pl.1.6VcPw.1uA71hp7e16l)7cusw-us-xPex71csx7w1V7PeVM
 1
1
1
1
1
1

30kM1 NOTICE: Failure to remove the oil spray bar in steps may result in damage to the studs.
NOTE: The nuts for the oil spray bar are captured nuts and remain on the oil spray bar.
O7osx71Pl.1.6VcPw.1uA71tL1s6e1VCwPH1jPwM1tssV7l1uA71lpuV1r1w7xsepu6slV1Pu1P1u6o716l1uA71V7Âp7lc71VAsyl1plu6e1uA71tL1s6e1VCwPH1jPw1cPl1j71w7osx7.M

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30EM1 NOTICE: Failure to remove the oil spray bar in steps may result in damage to the studs.
NOTE: The nuts for the oil spray bar are captured nuts and remain on the oil spray bar.
i

O7osx71Pl.1.6VcPw.1uA71OL1s6e1VCwPH1jPwM1tssV7l1uA71lpuV1r1w7xsepu6slV1Pu1P1u6o716l1uA71V7Âp7lc71VAsyl1plu6e1uA71OL1s6e1VCwPH1jPw1cPl1j71w7osx7.M
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1
1
1
1
1
1

30aM1 NOTE: Mark the location of the rocker arm assemblies prior to removing.
NOTE: Only one cylinder shown.
O7osx71uA71wscI7w1Pwo1PVV7oje67VM1
 1
1
1
1
1
1

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30:M1 NOTE: Do not disassemble the rocker arm assembly. They are serviced as an assembly only.
tssI6l21hwso1uA71V6.71sh1uA71wscI7w1Pwo1PVV7ojeH,16lVC7cu17PcA1wscI7w1Pwo1jPee1hsw1Vcphh6l2M1blVuPee1l7y1wscI7w1Pwo1PVV7oje67V1PV1w7Âp6w7.M
co
blVC7cu17PcA1wscI7w1Pwo1C6xsu1hssu1Pl.1cpC1hsw1C6uu6l21Pl.1Vcphh6l2M1blVuPee1l7y1wscI7w1Pwo1PVV7oje67V1PV1w7Âp6w7.M
n.
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1
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30(M1 NOTICE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
NOTE: Only one cylinder shown.
O7osx71uA71CpVA1ws.VM

1
1
1
1
1
1

30YM1
blVC7cu17PcA1CpVA1ws.1hsw1y7Pw1Pl.1.7CsV6uV1yA6cA1oPH1w7Vuw6cu1uA71hesy1sh1s6e16lus1uA71wscI7w1Pwo1PVV7ojeHM1blVuPee1P1l7y1CpVA1ws.1PV1l77.7.M
blVC7cu1uA71jPee17l.1sh1uA71CpVA1ws.,16h1uA717l.1.s7V1lsu1APx71P1Cse6VA7.1essI,1w7CePc71uA71CpVA1ws.M
 1
1
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1
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1

330M1 NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any
foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface
NOTE: The M12 cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
O7osx71Pl.1.6VcPw.1uA71"3r1cHe6l.7w1A7P.1jseuVM1O7osx71uA71"(1cHe6l.7w1A7P.1jseuVM

O7osx71uA71tL1cHe6l.7w1A7P.M

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333M1 O7osx71Pl.1.6VcPw.1uA71tL1cHe6l.7w1A7P.12PVI7u1Pl.1uA71cHe6l.7w1A7P.1.sy7eVM
 1
1
1
1
1
1

33rM1 DA7cI1uA71cHe6l.7w1A7P.1.6Vuswu6slM1
O7h7w1usq1DHe6l.7w1L7P.1m6Vuswu6sl1Bv0v-03f1Rl26l71-1aM:t1/sy7w1iuwsI71m67V7e,1d7l7wPe1/wsc7.pw7VgM
33vM1
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause
scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
NOTE: Clean the cylinder block bolt holes using compressed air. Make sure all coolant, oil or other foreign material is removed.
De7Pl1Pl.16lVC7cu1uA71cHe6l.7w1jescI1oPu6l21VpwhPc7M
DA7cI1uA71cHe6l.7w1jescI1.6Vuswu6slM1
O7h7w1usq1DHe6l.7w1fescI1m6Vuswu6sl1Bv0v-001Rl26l71iHVu7o1-1d7l7wPe1blhswoPu6sl,1d7l7wPe1/wsc7.pw7VgM

m
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33kM1 NOTICE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any
foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
i

NOTICE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface
rd

NOTE: The M12 cylinder head bolts must be discarded and new bolts installed. They are tighten-to-yield designed and cannot be reused.
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33EM1 O7osx71Pl.1.6VcPw.1uA71OL1cHe6l.7w1A7P.12PVI7u1Pl.1uA71cHe6l.7w1A7P.1.sy7eVM
 1
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1
1
1
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33aM1 DA7cI1uA71cHe6l.7w1A7P.1.6Vuswu6slM1
O7h7w1usq1DHe6l.7w1L7P.1m6Vuswu6sl1Bv0v-03f1Rl26l71-1aM:t1/sy7w1iuwsI71m67V7e,1d7l7wPe1/wsc7.pw7VgM
33:M1

m
NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause
scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
co
NOTE: Clean the cylinder block bolt holes using compressed air. Make sure all coolant, oil or other foreign material is removed.
De7Pl1Pl.16lVC7cu1uA71cHe6l.7w1jescI1oPu6l21VpwhPc7M
DA7cI1uA71cHe6l.7w1jescI1.6Vuswu6slM1
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ag

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1
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33(M1 NOTICE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original
positions or engine damage may occur.
NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.
NOTE: Only one valve tappet guide shown.
NOTE: Some valve tappets will be removed with the valve tappet guides.
O7osx71uA71xPex71uPCC7u12p6.7VM
 1
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33YM1 NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.
NOTE: Only one cylinder shown.
O7osx71uA71xPex71uPCC7uV1hwso1uA717l26l7M1

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3r0M1 NOTICE: To prevent engine damage, keep the hydraulic lash adjuster in the order in which they were removed. Install all hydraulic lash adjuster back in
their original positions or engine damage may occur.
ca

blVC7cu1uA71xPex71uPCC7u1Pl.1uA71AH.wPpe6c1ePVA1P.)pVu7w1hsw1y7Pw1sw1.PoP27M1bh1PlH1y7Pw1sw1.PoP2716V1hspl.,16lVC7cu1uA71cPoVAPhu1esj71hsw1y7Pw1sw1.PoP27M1O7CePc7
csoCsl7luV1PV1l7c7VVPwHM
 1
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1
1
1
1

3r3M1 O7osx71uA71jseuV1Pl.1uA71esy7w1s6e1CPlM1m6VcPw.1uA71esy7w1s6e1CPlM

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3rrM1 De7Pl1Pl.1Cw7CPw71uA71O 41V7Pe6l21VpwhPc7M

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 1
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3rvM1 NOTICE: Use care when removing the hose from the oil cooler, damage to the oil cooler may occur during removal.
n.
O7osx71uA71s6e1csse7w16le7u1AsV7M
'V71uA71d7l7wPe1RÂp6Co7luq1LsV71DePoC1O7osx7wXblVuPee7w
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3rkM1 NOTICE: Use care when removing the hose from the oil cooler, damage to the oil cooler may occur during removal.
m6Vcsll7cu1uA71AsV71w7uP6l7wVM1O7osx71uA71s6e1csse7w1spue7u1AsV7M1
'V71uA71d7l7wPe1RÂp6Co7luq1LsV71DePoC1O7osx7wXblVuPee7w
 1
1
1
1
1
1

3rEM1 NOTICE: In the event of a catastrophic engine failure, or if installing a new short block, always install a new oil cooler. Foreign material cannot be
removed from the oil cooler and engine damage may occur. Long blocks are equipped with a new oil cooler.
O7osx71uA71jseuV1Pl.1uA71s6e1csse7w1PVV7ojeHM1

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3raM1 O7osx71Pl.1.6VcPw.1uA71s6e1csse7w12PVI7uVM1
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3r:M1 O7osx71uA71w7uP6l7wV1Pl.1uA71s6e1h6eu7w1P.PCu7wM
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1
1
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3r(M1 O7osx71Pl.1.6VcPw.1uA71s6e1h6eu7w1P.PCu7w12PVI7uM1
 1
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3rYM1 O7osx71uA71jseuV1Pl.1uA71pCC7w1s6e1CPlM1

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3v0M1
O7osx71Pl.1.6VcPw.1uA71pCC7w1s6e1CPl12PVI7uM1
ca

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1
1
1
1
1
1

3v3M1 De7Pl1Pl.16lVC7cu1uA71pCC7w1s6e1CPl1V7Pe6l21VpwhPc7M
 1
1
1
1
1
1

3vrM1 De7Pl1Pl.16lVC7cu1uA71cHe6l.7w1jescI,1uA717l26l71hwslu1csx7w1Pl.1uA717l26l71w7Pw1csx7wM

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3vvM1 De7Pl1Pl.1Cw7CPw71uA71O 41V7Pe6l21VpwhPc7M

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O7h7w1usq1O 41i7Pe6l21ipwhPc71De7Pl6l21Pl.1/w7CPwPu6sl1Bv0v-001Rl26l71iHVu7o1-1d7l7wPe1blhswoPu6sl,1d7l7wPe1/wsc7.pw7VgM
ca
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3vkM1
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3M1 'V6l21P1c7lu7w1CplcA,1oPwI1P1escPu6sl1hsw1r1Ase7V13(01.72w77V1PCPwuM
rM1 NOTICE: Drill only deep enough to penetrate the slinger. Engine damage may occur if the slinger is drilled too deep.
ca

'V6l21P1.w6ee1j6u1sh1uA71PCCwsCw6Pu71V6871hsw1uA71Ve6.71APoo7w1.7lu1Cpee7w1j76l21pV7.,1.w6ee1P1Ase71sl17PcA1V6.71sh1uA71Ve6l27w1PV1VAsylM1
 1
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3vEM1 NOTICE: Use extreme care when removing the slinger or damage to the engine front cover may occur.
n.
'V6l21uA71r1.w6ee7.1Ase7V,1P1csoo7wc6PeeH1PxP6ePje71Ve6.71APoo7w1.7lu1Cpee7w,1yPeI1uA71Ve6l27w1shh1uA71cwPlIVAPhu1jH1Peu7wlPu6l21hwso1V6.71us1V6.7M1m6VcPw.1uA71Ve6l27wM

'V71uA71d7l7wPe1RÂp6Co7luq1ie6.71LPoo7w1m7lu1/pee7w
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 m
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3vaM1 NOTICE: Do not scratch or damage the crankshaft during removal or installation of the crankshaft front seal.
NOTE: The Front Crank Seal Remover needs to be threaded in until it stops turning.
'V6l21uA71VC7c6Pe1usse,1w7osx71Pl.1.6VcPw.1uA71cwPlIVAPhu1hwslu1V7PeM
'V71iC7c6Pe1i7wx6c71 sseq1v0v-3E3011O7osx7w,1Fwslu1DwPlI1i7PeM
 1
1
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1
1
1

3v:M1 De7Pl1Pl.16lVC7cu1uA71cwPlIVAPhu1V7Pe6l21VpwhPc7M
3v(M1 NOTICE: Use care when removing the engine front cover to not scratch the crankshaft sealing surface.
NOTE: Mark the location of the engine front cover bolts prior to removing them.
O7osx71uA717l26l71hwslu1csx7w1jseuVM

O7osx71uA717l26l71hwslu1csx7wM1

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3vYM1
O7osx71Pl.1.6VcPw.1uA717l26l71hwslu1csx7w12PVI7uVM
De7Pl1Pl.1Cw7CPw71uA71O 41V7Pe6l21VpwhPc7M
O7h7w1usq1O 41i7Pe6l21ipwhPc71De7Pl6l21Pl.1/w7CPwPu6sl1Bv0v-001Rl26l71iHVu7o1-1d7l7wPe1blhswoPu6sl,1d7l7wPe1/wsc7.pw7VgM

1
1
1
1
1
1
3k0M1 'V6l21uA71VC7c6Pe1usse,1cA7cI1uA71s6e1CpoC1.w6x7127Pw1jPcIePVAM
O7h7w1usq1iC7c6h6cPu6slV1Bv0v-03f1Rl26l71-1aM:t1/sy7w1iuwsI71m67V7e,1iC7c6h6cPu6slVgM
'V71iC7c6Pe1i7wx6c71 sseq1300-00r1B SSt-kr03-Dg11Lse.6l21F65upw71y6uA1m6Pe1bl.6cPusw1dPp27M

1
1
1
1
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3k3M1 NOTICE: Remove the oil pump evenly or damage to the roll pins may occur.
O7osx71uA71jseuV1Pl.1uA71s6e1CpoCM

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3krM1 NOTICE: Do not scratch or damage the crankshaft during removal or installation of the crankshaft rear seal.
'V6l21uA71VC7c6Pe1usse,1w7osx71Pl.1.6VcPw.1uA71cwPlIVAPhu1w7Pw1V7PeM1
'V71iC7c6Pe1i7wx6c71 sseq1v0v-3E3v11O7osx7w,1O7Pw1DwPlI1i7PeM
 1
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1
1
1
1

3kvM1 De7Pl1Pl.16lVC7cu1uA71cwPlIVAPhu1V7Pe6l21VpwhPc7M
3kkM1 NOTICE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.
O7osx71uA71jseuV1Pl.1uA717l26l71w7Pw1csx7wM1

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3kEM1 O7osx71Pl.1.6VcPw.1uA717l26l71w7Pw1csx7w12PVI7uM1
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1
1

3kaM1 "PI71Vpw71uA71oPu6l21VpwhPc7V1Pw71ce7Pl1Pl.1hw771sh1hsw762l1oPu7w6PeM
 1
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1

3k:M1 NOTE: Prior to removing any piston and rod assemblies, it is recommended that piston protrusion be evaluated. This will help identify bent or twisted
connecting rods.
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3k(M1 NOTICE: If evident from the top of the cylinder bore, remove the carbon ridge prior to removing the rod and piston assemblies. This reduces the chance
of piston ring land damage during removal.
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NOTE: Remove the carbon buildup, do not scratch the cylinder wall. Remove all debris from the cylinder.
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3E0M1 NOTICE: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented
correctly with the connecting rods or engine damage may occur.
NOTE: Mark the location of connecting rod cap prior to removal.
NOTE: Only one connecting rod cap shown.
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3EvM1 NOTE: The crankshaft gear contains a single timing mark. The camshaft contains a single timing mark. The high-pressure fuel injection pump drive gear
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contains a double timing mark. The engine is timed correctly when the single mark on the crankshaft drive gear is aligned with the double mark on the
camshaft gear, and the single mark on the camshaft drive gear is aligned with the double mark on the high-pressure fuel injection pump drive gear.
Additionally, the keyway on the high-pressure fuel injection pump drive gear must be at 12 o'clock position.
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3E:M1 NOTICE: Do not pry against the mating surface of the high-pressure fuel injection pump or damage to the high-pressure fuel injection pump may occur.
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3arM1 NOTE: RH side shown, LH side similar.

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3akM1 NOTE: Only the number 5 crankshaft main bearing cap has a thrust washer.
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3aYM1 NOTICE: If the camshaft is being replaced, the camshaft bearings have to be replaced and machined by a machine shop. Failure to follow this may result
in engine damage.
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NOTICE: Use care when removing the camshaft from the engine or damage to the camshaft and the bearings may occur.
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NOTICE: Use the slide hammer as a handle for the camshaft. Using the slide hammer as intended may result in engine damage.
NOTE: Use care when removing the camshaft, the camshaft will slide out the other end of the cylinder block.
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3:0M1 NOTE: Only one piston cooling tube shown.

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3:rM1 NOTE: Only one pipe plug shown.

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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Disassembly Procedure revision date: 10/30/2019

Engine - Enhanced Long Block

Special Tool(s) / General Equipment

205-036 (T70P-4067-A)
Wrench

303-050 (T70P-6000)
Lifting Bracket, Engine

303-1518
Bracket, Engine Removal
TKIT-2009C-F
TKIT-2009C-ROW
303-214 (T83T-6312-B)
Wrench, Fan Clutch Nut

310-230
Remover, Fuel Injector

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TKIT-2010FT-F
TKIT-2010FT-ROW

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Floor Crane
Hose Clamp Remover/Installer
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NOTE: This procedure assumes that the engine was removed using the recommended body off engine removal procedure. If it was necessary to remove the engine
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using the alternate body on engine removal procedure, some of the components in this procedure will have already been removed.
NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel opening to prevent the ingress of dirt or
other contamination. Remove caps, tape and other protective materials prior to installation.
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NOTE: For EXPORT ONLY vehicles (outside US/Canada) an Export Supplement is provided and should be referenced to identify differences that can impact
service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US
EPA or CARB Regulations".
NOTE: Refer to the exploded view under the Engine Component View in the Description and Operation.
1. Remove the engine.
Refer to: Engine - Body Off (303-01B Engine - 6.7L Power Stroke Diesel, Removal).
Refer to: Engine - Body On (303-01B Engine - 6.7L Power Stroke Diesel, Removal).
2.
Position the engine on wood blocks as needed. Remove the ratchet strap and the floor crane.
Use the General Equipment: Floor Crane
Verify that the engine is stable on the wooden blocks.
3. NOTICE: Discard the engine mount bracket bolts and install new bolts or damage to the vehicle may occur. They are a torque-to-yield design and cannot
be reused.
Remove the bolts and the LH engine mount bracket.
Discard the bolts.
4. NOTICE: Discard the engine mount bracket bolts and install new bolts or damage to the vehicle may occur. They are a torque-to-yield design and cannot
be reused.
Remove the bolts and the RH engine mount bracket.
Discard the bolts.

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5.
Disconnect the fan clutch electrical connector and the wire retainer.
Remove the fan clutch electrical connector bolt.
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6. Using the special tools, remove the cooling fan assembly.
Use Special Service Tool: 205-036 (T70P-4067-A) Wrench. , 303-214 (T83T-6312-B) Wrench, Fan Clutch Nut.
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7. Remove the clip and disconnect the coolant hose.

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8. Remove the clip and the lower radiator hose.
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9. Remove the coolant engine fill hose.

Use the General Equipment: Hose Clamp Remover/Installer
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10. If equipped with dual generator, remove the accessory drive belt.
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11. If equipped with single generator, remove the accessory drive belt.
12.
Position back the boot and remove the nut.
Disconnect the generator electrical connector.

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13. Disconnect the battery wire harness retainer from the bracket.
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14. Remove the bolts from the battery wire harness.
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15. Remove the LH ground bolt.

16. Disconnect the transmission oil cooler coolant hose.

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17. Remove the clip and disconnect the heater hose.

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18.
Disconnect the electrical connectors.
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Remove the nut and position out the battery wire harness.
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19. Remove the RH ground bolt.

20. Disconnect the A/C pressure switch electrical connector.

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21. Disconnect the A/C electrical connectors and the wire retainer.
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22. Remove the nuts, position out the coolant tube and the battery wire harness.
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23. Remove the nuts, the coolant hoses and the battery wire harness.
24. Remove the bolts and the A/C compressor.

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25. Remove the bolt and the accessory drive belt tensioner.
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26. If equipped with dual generator, disconnect the wire harness retainer.
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27. NOTE: Dual generator shown, single generator similar.

Remove the bolts and the secondary coolant pump.
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28. Remove the bolts, the engine lifting bracket and the cooling fan drive assembly.
Use Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.
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29. If equipped with dual generator, remove the idler pulley.

30. Remove the bolts and the power steering pump mounting bracket.

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31. Disconnect the engine vacuum hose at the tee.

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32. Remove the nut, the bolt and the transmission oil cooler coolant tube.
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33. Remove the stud bolt and the transmission oil cooler coolant tube.
34. NOTE: Only one tube shown.

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Remove and discard the transmission oil cooler coolant tube O-ring seals.

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35. Remove the stator standoffs.

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36. If equipped, remove the push pins and the RH sound shield. co
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37. If equipped, remove the push pins and the LH sound shield.
38. Remove the bolt and the oil fill pipe.

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39. Remove and discard the oil fill pipe O-ring seal.
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40. Remove the oil level indicator tube.
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41. Remove and discard the oil level indicator tube O-ring seals.
42. Disconnect the EGR valve electrical connector and the wire retainer.

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43. Disconnect the electrical connector and the vacuum hoses from the bypass valve solenoid. Detach the wire harness retainer.
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44. Remove the bolts and EGR cooler inlet tube bracket. Discard the bolts.
45.
Remove the bolts and the EGR cooler inlet tube.
Remove and discard the gaskets.

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46. Remove the bolts and position aside the engine wire harness.
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47. Remove the stud bolts, the bolts and the EGR cooler assembly.
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48. Remove and discard the EGR cooler gaskets.

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49. Leak test the EGR cooler.
Refer to: Exhaust Gas Recirculation (EGR) Cooler Leak Test (303-08B Engine Emission Control - 6.7L Power Stroke Diesel, General Procedures).
50. Remove the CKP sensor cover.
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51. Disconnect the CKP sensor electrical connector and the wire retainer.
52.

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Remove the bolt and the ground strap.
Disconnect the wire retainers.

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53. Disconnect the LH valve cover wiring.

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54. Disconnect the fuel pressure and temperature sensor, the ECT sensor electrical connectors and the wire retainers.
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55. Disconnect the CMP sensor electrical connector and the wire retainers.
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56. Disconnect the fuel volume control valve electrical connector.

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57. Disconnect the RH valve cover wiring.

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58.
Remove the bolt and disconnect the engine wire harness retainers.
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Pull forward to disconnect the engine wire harness retainer and then pull up to disconnect the other retainer. Remove the engine wire harness from the engine.
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59. Disconnect the fuel injection pump hose from the fuel rail.
Refer to: Spring Lock Couplings (310-00B Fuel System - General Information - 6.7L Power Stroke Diesel, General Procedures).
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60. Disconnect the fuel injector return hose and the fuel injection pump supply tube.
Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 6.7L Power Stroke Diesel) .
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61. Remove and discard the fuel injection pump supply tube assembly bolts.
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62. Remove the bolt and the fuel injection pump supply tube assembly. Discard the bolt.
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63. Remove and discard the fuel injection pump supply tube assembly O-ring seals.
64. Remove the bolts and crankcase vent oil separator. Discard the crankcase vent oil separator.

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65. NOTE: Rotate the fuel filter counter clockwise to remove.

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Remove and discard the secondary fuel filter.

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66. Remove the bolts and the secondary fuel filter bracket.
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67. Remove the TC coolant tube.

68. Remove and discard the O-ring seal and the grommet.

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69. Remove the bolts and heater supply tube.
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70. Remove and discard the heater supply tube O-ring seal.
71.

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NOTICE: The center lock of the fuel injector return hose connectors must be pulled completely out before the connector can be removed from the
fuel injector or damage may occur to the connector.

Disconnect the fuel injector return hose fittings from the fuel injectors.
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Push down on the tabs and pull up on the center of the fuel injector return hose fitting to unlock the fitting.

Disconnect and remove the fuel injector return hose and vacuum hose assembly from the retaining clips.
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72. NOTE: Only one shown.

Remove and discard the fuel injector supply tubes.
73. Disconnect the fuel rail supply tube assembly from the LH fuel rail.

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74. Disconnect the fuel rail supply tube assembly from the RH fuel rail.
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75. Disconnect the fuel rail supply tube assembly at the high-pressure fuel injection pump.
76.
Remove the bolts for the fuel rail supply tube assembly.
Remove and discard the fuel rail supply tube assembly.

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77. Remove the bolts and the LH fuel rail.
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78. Remove the bolts and the RH fuel rail.

79. NOTE: Note the different lengths of the bolts.
Remove the bolts and the thermostat housing.
Remove and discard the thermostat.

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80. Remove the bolts and the coolant crossover manifold.

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81. Remove and discard the coolant crossover manifold gaskets.

82. WARNING: Support the vibration damper during mounting bolt removal. The damper can slide off the nose of the crankshaft. Failure to follow this
instruction may result in serious personal injury.
NOTICE: To prevent engine damage, always install new bolts when installing the crankshaft pulley.
Remove the bolts and the crankshaft pulley.
Discard the bolts.

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83. Remove the bolts and the vacuum pump.

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84. Remove and discard the vacuum pump gasket.
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85.
Remove the bolts and the flexplate.
Discard the bolts.
86. NOTICE: Do not use magnetic screwdrivers or other magnetic tools around the CKP sensor and the crankshaft sensor pulse ring or damage to the
components may occur.
Remove the crankshaft sensor pulse ring.

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87. Remove the bolts and the LH exhaust manifold heat shield.

88. Remove the bolts and the RH exhaust manifold heat shield.
89. Remove and discard the exhaust manifold studs.

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90. NOTE: Mark the location of the spacers before removal.
Remove the nuts, the spacers and the LH exhaust manifold.
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Discard the nuts.

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91. Remove and discard the exhaust manifold gasket.

92. NOTE: Mark the location of the spacers before removal.
Remove the nuts, the spacers and the RH exhaust manifold.

Discard the nuts.

93. Remove and discard the exhaust manifold gasket.

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94. NOTE: The fuel injector hold-down clamp bolts are torque-to-yield and cannot be reused.
Remove and discard the fuel injector bolts.
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Remove and discard the fuel injector hold-downs.

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95. NOTE: Mark the location of the fuel injector prior to removal.
Install the special tool to the fuel injector and fully hand-tighten the special tool mounting bolt.
Use Special Service Tool: 310-230 Remover, Fuel Injector.
Install the push bolt and tighten to remove the fuel injector.
Remove the special tool mounting bolt and the lower portion of the special tool. Remove the fuel injector.
96. NOTE: Only one fuel injector shown.
Remove and discard the O-ring seals and the copper combustion gasket.

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97. NOTE: Only one glow plug shown.

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Remove the glow plugs.

98. Remove the high-pressure fuel injection pump drive gear nut.
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99. Remove the bolts and the fuel rail supply tube bracket.
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100. Remove the high-pressure fuel injection pump spacers.

101. NOTICE: Do not pry against the mating surface of the high-pressure fuel injection pump or damage to the high-pressure fuel injection pump may occur.
NOTE: Engine front cover removed for clarity.

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Position the high-pressure fuel injection pump rearward until the gear contacts the cylinder block. Using a mallet, tap the high-pressure fuel injection pump shaft to free the
gear from the pump. Remove the high-pressure fuel injection pump and drive gear.
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102. Remove and discard the high-pressure fuel injection pump O-ring seal.
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103. If equipped, remove the block heater.

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104. Using the floor crane, remove the engine from the wooden blocks.
Use the General Equipment: Floor Crane
105. Remove Special Service Tool: 303-1518 Bracket, Engine Removal.
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Disassembly and Assembly of Subassemblies

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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Disassembly and Assembly of Subassemblies Procedure revision date: 10/30/2019

Piston
DISASSEMBLY
NOTE: If the piston and connecting rod are to be reinstalled, they must be assembled in the same orientation. Mark the piston orientation to the connecting rod for
reassembly.
1. Remove and discard the piston rings.

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2. NOTE: Note the position of the piston pin retainer.
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NOTE: The piston pins are a floating type piston pin and should not require a press to remove or install them.
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Remove and discard the piston pin retainers.
Remove the piston pin.
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3. Remove the piston from the connecting rod.

 4. Inspect the piston and the connecting rod.
Refer to: Piston Inspection (303-00 Engine System - General Information, General Procedures).

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ASSEMBLY
1. NOTE: Align the piston-to-connnecting rod orientation marks made during disassembly.
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NOTE: If installing a new piston, install with the arrow towards the front of the engine.
Install the piston to the connecting rod.
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Lubricate with clean engine oil and install the piston pin.
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2. NOTE: The piston pins are a floating type piston pin and should not require a press to remove or install them.

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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3. NOTE: Install the piston pin retainer with the gap between the 11:00 o'clock and the 1:00 o'clock position.
Install the piston pin retainers.
4. NOTE: The top compression ring is identified with a orange stripe on the running surface. Install the ring with pip mark toward the top of the piston.
NOTE: The intermediate ring is identified with green stripe on the running surface. Install the ring with the under cut to the bottom.

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NOTE: The oil control ring is identified with a yellow and light blue strip on the running surface.
Lubricate with clean engine oil and install the piston rings.
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Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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5. NOTE: The arrow on the top of the piston indicates the front of the engine.
1. Upper compression ring gap location.
2. Lower compression ring gap location.
3. Piston oil control ring gap location (reference only).
4. Piston oil control ring gap location (reference only).
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Disassembly and Assembly of Subassemblies Procedure revision date: 10/30/2019

Cylinder Head
Special Tool(s) / General Equipment

303-1B1
Engie6..ne7LPowr6LSietkD

303-300Lsl2FE- B B-5uL
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lyAl-1m22-bcSlAP5
l22E-1000-Sl
lyAl-1m22-ld5Ecd
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ann:6kL/wnTh

Materials

Name Specification

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DISASSEMBLY
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NOTE: If the engine components are to be reinstalled, they must be reinstalled in the same positions. Mark the components removed for locations.
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1)L NOTE: It will be necessary to adjust the Valve Spring Compressor as needed to get proper alignment with the valves.
NOTE: Position the cylinder head on 2 pieces of wood to aid on removing the valves.
NOTE: Use a small screwdriver and multi-purpose grease to remove the valve collets.
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NOTE: It may necessary to file the tip of the valve to aid in removal of the valve from the cylinder head.
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ASSEMBLY
1)L NOTE: If installing the original valves, make sure the valves are installed in the same position from which they were removed.
NOTE: Apply oil to the outer diameter of the valve and valve tip prior to valve and seal installation. The valve must rotate freely.

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NOTE: The valve seal assembly will not seat completely by hand. The Valve Spring Compressor will seat the valve seal assembly when installing the valve
stem keys.
NOTE: Use commercially available valve stem seal pliers.
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NOTE: Use a small screwdriver and multi-purpose grease to install the valve collets. Check the seating of the valve collets.
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Assembly
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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Assembly Procedure revision date: 01/7/2020

Engine
Special Tool(s) / General Equipment

100-001 (T50T-100-A)
Slide Hammer

100-002 (TOOL-4201-C)
Holding Fixture with Dial Indicator Gauge

205-036 (T70P-4067-A)
Wrench

303-050 (T70P-6000)
Lifting Bracket, Engine

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303-103 (T74P-6375-A)
Holding Tool, Flywheel
T74P-77000-A
TKIT-2009TC-F

303-1509
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Installer, Front Crank Seal
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TKIT-2009C-ROW
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303-1509-01
6.7L Front Seal Installer
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303-1514
Installer, Rear Crank Seal
TKIT-2009C-F
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TKIT-2009C-ROW

303-1517
Adapter, Camshaft Remover/Installer
TKIT-2009C-F
TKIT-2009C-ROW
303-1518
Bracket, Engine Removal
TKIT-2009C-F
TKIT-2009C-ROW

303-214 (T83T-6312-B)
Wrench, Fan Clutch Nut

Feeler Gauge
Strap Wrench
Floor Crane
Mounting Stand
Hose Clamp Remover/Installer
Piston Ring Compressor

Materials

Name Specification
Motorcraft® Thread Sealant with PTFE WSK-M2G350-A2
TA-24-B
Motorcraft® High Performance Engine RTV Silicone WSE-M4G323-A6
TA-357
Motorcraft® Metal Surface Prep Wipes -
ZC-31-B

NOTICE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket
surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
NOTE: This procedure assumes the engine will be installed using the recommended body off engine installation procedure. If it will be necessary to install the engine
using the alternate body on engine installation procedure, some of the components in this procedure should not be installed at this time. Refer to Engine - Body On in
this section.
NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel opening to prevent the ingress of dirt or
other contamination. Remove caps, tape and other protective materials prior to installation.
NOTE: Refer to the exploded view under the Engine Component View in the Description and Operation.
NOTE: For EXPORT ONLY vehicles (outside US/Canada) an Export Supplement is provided and should be referenced to identify differences that can impact
service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US
EPA or CARB Regulations".
1. If removed, install a new cylinder block zero clearance patch on the engine.

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2. If removed, install the turbocharger alignment dowels.

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3. If removed, apply thread sealant to the threads and install the oil cooler coolant fitting.

Material: Motorcraft® Thread Sealant with PTFE / TA-24-B (WSK-M2G350-A2)

Torque: 30 lb.ft (40 Nm)
4. If equipped, apply clean engine coolant to the O-ring seal and install the block heater.

Refer to: Specifications (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Specifications).
Torque: 30 lb.ft (40 Nm)

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5. NOTE: Only one pipe plug shown.

NOTE: Apply thread sealant to the threads prior to installing.
If removed, install the pipe plugs.

Material: Motorcraft® Thread Sealant with PTFE / TA-24-B (WSK-M2G350-A2)

Torque:
3/4 x 14 cylinder block plug (HP oil):
Stage 1: 177 lb.in (20 Nm)
Stage 2: 720 °
1/2 x 14 cylinder block upper plug (HP oil):
Stage 3: 30 lb.ft (40 Nm)
Stage 4: 360 °
1/2 x 14 cylinder block lower plug (water jacket drains) : 30 lb.ft (40 Nm)
M27 x 2 x 6 cylinder block heater plug : 53 lb.ft (72 Nm)
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Install the high-pressure fuel injection pump mounting bolts.

Torque: 35 lb.ft (48 Nm)

If removed, install the roll pin(s).
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7. NOTE: Only one piston cooling tube shown.

Lubricate with clean engine oil and install the piston cooling tubes and the bolts.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Torque: 89 lb.in (10 Nm)
8. NOTICE: If the camshaft is being replaced, the camshaft bearings have to be replaced and machined by a machine shop. Failure to follow this may result
in engine damage.
NOTICE: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage may occur.
NOTICE: Use the slide hammer as a handle for the camshaft. Using the slide hammer as intended may result in engine damage.
NOTE: Use care when installing the camshaft, the camshaft will slide out the other end of the cylinder block.

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Lubricate with clean engine oil and using the special tools, install the camshaft.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Use Special Service Tool: 303-1517 Adapter, Camshaft Remover/Installer. , 100-001 (T50T-100-A) Slide Hammer.

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9. Lubricate with clean engine oil and install the camshaft thrust plate and the bolts.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Torque: 18 lb.ft (25 Nm)
10. NOTE: Use a suitable tool in the top camshaft gear hole to prevent the camshaft from turning. Make sure the suitable tool is secured against the cylinder
block prior to tightening the camshaft bolt.
Install the camshaft gear and bolt.
Torque:
Stage 1: 52 lb.ft (70 Nm)
Stage 2: 60 °

11. NOTICE: The crankshaft bearings are tangless and must be positioned in the center of the bearing cap or engine damage may occur.

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NOTE: Verify there is no debris in the saddles in the cylinder block or main bearing caps
Lubricate with clean engine oil and install the new upper crankshaft main bearings into the cylinder block.
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Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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12. Position the camshaft with the 2 timing marks pointing up.
13. Lubricate with clean engine oil and install the crankshaft into the cylinder block, aligning the single timing mark between the 2 timing marks.

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).

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14. Verify the timing marks are properly aligned.

15. NOTE: Assemble the grooved side of the upper crankshaft main bearing thrust washer toward the crankshaft thrust surface.
Apply clean engine oil to the thrust faces of the crankshaft prior to installing the upper crankshaft main bearing thrust washers.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Push the crankshaft rearward and install the upper crankshaft main bearing thrust washer to the rear of the number 5 bulkhead.

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16. NOTE: Assemble the grooved side of the upper crankshaft main bearing thrust washer toward the crankshaft thrust surface.
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Apply clean engine oil to the thrust faces of the crankshaft prior to installing the upper crankshaft main bearing thrust washers.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Push the crankshaft forward and install the upper crankshaft main bearing thrust washer to the front of the number 5 bulkhead.
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17. NOTICE: The crankshaft bearings are tangless and must be positioned in the center of the bearing cap or engine damage may occur.
NOTE: Assemble the grooved side of the lower crankshaft main bearing thrust washer toward the crankshaft thrust surface.
NOTE: The thrust washer tang will be positioned in a groove.
NOTE: Only one lower bearing shown.
Install the new lower crankshaft main bearings into the crankshaft main bearing caps. Position the lower crankshaft main bearing thrust washer on the number 5 crankshaft
main bearing cap.
18. NOTE: Do not use the bolts to seat the crankshaft main bearing caps.
Position commercially available plastigage in the center of each main bearing cap.
Apply clean engine oil to the lower crankshaft main bearing thrust washer and to the rear face of number 5 crankshaft main bearing cap. Align the tab on the thrust
washer with the slot in the number 5 main bearing cap.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Apply clean engine oil to the remaining lower crankshaft main bearings. Install the crankshaft main bearing caps in the cylinder block.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Install the oil pump support bracket and loosely install the crankshaft main bearing cap bolts.

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19. NOTE: RH side shown, LH side similar.

Loosely install the crankshaft main bearing cap side bolts.
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20. Snug all the bolts. Tighten the crankshaft main bearing cap bolts.

Torque:
Stage 1: Tighten bolts 1 through 20 to : 177 lb.in (20 Nm)
Stage 2: Tighten bolts 1 through 10 to : 59 lb.ft (80 Nm)
Stage 3: Tighten bolts 11 through 20 to : 118 lb.ft (160 Nm)
Stage 4: Tighten bolts 1 through 20 an additional : 90 °
Stage 5: Tighten bolts 21 through 30 to : 30 lb.ft (40 Nm)
Stage 6: Tighten bolts 21 through 30 an additional : 90°
21. NOTE: RH side shown, LH side similar.
Remove the crankshaft main bearing cap side bolts.

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Remove the crankshaft main bearing cap bolts and the oil pump support bracket.
Remove the crankshaft main bearing caps.
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23. Measure the clearances for the crankshaft main bearing caps.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
24. NOTE: Do not use the bolts to seat the crankshaft main bearing caps.
Apply clean engine oil to the lower crankshaft main bearing thrust washer and to the rear face of number 5 crankshaft main bearing cap. Align the tab on the thrust
washer with the slot in the number 5 main bearing cap.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Apply clean engine oil to the remaining lower crankshaft main bearings. Install the crankshaft main bearing caps into the cylinder block.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Install the oil pump support bracket and loosely install the crankshaft main bearing cap bolts.

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25. NOTE: RH side shown, LH side similar.

Loosely install the crankshaft main bearing cap side bolts.

26. Snug all the bolts. Tighten the crankshaft main bearing cap bolts.

Torque:
Tighten bolts 1 through 20 to : 177 lb.in (20 Nm)
27. Back off the number 9 and 10 bolts.

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28.
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Push the crankshaft forward and the number 5 crankshaft main bearing cap rearward to align the crankshaft rear thrust washers.
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Continue to hold the crankshaft forward and the number 5 crankshaft main bearing cap rearward against the crankshaft thrust surface while tightening the outer
bolts 9 and 10 on the crankshaft main bearing cap.
Torque: 177 lb.in (20 Nm)
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29. Tighten the crankshaft main bearing cap bolts.

Torque:
Stage 1: Tighten bolts 1 through 10 to : 59 lb.ft (80 Nm)
Stage 2: Tighten bolts 11 through 20 to : 118 lb.ft (160 Nm)
Stage 3: Tighten bolts 1 through 20 an additional : 90 °
Stage 4: Tighten bolts 21 through 30 to : 30 lb.ft (40 Nm)
Stage 5: Tighten bolts 21 through 30 an additional : 90°
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30. Using the special tool, measure the crankshaft end play.

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
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31. Using the special tool, measure the camshaft end play.

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
32. Using the special tool, measure the camshaft gear backlash.

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Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

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33. Install a new high-pressure fuel injection pump O-ring seal and lubricate with clean engine oil.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
34. Install the high-pressure fuel injection pump and the high-pressure fuel injection pump spacers.
Torque: 18 lb.ft (24 Nm)

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35. Install the fuel rail supply tube bracket and the bolts.
Torque: 89 lb.in (10 Nm)
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36. NOTE: The crankshaft gear contains a single timing mark. The camshaft gear contains a single timing mark and a double timing mark. The high-pressure
fuel injection pump gear contains a double timing mark. The engine is timed correctly when the single mark on the crankshaft gear is aligned with the double
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mark on the camshaft gear, and the single mark on the camshaft gear is aligned with the double mark on the high-pressure fuel injection pump gear.
Additionally, the keyway on the high-pressure fuel injection pump drive gear must be at 12 o'clock position.
Install the high pressure fuel injection pump drive gear and the nut.
Torque: 59 lb.ft (80 Nm)
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Verify the timing marks are aligned.

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37. Using the special tool, check the high-pressure fuel injection pump drive gear backlash.
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Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
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38. NOTICE: The connecting rods are powdered metal cracked rods. Make sure the connecting rod and cap are installed as a set or engine damage may
occur.
NOTICE: The connecting rod bearings are tangless and must be positioned in the center of the bearing cap or engine damage may occur.
NOTE: Only one piston assembly shown.
NOTE: The dark bearing is the upper connecting rod bearing. The bright aluminum bearing is the lower connecting rod bearing.
Install the new connecting rod bearings.
39. NOTE: Make sure the piston rings are positioned to specifications for installation. Refer to Piston in this section.
NOTE: Install the piston assembly with the arrow toward the front of the engine.
NOTE: Use care when installing the piston assembly to not damage the piston cooling tubes. If the tube is bent during installation of the piston assembly,
install a new piston cooling tube.
Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).

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Using the piston ring compressor, install the piston and connecting rod assemblies. Repeat until all 8 piston assemblies are installed.
Use the General Equipment: Piston Ring Compressor

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40. NOTICE: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented
correctly with the connecting rods or engine damage may occur.
NOTE: Only one connecting rod cap shown.
Position a piece of plastigage across the bearing surface.
Lubricate the connecting rod bearings with clean engine oil. Position the connecting rod caps and install the bolts.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Torque:
Stage 1: 177 lb.in (20 Nm)
Stage 2: 35 lb.ft (48 Nm)
Stage 3: 105 °
41.
Remove the bolts and the connecting rod caps.
Discard the bolts.

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42. Measure the clearances for the connecting rod cap.

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Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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43. NOTICE: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented
correctly with the connecting rods or engine damage may occur.
NOTE: Only one connecting rod cap shown.
Lubricate the connecting rod bearings with clean engine oil. Position connecting rod caps and install the new bolts.

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Torque:
Stage 1: 177 lb.in (20 Nm)
Stage 2: 35 lb.ft (48 Nm)
Stage 3: 105 °

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44. Using a feeler gauge, check the connecting rod side clearance. co
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Use the General Equipment: Feeler Gauge
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45. Install a new gasket in the engine rear cover.

46. NOTICE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.
Install the engine rear cover and the bolts.
Torque:
Stage 1: Tighten bolts 1 through 9 to : 89 lb.in (10 Nm)
Stage 2: Tighten bolt 10 to : 35 lb.ft (48 Nm)

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47. NOTICE: Do not use grease or petroleum jelly instead of oil. Failure to follow this may result in crankshaft rear seal leakage.
Apply clean engine oil to the inner diameter of the crankshaft seal bore in the engine rear cover.

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
48. NOTICE: Failure to install the crankshaft rear seal with the part numbers facing out may result in engine damage.
NOTE: Do not discard the installation sleeve provided with the crankshaft rear seal. It is used for installation of the crankshaft rear seal.
NOTE: Check for correct orientation of the installation sleeve prior to sliding the seal on the crankshaft.
Position the installation sleeve onto the crankshaft, slide the new crankshaft rear seal over the installation sleeve onto the crankshaft. Remove the installation sleeve.
Using the special tool, install the new crankshaft rear seal.
Use Special Service Tool: 303-1514 Installer, Rear Crank Seal.

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49. Prime the oil pump. Add 2 tablespoons of clean engine oil to the large round oil pump hole and rotate the oil pump by hand.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
50. NOTICE: Install the oil pump evenly or damage to the roll pins may occur.
Install the oil pump and the bolts finger tight.

Torque:
Tighten bolts 1 through 4 to::
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °
Tighten the lower oil pump bolts 5 and 6 to: : 18 lb.ft (25 Nm)
51. Using the special tool, check the oil pump drive gear backlash.

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

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52. NOTICE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine
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damage.
NOTE: If the engine front cover is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal
surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Install the engine front cover press-in-place gaskets.
Apply a 4.5 mm (0.18 in) bead of Motorcraft® High Performance Engine RTV Silicone Sealant to the chamfer on the engine front cover sealing surface.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
53. NOTICE: Use care when installing the engine front cover not to scratch the crankshaft sealing surface.
NOTE: If the engine front cover is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal
surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Install the engine front cover.

Hand start bolt numbers 1 and 2.

Install the remaining engine front cover bolts. Tighten the engine front cover bolts.

Torque: 18 lb.ft (24 Nm)

Remove the excess sealant from the engine front cover to the cylinder block T-joint wiping outward from the crankshaft.

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54. Apply clean engine oil to the inner diameter of the crankshaft seal bore in the engine front cover.

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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55. NOTICE: Failure to install the crankshaft front seal with the part numbers facing out may result in engine damage.
NOTE: Do not discard the installation sleeve provided with the crankshaft front seal. It is used for installation of the crankshaft front seal.
NOTE: Check for correct orientation of the installation sleeve prior to sliding the seal on the crankshaft.
Position the installation sleeve onto the crankshaft, slide the new crankshaft front seal over the installation sleeve onto the crankshaft. Remove the installation sleeve.
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56.
Apply clean engine oil to the inner diameter of the crankshaft oil slinger.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Position the new front crankshaft slinger on the crankshaft.
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57. Using the special tools, install the new crankshaft front seal and the front crankshaft slinger.

Use Special Service Tool: 303-1509 Installer, Front Crank Seal. , 303-1509-01 6.7L Front Seal Installer.
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58. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
Position 2 guide studs in the cylinder block at the location shown.

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59.
Install the oil pan press-in-place gaskets.
Position the upper oil pan gasket.
60. NOTICE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine
damage.
NOTE: The bead of Motorcraft® High Performance Engine RTV Silicone Sealant should cover the openings of the front and rear engine cover gaskets.
NOTE: If the upper oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with metal

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surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 12 mm (0.47 in) diameter of Motorcraft® High Performance Engine RTV Silicone Sealant at the T-joint areas.

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Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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61. NOTE: Final torque must be reached within 15 minutes of sealant application.
Install the upper oil pan and the bolts.
Torque:
Stage 1: 18 lb.in (2 Nm)
Stage 2: Tighten bolts 1 through 8, 11 through 14 and 19 through 24 to 18 Nm (159 lb-in) plus : 25 °
Stage 3: Tighten bolts 9, 10 and 15 through 18 to 18 Nm (159 lb-in) plus : 90 °
62. Install a new oil filter adapter gasket.

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63. Install the oil filter adapter and retainers.

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Torque: 89 lb.in (10 Nm)

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64. Install the new oil cooler gaskets.
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65. NOTICE: In the event of a catastrophic engine failure, or if installing a new short block, always install a new oil cooler. Foreign material cannot be
removed from the oil cooler and engine damage may occur. Long blocks are equipped with a new oil cooler.
Stage 1: Install the oil cooler assembly and hand start number 2, 4 and 7 bolts.

Stage 2: Hand start number 1, 3, 5 and 6 bolts.

Stage 3: Tighten to 2 Nm (18 lb-in) in a counter clockwise sequence starting with the number 1 bolt.

Stage 4: Tighten to 10 Nm (89 lb-in) in a counter clockwise sequence starting with the number 1 bolt.
66. NOTE: Use care when installing the hose on the oil cooler, damage to the oil cooler may occur during installation.
Install the oil cooler outlet hose and connect the hose retainers.
Use the General Equipment: Hose Clamp Remover/Installer

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67. NOTE: Use care when installing the hose on the oil cooler, damage to the oil cooler may occur during installation.
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Install the oil cooler inlet hose.

Use the General Equipment: Hose Clamp Remover/Installer
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68.
1. Wipe the new lower oil pan sealing surface with a Motorcraft® Metal Surface Prep Wipe.
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Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

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2. NOTE: If the lower oil pan is not secured within 10 minutes of sealant application, the sealant must be removed and the sealing area cleaned with
metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future
oil leakage.
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Apply a 4.5 mm (0.18 in) diameter bead of Motorcraft® High Performance Silicone Sealant to the chamfer on the lower oil pan sealing surface.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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69. Install the lower oil pan and the bolts.
Torque: 89 lb.in (10 Nm) co
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70. NOTE: Only one cylinder shown.

Apply clean engine oil to the valve tappet bores.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
71. NOTICE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original
positions.
NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.
NOTE: Only one cylinder shown.

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Apply clean engine oil to the valve tappets.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).

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72. NOTICE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original
positions.
NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.
NOTE: Only one cylinder shown.
Install the valve tappets.
73. NOTE: Only one cylinder shown.
Install the valve tappet guides. Verify that the retainer is fully seated.

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74. Install the new RH cylinder head dowels and the cylinder head gasket.

75. NOTICE: Using too much engine oil on the threads of the cylinder head bolts may cause damage to the threads and result in poor sealing. Using anti-
seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads may affect the true torque value of the bolts.
Install the RH cylinder head.
Lightly lubricate the new M12 cylinder head bolt threads and flanges with clean engine oil. Install the cylinder head bolts finger tight.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
76. Tighten the RH cylinder head bolts.

Torque:
Stage 1: Tighten bolts 1 through 18 to : 168 lb.in (19 Nm)
Stage 2: Tighten bolts 1 through 18 to : 36 lb.ft (49 Nm)
Stage 3: Tighten bolts 1 through 18, a second time to : 36 lb.ft (49 Nm)
Stage 4: Tighten bolts 1 through 18, a third time to : 36 lb.ft (49 Nm)
Stage 5: Tighten bolts 1 through 18, an additional : 90 °

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Stage 6: Tighten bolts 1 through 18, a second time, an additional : 90°
Stage 7: Tighten bolts 1 through 18, a third time, an additional : 90°
Stage 8: Tighten bolts 19 through 22 to : 22 lb.ft (30 Nm)

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77. Install the new LH cylinder head dowels and the cylinder head gasket.

78. NOTICE: Using too much engine oil on the threads of the cylinder head bolts may cause damage to the threads and result in poor sealing. Using anti-
seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads may affect the true torque value of the bolts.
Install the LH cylinder head.
Lightly lubricate the new M12 cylinder head bolt threads and flanges with clean engine oil. Install the cylinder head bolts finger tight.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
79. Tighten the LH cylinder head bolts.

Torque:
Stage 1: Tighten bolts 1 through 18 to : 168 lb.in (19 Nm)
Stage 2: Tighten bolts 1 through 18 to : 36 lb.ft (49 Nm)
Stage 3: Tighten bolts 1 through 18, a second time to : 36 lb.ft (49 Nm)
Stage 4: Tighten bolts 1 through 18, a third time to : 36 lb.ft (49 Nm)
Stage 5: Tighten bolts 1 through 18, an additional : 90 °

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Stage 6: Tighten bolts 1 through 18, a second time, an additional : 90°
Stage 7: Tighten bolts 1 through 18, a third time, an additional : 90°
Stage 8: Tighten bolt 19 through 23 to : 22 lb.ft (30 Nm)

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80. NOTICE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
NOTE: Only one cylinder shown.
Apply clean engine oil to the ball end of the push rod. Install the push rods and verify the push rod socket is engaged on the hydraulic lash adjuster.

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
81. Rotate the crankshaft clockwise and position cylinder number No. 1 approximately 155 degrees after TDC by observing the crankshaft pulley dowel pin and clocking it
to the 3:40 position (as viewed from the front of the engine).

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82. NOTE: Verify the push rod socket is on the hydraulic lash adjuster prior to installing the rocker arm assembly.
Determine which cylinder is actually in the firing position by observing the push rods. No. 1 cylinder exhaust push rods should be raised 1.0 mm (0.039 in) and No.
4 cylinder exhaust push rods should be raised 1.5 mm (0.059 in). If the push rods are not in the correct position, rotate the engine one full revolution clockwise
(360 degrees).

Apply clean engine oil to each rocker arm pivot ball of the rocker arm assemblies. Install the rocker arm assemblies for the RH cylinder head (cylinder numbers 1,
2, 3 and 4).

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Verify the top of the push rod engages the socket on each rocker arm.
Torque:
Stage 1: 35 lb.in (4 Nm)
Stage 2: 71 lb.in (8 Nm)
Stage 3: 115 lb.in (13 Nm)
Stage 4: Tighten a second time to : 115 lb.in (13 Nm)
Stage 5: Tighten an additional : 80°
83. Apply clean engine oil on the O-ring seal on the RH oil spray bar.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).

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84. NOTICE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.
Install the RH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown until the RH oil spray bar nuts can be tightened.
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Torque:
Stage 1: : 106 lb.in (12 Nm)
Stage 2: Tighten a second time to: : 106 lb.in (12 Nm)
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85. Rotate the crankshaft clockwise one revolution (360 degrees) back to 155 degrees after TDC by observing the crankshaft pulley dowel pin and clocking it to the 3:40
position (as viewed from the front of the engine).
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86. NOTE: Verify the push rod socket is on the hydraulic lash adjuster prior to installing the rocker arm assembly.
Apply clean engine oil to each rocker arm pivot ball of the rocker arm assemblies. Install the rocker arm assemblies for the LH cylinder head (cylinder numbers 5,
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6, 7 and 8).

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Verify the top of the push rod engages the socket on each rocker arm.

Torque:
Stage 1: 35 lb.in (4 Nm)
Stage 2: 71 lb.in (8 Nm)
Stage 3: 115 lb.in (13 Nm)
Stage 4: Tighten a second time to : 115 lb.in (13 Nm)
Stage 5: Tighten an additional : 80°
87. Apply clean engine oil on the O-ring seal on the LH oil spray bar.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).

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88. NOTICE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.
Install the LH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown until the LH oil spray bar nuts can be tightened.
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Torque:
Stage 1: : 106 lb.in (12 Nm)
Stage 2: Tighten a second time to: : 106 lb.in (12 Nm)
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89. NOTE: Verify that the fuel injector-to-valve cover seal is squarely seated in the valve cover.
Using a 22 mm (0.866 in) socket or equivalent, install the new fuel injector-to-valve cover seals.
90. Install a new LH valve cover gasket.

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91. NOTICE: Failure to install the fuel injectors during the valve cover installation may result in engine failure.
NOTE: The valve cover will have to be tightened a second time after the fuel injectors are installed.
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Install the LH valve cover, the stud bolts and the bolts.
Torque: 106 lb.in (12 Nm)
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92. Install a new RH valve cover gasket.
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93. NOTICE: Failure to install the fuel injectors during the valve cover installation may result in engine failure.
NOTE: The valve cover will have to be tightened a second time after the fuel injectors are installed.
Install the RH valve cover, the stud bolts and the bolts.
Torque: 106 lb.in (12 Nm)
94. NOTE: Do not apply engine oil to the fuel injectors.
NOTE: Only one fuel injector shown.
NOTE: If the fuel injector is being reused, make sure to install it in the original location.

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Install a new copper combustion gasket, O-ring seal and fuel injector return O-ring seal on the fuel injectors. Position the fuel injectors into the engine.

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95. NOTICE: Failure to tighten the fuel injector correctly can lead to engine failure.
Install the fuel injector hold-down clamps and the new fuel injector bolts.
Torque:
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Stage 1: 22 lb.ft (30 Nm)

Stage 2: 90°
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96. Final tighten the LH valve cover bolts in the sequence shown.

Torque: 106 lb.in (12 Nm)

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97. Final tighten the RH valve cover bolts in the sequence shown.

Torque: 106 lb.in (12 Nm)

98. Install the glow plugs.
Torque:
Stage 1: 35 lb.in (4 Nm)

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Stage 2: 50 °

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99. NOTE: Cylinder number 4 will have longer exhaust studs.

Install the new exhaust manifold stud(s) as needed.

Torque: 115 lb.in (13 Nm)

Install a new exhaust manifold gasket.
100. NOTE: Install the spacers as marked on removal.
Install the RH exhaust manifold, the spacers and the new nuts.

Torque:
Stage 1: 159 lb.in (18 Nm)
Stage 2: 18 lb.ft (25 Nm)

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Stage 3: Tighten a second time to: : 18 lb.ft (25 Nm)

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101. NOTE: Cylinder number 8 will have longer exhaust studs.

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Install the new exhaust manifold stud(s) as needed.

Torque: 115 lb.in (13 Nm)

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Install a new exhaust manifold gasket.

102. NOTE: Install the spacers as marked on removal.

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Install the LH exhaust manifold, the spacers and the new nuts.

Torque:
Stage 1: 159 lb.in (18 Nm)
Stage 2: 18 lb.ft (25 Nm)
Stage 3: Tighten a second time to: : 18 lb.ft (25 Nm)
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103. Apply clean engine oil to the threads and install the exhaust manifold studs.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Torque: 115 lb.in (13 Nm)
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104. Install the RH exhaust manifold heat shield and the bolts.
Torque: 89 lb.in (10 Nm) co
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105. Install the LH exhaust manifold heat shield and the bolts.
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Torque: 89 lb.in (10 Nm)

106. NOTICE: Do not use magnetic screwdrivers or other magnetic tools around the CKP sensor and the crankshaft sensor pulse ring or damage to the
components may occur.
Install the CKP sensor and the bolt.
Torque: 89 lb.in (10 Nm)
107. Install the crankshaft sensor pulse ring.

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108. Install the flexplate and the new bolts.

Use Suggested Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel. Tool shown or a commercially available equivalent can be used.
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Torque:
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Stage 1: 44 lb.in (5 Nm)

Stage 2: 74 lb.ft (100 Nm)
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109. Install a new vacuum pump gasket. co
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110. Install the vacuum pump and the bolts.

Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °
111. NOTICE: To prevent engine damage, always install new bolts when installing the crankshaft pulley.

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NOTE: Use the strap wrench to prevent the engine from turning while tightening the bolts.
Position the crankshaft pulley and install the new bolts.
Use the General Equipment: Strap Wrench
Torque:
Stage 1: 22 lb.ft (30 Nm)
Stage 2: 90 °
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112. Install new coolant crossover manifold gaskets.

113. Install the coolant crossover manifold and the bolts. Finger-tighten the bolts.

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114. Inspect the thermostat seal for tears, nicks or cuts. Inspect the thermostat springs and valve seats for wear or damage. Replace if necessary.
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115. Install the thermostat, the thermostat housing and the bolts. Finger-tighten the bolts.
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116. Tighten the coolant crossover manifold bolts and the thermostat housing bolts.
Torque: 89 lb.in (10 Nm)
117. Position the RH fuel rail and loosely install the bolts.

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118. Position the LH fuel rail and loosely install the bolts.
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119. Position the fuel rail supply tube assembly. Hand start the fuel rail supply tube assembly connectors.
120. NOTE: Only 1 fuel injector supply tube shown.

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NOTE: Only hand start the fuel injector supply tube.
Install the fuel injector supply tubes.
Start from front to rear of the engine.
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121. NOTE: Only hand start the fuel rail supply tube assembly bolts.
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Install the fuel rail supply tube assembly bolts.

122. Tighten the LH fuel rail bolts.

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Torque: 18 lb.ft (24 Nm)

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123. Tighten the RH fuel rail bolts.

Torque: 18 lb.ft (24 Nm)

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124. Tighten the LH fuel injector supply tubes in the sequence shown.

Torque: 89 lb.in (10 Nm) co

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125. Tighten the RH fuel injector supply tubes in the sequence shown.
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Torque: 89 lb.in (10 Nm)

126. Tighten the fuel rail supply tube assembly connectors in the sequence shown.

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Torque: 89 lb.in (10 Nm)

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127. Tighten the LH fuel injector supply tubes in the sequence shown.

Torque: 65 °
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128. Tighten the RH fuel injector supply tubes in the sequence shown.

Torque: 65 °
129. Tighten the fuel rail supply tube assembly connectors in the sequence shown.

Torque: 65 °

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130. Tighten the fuel rail supply tube assembly bolts in the sequence shown.

Torque: 89 lb.in (10 Nm)

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131.
Position the fuel injector return hose and vacuum hose assembly on the engine and connect the retaining clips.
Connect the fuel injector return hose fittings to the fuel injectors.
Push down on the center of the fuel injector return hose fitting to lock the fitting.
132. Install a new O-ring seal on the heater supply tube and lubricate with clean engine coolant.

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Refer to: Specifications (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Specifications).

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133. Install the heater supply tube and the bolts.

Torque: 89 lb.in (10 Nm)
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134. NOTE: Make sure the grommet is properly seated in the tube.
Install the TC coolant tube O-ring seal and the grommet.
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135. Lubricate with clean engine coolant and install the TC coolant tube.
Refer to: Specifications (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Specifications).
136. Install the secondary fuel filter bracket and the bolts.
Torque:

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Stage 1: 71 lb.in (8 Nm)
Stage 2: 45 °

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137. NOTE: Rotate the fuel filter clockwise to install.

Install the new secondary fuel filter.
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138. If necessary, install the new crankcase vent oil separator gasket and the O-ring seal.

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139. NOTE: Do not lubricate the O-ring seal or gasket prior to installation.
Install the crankcase vent oil separator and bolts.
Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °
140. Install the new O-ring seals on the fuel injection pump supply tube and lubricate with clean engine oil.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).

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141. Install the fuel injection pump supply tube assembly and hand start the bolt.
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142. Hand start the fuel injection pump supply tube assembly bolts.
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143. Tighten the fuel injection pump supply tube assembly bolt.

Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °
144. Tighten the fuel injection pump supply tube assembly bolts.

Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °

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145. Position back and connect the fuel injector return hose and the fuel injection pump supply tube.
Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 6.7L Power Stroke Diesel) .
146. Connect the fuel injection pump hose to the fuel rail.
Refer to: Spring Lock Couplings (310-00B Fuel System - General Information - 6.7L Power Stroke Diesel, General Procedures).

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147. Position the engine wire harness over the engine. Connect the retainers and install the bolt.
Torque: 106 lb.in (12 Nm)
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148. Connect the RH valve cover wiring.

149. Connect the fuel volume control valve electrical connector.

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150. Connect the CMP sensor electrical connector and the wire retainers.
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151. Connect the fuel pressure and temperature sensor, the ECT sensor electrical connectors and the wire retainers.
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152. Connect the LH valve cover wiring.

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153.
Connect the wire retainers.
Install the ground strap and the bolt.
Torque: 97 lb.in (11 Nm)
154. Connect the CKP sensor electrical connector and the wire retainer.

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155. Install the CKP sensor cover.

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156. Install the new EGR cooler gaskets.
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157. Install the EGR cooler assembly and the bolts.

Torque:
Stage 1: Tighten bolt 3 to: : 89 lb.in (10 Nm)
Stage 2: Tighten bolt 1 to: : 89 lb.in (10 Nm)
Stage 3: Tighten bolts 2, 4, 5 and 6 to: : 89 lb.in (10 Nm)
158. Position the engine wire harness and install the bolts.
Torque: 80 lb.in (9 Nm)

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159.
Using new gaskets, install the EGR cooler inlet tube and the bolts.
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Tighten the bolts at the exhaust manifold.

Torque: 177 lb.in (20 Nm)

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Tighten the bolts at the EGR cooler.

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Torque: 89 lb.in (10 Nm)

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160.
1. Install the EGR cooler inlet tube bracket and hand start the bolts.
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2. Install the bolt.

Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °
3. Tighten the bolt.
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Torque:
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Stage 1: 89 lb.in (10 Nm)

Stage 2: 45 °
4. Tighten the bolt.
Torque:
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Stage 1: 89 lb.in (10 Nm)

Stage 2: 45 °
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161. Connect the electrical connector and the vacuum tubes to the EGR bypass valve solenoid. Attach the wire harness retainer.
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162. Connect the EGR valve electrical connector and the wire retainer.
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163. Install new O-ring seals on the oil level indicator tube and lubricate with clean engine oil.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).

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164. Install the oil level indicator tube.

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165. Install a new O-ring seal on the oil fill pipe and lubricate with clean engine oil.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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166. Install the oil fill pipe and the bolt.

Torque: 89 lb.in (10 Nm)
167. If equipped, install the LH sound shield and the push pins.

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168. If equipped, install the RH sound shield and the push pins.
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169. Install the stator standoffs.

Torque: 17 lb.ft (23 Nm)
170. NOTE: Only one tube shown.

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Install the new transmission oil cooler coolant tube O-ring seals and lubricate with clean engine coolant.
Refer to: Specifications (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Specifications).

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171. Install the transmission oil cooler coolant tube and the stud bolt.
Torque: 89 lb.in (10 Nm)
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172. Install the transmission oil cooler coolant tube, the bolt and the nut.
Torque:
Bolt : 89 lb.in (10 Nm)
Nut : 115 lb.in (13 Nm)
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173. Connect the engine vacuum hose at the tee.

174.

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1. Install the power steering pump mounting bracket and the bolts.
Torque: 18 lb.ft (25 Nm)
2. Install the remaining bolts.
Torque: 18 lb.ft (25 Nm)
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175. If equipped with dual generator, install the idler pulley.

Torque: 35 lb.ft (48 Nm)

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176. Install the cooling fan drive assembly, the engine lifting bracket and the bolts.
Use Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.
Torque: 18 lb.ft (25 Nm)
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177. NOTE: Dual generator shown, single generator similar.

Install the secondary coolant pump assembly and the bolts.
Torque: 18 lb.ft (25 Nm)
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178. If equipped with dual generator, connect the wire retainer.
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179. Install the accessory drive belt tensioner and the bolt.
Torque: 35 lb.ft (48 Nm)
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180. Install the A/C compressor and the bolts.
Torque: 18 lb.ft (25 Nm)

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181. Install the battery wire harness, the coolant hoses and the nuts.
Torque: 106 lb.in (12 Nm)
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182. Position back the battery wire harness and coolant tube. Install the nuts.
Torque: 106 lb.in (12 Nm) co
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183. Connect the A/C electrical connectors and the wire retainer.
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184. Connect the A/C pressure switch electrical connector.

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185. Position back the RH ground cable and install the bolt.
Torque: 18 lb.ft (25 Nm)
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186.
Position back the battery wire harness and install the nut.
Torque: 106 lb.in (12 Nm)
Connect the electrical connectors.
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187. Connect the heater hose and install the clip.

188. Connect the transmission oil cooler coolant hose.

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189. Position back the LH ground cable and install the bolt.
Torque: 18 lb.ft (25 Nm)
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190. Install the bolts for the battery wire harness.
Torque: 106 lb.in (12 Nm)
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191. Connect the battery wire harness retainer to the bracket.

192.
Position back the cable and install the nut. Position back the boot.
Torque: 159 lb.in (18 Nm)
Connect the generator electrical connector.

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193. If equipped with single generator, install the accessory drive belt.
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194. If equipped with dual generator, install the accessory drive belt.
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195. Install the coolant engine fill hose.

Use the General Equipment: Hose Clamp Remover/Installer
196. Install the lower radiator hose and install the clip.

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197. Connect the coolant hose and install the clip.

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198. Using the special tools, install the cooling fan assembly.
Use Special Service Tool: 205-036 (T70P-4067-A) Wrench. , 303-214 (T83T-6312-B) Wrench, Fan Clutch Nut.
Torque: 98 lb.ft (133 Nm)
199.
Install the fan clutch electrical connector bolt.
Torque: 18 lb.ft (25 Nm)
Connect the fan clutch electrical connector and the wire retainer.

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200. Install Special Service Tool: 303-1518 Bracket, Engine Removal.

Torque: 41 lb.ft (55 Nm)
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201. Using a floor crane and the ratchet strap, remove the engine from the mounting stand.

Use the General Equipment: Mounting Stand

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Use the General Equipment: Floor Crane

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202. NOTICE: Do not tighten the engine mount bracket bolts more than 90 degrees after initial torque or damage to the bolts may occur.
NOTICE: Clean the engine mount mating surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in
engine mount bracket or engine mount damage.
NOTE: Place a visible mark on the engine mount bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.
Install the RH engine mount bracket and the new bolts.
Torque:
Stage 1: 41 lb.ft (55 Nm)
Stage 2: 60 °
203. NOTICE: Do not tighten the engine mount bracket bolts more than 90 degrees after initial torque or damage to the bolts may occur.
NOTICE: Clean the engine mount mating surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in
engine mount bracket or engine mount damage.
NOTE: Place a visible mark on the engine mount bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.
Install the LH engine mount bracket and the new bolts.
Torque:

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Stage 1: 41 lb.ft (55 Nm)
Stage 2: 60 °

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204. Install the engine.

Refer to: Engine - Body Off (303-01B Engine - 6.7L Power Stroke Diesel, Installation).
Refer to: Engine - Body On (303-01B Engine - 6.7L Power Stroke Diesel, Installation).
303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Assembly Procedure revision date: 10/30/2019

Engine - Enhanced Long Block

Special Tool(s) / General Equipment

100-002 (TOOL-4201-C)
Holding Fixture with Dial Indicator Gauge

205-036 (T70P-4067-A)
Wrench

303-050 (T70P-6000)
Lifting Bracket, Engine

303-103 (T74P-6375-A)
Holding Tool, Flywheel
T74P-77000-A
TKIT-2009TC-F

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303-1518
Bracket, Engine Removal
TKIT-2009C-F
TKIT-2009C-ROW
303-214 (T83T-6312-B)
Wrench, Fan Clutch Nut
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308-021 (T75L-4201-A)
Gauge, Clutch Housing
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Strap Wrench

Floor Crane
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Hose Clamp Remover/Installer

NOTE: This procedure assumes the engine will be installed using the recommended body off engine installation procedure. If it will be necessary to install the engine
using the alternate body on engine installation procedure, some of the components in this procedure should not be installed at this time. Refer to Engine — Body
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On in this section.
NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel opening to prevent the ingress of dirt or
other contamination. Remove caps, tape and other protective materials prior to installation.
NOTE: For EXPORT ONLY vehicles (outside US/Canada) an Export Supplement is provided and should be referenced to identify differences that can impact
service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US
EPA or CARB Regulations".
NOTE: Refer to the exploded view under the Engine Component View in the Description and Operation.
1. Install Special Service Tool: 303-1518 Bracket, Engine Removal.
Torque: 41 lb.ft (55 Nm)
2.
Using a Floor Crane, remove the engine from the shipping crate. Position the engine on wood blocks as needed.
Use the General Equipment: Floor Crane
Verify that the engine is stable on the wooden blocks.

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3. If equipped with a block heater, remove the block heater plug.

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4. If equipped, apply clean engine coolant to the O-ring seal and install the block heater.

Refer to: Specifications (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Specifications).
Torque: 30 lb.ft (40 Nm)
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5. Install a new high-pressure fuel injection pump O-ring seal and lubricate with clean engine oil.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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6. Install the high-pressure fuel injection pump and the high-pressure fuel injection pump spacers.
Torque: 18 lb.ft (24 Nm)
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7. Install the fuel rail supply tube bracket and the bolts.
Torque: 89 lb.in (10 Nm)
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8. NOTE: The crankshaft gear contains a single timing mark. The camshaft gear contains a single timing mark and a double timing mark. The high-pressure
fuel injection pump gear contains a double timing mark. The engine is timed correctly when the single mark on the crankshaft gear is aligned with the double
mark on the camshaft gear, and the single mark on the camshaft gear is aligned with the double mark on the high-pressure fuel injection pump gear.
Additionally, the keyway on the high-pressure fuel injection pump drive gear must be at 12 o'clock position.
Install the high pressure fuel injection pump drive gear and nut.
Torque: 59 lb.ft (80 Nm)
Verify the timing marks are aligned.
 9. Using the special tool, check the high-pressure fuel injection pump drive gear backlash.

Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge. , 308-021 (T75L-4201-A) Gauge, Clutch Housing.

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10. NOTE: Do not apply engine oil to the fuel injectors.

NOTE: Only one fuel injector shown.
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NOTE: If the fuel injector is being reused, make sure to install it in the original location.
Install a new copper combustion gasket, O-ring seal and fuel injector return O-ring seal on the fuel injectors. Position the fuel injectors into the engine.
11.
NOTICE: Failure to tighten the fuel injector correctly can lead to engine failure.
Install the fuel injector hold-down clamps and the new fuel injector bolts.
Torque:
Stage 1: 22 lb.ft (30 Nm)
Stage 2: 90°

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12. Final tighten the LH valve cover bolts in the sequence shown.

Torque: 106 lb.in (12 Nm)

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13. Final tighten the RH valve cover bolts in the sequence shown.

Torque: 106 lb.in (12 Nm)

14. Install the glow plugs.
Torque:
Stage 1: 35 lb.in (4 Nm)
Stage 2: 50 °

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15. Install a new RH exhaust manifold gasket.

16. NOTE: Install the spacers as marked on removal.

Install the RH exhaust manifold, the spacers and the new nuts.

Torque:
Stage 1: 159 lb.in (18 Nm)
Stage 2: 18 lb.ft (25 Nm)
Stage 3: Tighten a second time to : 18 lb.ft (25 Nm)
17. Install a new LH exhaust manifold gasket.

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18. NOTE: Install the spacers as marked on removal.
Install the LH exhaust manifold, the spacers and the new nuts.

Torque:
Stage 1: 159 lb.in (18 Nm)
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Stage 2: 18 lb.ft (25 Nm)
Stage 3: Tighten a second time to : 18 lb.ft (25 Nm)
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19. Apply clean engine oil to the threads and install the exhaust manifold studs.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Torque: 115 lb.in (13 Nm)

20. Install the RH exhaust manifold heat shield and the bolts.
 Torque: 89 lb.in (10 Nm)

21. Install the LH exhaust manifold heat shield and the bolts.
Torque: 89 lb.in (10 Nm)

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22. NOTICE: Do not use magnetic screwdrivers or other magnetic tools around the CKP sensor and the crankshaft sensor pulse ring or damage to the
components may occur.
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Install the crankshaft sensor pulse ring.
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23. Install the flexplate and the new bolts.

Use Suggested Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel. Tool shown or a commercially available equivalent can be used.
Torque:
Stage 1: 44 lb.in (5 Nm)
Stage 2: 74 lb.ft (100 Nm)
24. Install a new vacuum pump gasket.

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25. Install the vacuum pump and the bolts.

Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °
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26. NOTICE: To prevent engine damage, always install new bolts when installing the crankshaft pulley.
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NOTE: Use the strap wrench to prevent the engine from turning while tightening the bolts.
Position the crankshaft pulley and install the new bolts.
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Use the General Equipment: Strap Wrench

Torque:
Stage 1: 22 lb.ft (30 Nm)
Stage 2: 90 °
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27. Install the new coolant crossover manifold gaskets.

28. Install the coolant crossover manifold and the bolts. Finger-tighten the bolts.

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29. Install the new thermostat, the thermostat housing and the bolts. Finger-tighten the bolts.
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30. Tighten the coolant crossover manifold bolts and the thermostat housing bolts.
Torque: 89 lb.in (10 Nm)
31. Position the RH fuel rail and loosely install the bolts.

32. Position the LH fuel rail and loosely install the bolts.

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33. Position the fuel rail supply tube assembly. Hand start the fuel rail supply tube assembly connectors.
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34. NOTE: Only one fuel injector supply tube shown.

NOTE: Only hand start the fuel injector supply tube.
Install the fuel injector supply tubes.
Start from front to rear of the engine.

35. NOTE: Only hand start the fuel rail supply tube assembly bolts.
Install the fuel rail supply tube assembly bolts.
36. Tighten the LH fuel rail bolts.

Torque: 18 lb.ft (24 Nm)

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37. Tighten the RH fuel rail bolts.
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Torque: 18 lb.ft (24 Nm)

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38. Tighten the LH fuel injector supply tubes in the sequence shown.

Torque: 89 lb.in (10 Nm)

39. Tighten the RH fuel injector supply tubes in the sequence shown.

Torque: 89 lb.in (10 Nm)

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40. Tighten the fuel rail supply tube assembly connectors in the sequence shown.

Torque: 89 lb.in (10 Nm)

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41. Tighten the LH fuel injector supply tubes in the sequence shown.

Torque: 65 °

42. Tighten the RH fuel injector supply tubes in the sequence shown.

Torque: 65 °
43. Tighten the fuel rail supply tube assembly connectors in the sequence shown.

Torque: 65 °

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44. Tighten the fuel rail supply tube assembly bolts in the sequence shown.

Torque: 89 lb.in (10 Nm)

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45.
Position the fuel injector return hose and vacuum hose assembly on the engine and connect the retaining clips.
Connect the fuel injector return hose fittings to the fuel injectors.
Push down on the center of the fuel injector return hose fitting to lock the fitting.
46. Install a new O-ring seal on the heater supply tube and lubricate with clean engine coolant.
Refer to: Specifications (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Specifications).

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47. Install the heater supply tube and the bolts.

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Torque: 89 lb.in (10 Nm)

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48. NOTE: Make sure the grommet is properly seated in the tube.
Install the TC coolant tube O-ring seal and the grommet.
49. Lubricate with clean engine coolant and install the TC coolant tube.
Refer to: Specifications (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Specifications).

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50. Install the secondary fuel filter bracket and bolts.
Torque:
Stage 1: 71 lb.in (8 Nm)
Stage 2: 45 °
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51. NOTE: Rotate the fuel filter clockwise to install.

Install the new secondary fuel filter.
52. If necessary, install the new crankcase vent oil separator gasket and the O-ring seal.

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53. NOTE: Do not lubricate the O-ring seal or gasket prior to installation.
Install the crankcase vent oil separator and bolts.
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Torque:
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Stage 1: 89 lb.in (10 Nm)

Stage 2: 45 °
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54. Install the new O-ring seals on the fuel injection pump supply tube assembly and lubricate with clean engine oil.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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55. Install the fuel injection pump supply tube assembly and hand start the bolt.
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56. Hand start the fuel injection pump supply tube assembly bolts.
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57. Tighten the fuel injection pump supply tube assembly bolt.
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Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °
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58. Tighten the fuel injection pump supply tube assembly bolts.

Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °
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59. Connect the fuel injector return hose and the fuel injection pump supply tube.
Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 6.7L Power Stroke Diesel) .

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60. Connect the fuel injection pump hose to the fuel rail.
Refer to: Spring Lock Couplings (310-00B Fuel System - General Information - 6.7L Power Stroke Diesel, General Procedures).
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61. Position the engine wire harness over the engine. Connect the retainers and install the bolt.
Torque: 106 lb.in (12 Nm) co
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62. Connect the RH valve cover wiring.

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63. Connect the fuel volume control valve electrical connector.
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64. Connect the CMP sensor electrical connector and the wire retainers.
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65. Connect the fuel pressure and temperature sensor, the ECT sensor electrical connectors and the wire retainers.
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66. Connect the LH valve cover wiring.

67.
Connect the wire retainers.
Install the ground strap and the bolt.
Torque: 97 lb.in (11 Nm)

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68. Connect the CKP sensor electrical connector and the wire retainer.
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69. Install the CKP sensor cover.
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70. Install the new EGR cooler gaskets.

71. Install the EGR cooler assembly and the bolts.
Torque:
Stage 1: Tighten bolt 3 to: : 89 lb.in (10 Nm)

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Stage 2: Tighten bolt 1 to: : 89 lb.in (10 Nm)
Stage 3: Tighten bolts 2, 4, 5 and 6 to: : 89 lb.in (10 Nm)

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72. Position the engine wire harness and install the bolts.
Torque: 80 lb.in (9 Nm)
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73.
Using new gaskets, install the EGR cooler inlet tube and the bolts.
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Tighten the bolts at the exhaust manifold.

Torque: 177 lb.in (20 Nm)

Tighten the bolts at the EGR cooler.
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Torque: 89 lb.in (10 Nm)

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74.
1. Install the EGR cooler inlet tube bracket and hand start the bolts.
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2. Install the bolt.

Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °
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3. Tighten the bolt.

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Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °
4. Tighten the bolt.
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Torque:
Stage 1: 89 lb.in (10 Nm)
Stage 2: 45 °
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75. Connect the electrical connector and the vacuum tubes to the EGR bypass valve solenoid. Attach the wire harness retainer.
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76. Connect the EGR valve electrical connector and the wire harness retainer.
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77. Install new O-ring seals on the oil level indicator tube and lubricate with clean engine oil.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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78. Install the oil level indicator tube.

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79. Install a new O-ring seal on the oil fill pipe and lubricate with clean engine oil.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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80. Install the oil fill pipe and the bolt.

Torque: 89 lb.in (10 Nm)
81. If equipped, install the LH sound shield and the push pins.

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82. If equipped, install the RH sound shield and the push pins.
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83. Install the stator standoffs.

Torque: 17 lb.ft (23 Nm)
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84. NOTE: Only one tube shown.
Install the new transmission oil cooler coolant tube O-ring seals and lubricate with clean engine coolant.
Refer to: Specifications (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Specifications).
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85. Install the transmission oil cooler coolant tube and the stud bolt.
Torque: 89 lb.in (10 Nm)
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86. Install the transmission oil cooler coolant tube, the bolt and the nut.
Torque:
Nut : 115 lb.in (13 Nm)
Bolt : 89 lb.in (10 Nm) co
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87. Connect the engine vacuum hose at the tee.

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88.
1. Install the power steering pump mounting bracket and the bolts.
Torque: 18 lb.ft (25 Nm)
2. Install the remaining bolts.
Torque: 18 lb.ft (25 Nm)
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89. If equipped with dual generator, install the idler pulley.

Torque: 35 lb.ft (48 Nm)

90. Install the cooling fan drive assembly, the engine lifting bracket and the bolts.
Use Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.

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Torque: 18 lb.ft (25 Nm)

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91. NOTE: Dual generator shown, single generator similar.

Install the secondary coolant pump assembly and the bolts.
Torque: 18 lb.ft (25 Nm)
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92. If equipped with dual generator, connect the wire harness retainer.
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93. Install the accessory drive belt tensioner and the bolt.
Torque: 35 lb.ft (48 Nm)
94. Install the A/C compressor and the bolts.
Torque: 18 lb.ft (25 Nm)

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95. Install the battery wire harness, the coolant hoses and the nuts.
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Torque: 106 lb.in (12 Nm)

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96. Position back the battery wire harness and coolant tube. Install the nuts.
Torque: 106 lb.in (12 Nm)
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97. Connect the A/C electrical connectors and the wire retainer.
98. Connect the A/C pressure switch electrical connector.

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99. Position back the RH ground cable and install the bolt.
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Torque: 18 lb.ft (25 Nm)

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100.
Position back the battery wire harness and install the nut.
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Torque: 106 lb.in (12 Nm)

Connect the electrical connectors.
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101. Connect the heater hose and install the clip.

102. Connect the transmission oil cooler coolant hose.

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103. Position back the LH ground cable and install the bolt.
Torque: 18 lb.ft (25 Nm)
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104. Install the bolts for the battery wire harness.

Torque: 106 lb.in (12 Nm)
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105. Connect the battery wire harness retainer to the bracket.

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106.
Position back the cable and install the nut. Position back the boot.
Torque: 159 lb.in (18 Nm)
Connect the generator electrical connector.
107. If equipped with single generator, install the accessory drive belt.

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108. If equipped with dual generator, install the accessory drive belt.
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109. Install the coolant engine fill hose.
Use the General Equipment: Hose Clamp Remover/Installer
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110. Install the lower radiator hose and install the clip.
111. Connect the coolant hose and install the clip.

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112. Using the special tools, install the cooling fan assembly.
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Use Special Service Tool: 205-036 (T70P-4067-A) Wrench. , 303-214 (T83T-6312-B) Wrench, Fan Clutch Nut.
Torque: 98 lb.ft (133 Nm)
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113.
Install the fan clutch electrical connector bolt.
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Torque: 18 lb.ft (25 Nm)

Connect the fan clutch electrical connector and the retainer.
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114. NOTICE: Do not tighten the engine mount bracket bolts more than 90 degrees after initial torque or damage to the bolts may occur.
NOTICE: Clean the engine mount mating surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in
engine mount bracket or engine mount damage.
NOTE: Place a visible mark on the engine mount bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.
Install the RH engine mount bracket and the new bolts.
Torque:
Stage 1: 41 lb.ft (55 Nm)
Stage 2: 60 °
115. NOTICE: Do not tighten the engine mount bracket bolts more than 90 degrees after initial torque or damage to the bolts may occur.
NOTICE: Clean the engine mount mating surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in
engine mount bracket or engine mount damage.
NOTE: Place a visible mark on the engine mount bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.
Install the LH engine mount bracket and the new bolts.
Torque:

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Stage 1: 41 lb.ft (55 Nm)
Stage 2: 60 °

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116. Using the Floor Crane and a ratchet strap, remove the engine from the wooden blocks.
Use the General Equipment: Floor Crane
NOTE: The following steps are done on the body before the engine is installed.
117. Remove the CAC.
Refer to: Charge Air Cooler (CAC) (303-12B Intake Air Distribution and Filtering - 6.7L Power Stroke Diesel, Removal and Installation).
118. Flush the CAC and the CAC tubes with Simple Green® Pro HD.
Refer to: Charge Air Cooler (CAC) Cleaning (303-12B Intake Air Distribution and Filtering - 6.7L Power Stroke Diesel, General Procedures).
119. Install the CAC.
Refer to: Charge Air Cooler (CAC) (303-12B Intake Air Distribution and Filtering - 6.7L Power Stroke Diesel, Removal and Installation).
120. NOTE: Ensure the fuel is free of contaminants.
Replace the fuel filter.
Refer to: Fuel Filter (310-01B Fuel Tank and Lines - 6.7L Power Stroke Diesel, Removal and Installation).
121. Replace the TB (throttle body) gasket.
Refer to: Throttle Body (303-04B Fuel Charging and Controls - 6.7L Power Stroke Diesel, Removal and Installation).
122. Install the engine.
Refer to: Engine - Body Off (303-01B Engine - 6.7L Power Stroke Diesel, Installation).
Refer to: Engine - Body On (303-01B Engine - 6.7L Power Stroke Diesel, Installation).
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Installation

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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Installation Procedure revision date: 01/7/2020

Engine - Body OSS

pceailT (ooTs)/ G reneqlT EumictenM

303-050 (T70P-6000)
Lifting Bracket, Engine

303-1518
Bracket, Engine Removal
TKIT-2009C-F
TKIT-2009C-ROW
307-346 (T97T-7902-A)
Retainer, Torque Converter
TKIT-1998-LM (NavigatoR)
TKIT-1997-F/FLM/LT

Floor Crane
Transmission Jack
Hose Clamp Remover/Installer

NlMeqilT)

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flte pceaiSialMion
Motorcraft® Multi-Purpose Grease Spray ESB-M1C93-B
XL-5-A co
fO(ICE: Chlnge Mhe engine oiT lny Mite Mhe Mmqboahlqgeq i) qetoved Sqot Mhe engine. (he cl))lge) in Mhe bToak, ToalMed mndeqnelMh Mhe Mmqboahlqgeq, lqe
diqeaM cl))lge) Mo Mhe TmbqialMion )y)Met. Debqi) lndGoq aooTlnM tly enMeq Mhe TmbqialMion )y)Met lnd engine dltlge tly oaamq.
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fO(E: It is recommended that this component be serviced with the vehicle body removed. If the vehicle body was not removed, refer to Engine — Body On in this
section.
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fO(E: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel openings to prevent the ingress of dirt or
other contamination. Remove caps, tape and other protective materials prior to installation.
fO(E: For EXPORT ONLY vehicles (outside US/Canada), an Export Supplement is provided and should be referenced to identify differences that can impact
service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US
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EPA or CARB Regulations."

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1. fO(ICE: FliTmqe Mo in)ceaM Mhe aotconenM) Soq debqi) tly qe)mTM in qecelM SliTmqe).
fO(E: It may be necessary to use a borescope to inspect the components.
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When an engine or turbocharger is replaced due to a failure, inspect the following components for potential metal debris. If evidence of debris is found, clean or replace
the components as needed.
CAC and the CAC tubes
Intake air system
Exhaust manifolds
EGR cooler and pipes
Diesel Oxidation Catalyst (DOC)
Turbocharger (on engine failure only)
2. Remove Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.
3. fO(ICE: Rqioq Mo in)MlTTlMion oS Mhe engine, TmbqialMe Mhe Moqume aonveqMeq ciToM hmb oq dltlge Mo Mhe Moqume aonveqMeq oq Mhe engine aqlnk)hlSM aln
oaamq.
Lubricate the torque converter pilot hub with multi-purpose grease and align the paint dot on the torque converter in the 12 o'clock position.
Material: Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)

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4. fO(ICE: Dmqing in)MlTTlMion oS Mhe engine, Mhe engine oiT aooTeq xiTT cl)) veqy aTo)e Mo Mhe Sqlte aqo))tetbeq. In)MlTT Mhe engine )ToxTy, aonMinmlTTy
aheaking Mo tlke )mqe Mhe engine oiT aooTeq doe) noM hiM Mhe Sqlte aqo))tetbeq, oq aotconenM dltlge tly oaamq.
fO(E: Use caution to make sure the torque converter studs align with the holes in the flexplate while joining the engine to the transmission.
Using the floor crane and the ratchet strap, install the engine into the vehicle and join the engine to the transmission.

Use the General Equipment: Floor Crane

5. Install the RH bellhousing bolts.
Torque: 46 lb.ft (63 Nm)

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6. Install the LH bellhousing stud bolt and the bolt.

Torque: 46 lb.ft (63 Nm)
 7. Remove the transmission jack.
Use the General Equipment: Transmission Jack

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8. Install the lower engine bellhousing bolts and the stud bolt.
Torque: 46 lb.ft (63 Nm)

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9. Install the transmission heat shield and the nuts.

Torque: 80 lb.in (9 Nm)
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10.
Lower the engine into position.
Remove the ratchet strap.
Remove the floor crane.
Use the General Equipment: Floor Crane
11. Position back the valve and install the nuts.
Torque: 106 lb.in (12 Nm)

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12. Connect the electrical connector and the retainers.

13. fO(ICE: FliTmqe Mo qecTlae Mhe engine tomnM aqo)) boTM) tly qe)mTM in engine tomnM dltlge.
fO(ICE: OnTy m)e hlnd MooT) xhen in)MlTTing Mhe engine tomnM aqo)) boTM) oq dltlge Mo Mhe engine tomnM aqo)) boTM) tly oaamq.
Install the LH engine mount cross bolt.
Torque: 258 lb.ft (350 Nm)
14. fO(ICE: FliTmqe Mo qecTlae Mhe engine tomnM aqo)) boTM) tly qe)mTM in engine tomnM dltlge.
fO(ICE: OnTy m)e hlnd MooT) xhen in)MlTTing Mhe engine tomnM aqo)) boTM) oq dltlge Mo Mhe engine tomnM aqo)) boTM) tly oaamq.
Install the RH engine mount cross bolt.
Torque: 258 lb.ft (350 Nm)

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15. fO(ICE: FliTmqe Mo qecTlae Mhe Mqln)ti))ion )mccoqM in)mTlMoq nmM) tly qe)mTM in Mqln)ti))ion )mccoqM in)mTlMoq dltlge.
Remove and discard the transmission support insulator nuts.
16. Tighten the transmission support insulator studs.

Torque: 66 lb.ft (90 Nm)

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17. fO(ICE: FliTmqe Mo qecTlae Mhe Mqln)ti))ion )mccoqM in)mTlMoq nmM) tly qe)mTM in Mqln)ti))ion )mccoqM in)mTlMoq dltlge.
fO(ICE: OnTy m)e hlnd MooT) xhen in)MlTTing Mhe Mqln)ti))ion )mccoqM in)mTlMoq nmM) oq dltlge Mo Mhe Mqln)ti))ion )mccoqM in)mTlMoq tly oaamq.
Install new transmission support insulator nuts.
Torque: 85 lb.ft (115 Nm)
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18.
Remove Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.
Torque: 18 lb.ft (25 Nm)
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19. Remove Special Service Tool: 303-1518 Bracket, Engine Removal.
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20. Remove and discard the TC oil supply filter.

21. Install a new TC oil supply filter.

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22. Install a new TC mounting gasket.

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23. Install the TC and the new bolts.
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Torque:
Stage 1: 133 lb.in (15 Nm)
Stage 2: 41 lb.ft (55 Nm)
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24. Lubricate the TC coolant outlet tube O-ring with clean engine coolant. Position back the TC coolant outlet tube and install the new bolt.

Refer to: Specifications (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Specifications).
Torque:
Stage 1: 106 lb.in (12 Nm)
Stage 2: 30 °
25. fO(E: Clean all exhaust connections before assembly.
Install a new LH turbocharger inlet pipe gasket.

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26. fO(ICE: Do noM bend oq Mxi)M Mhe Mmqboahlqgeq inTeM cice) oq dltlge Mo Mhe beTTox) on Mhe Mmqboahlqgeq inTeM cice) tly oaamq.
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Install the LH turbocharger inlet pipe, the new turbocharger clamp and the new nuts.
Torque:
Stage 1: Tighten the clamp nut to: : 106 lb.in (12 Nm)
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Stage 2: Tighten the nuts to: : 18 lb.ft (25 Nm)

Stage 3: Tighten the nuts a second time to: : 18 lb.ft (25 Nm)
Stage 4: Loosen the clamp nut : 1 turn(s)
Stage 5: Tighten the clamp nut to: : 159 lb.in (18 Nm)
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27. Install the TC outlet pipe and the new clamp. Install the bolt hand tight.
Torque:
Stage 1: Tighten the clamp nut to: : 106 lb.in (12 Nm)
Stage 2: Tighten the bolt to: : 18 lb.ft (25 Nm)
Stage 3: Loosen the clamp nut : 1 turn(s)
Stage 4: Tighten the clamp nut to: : 159 lb.in (18 Nm)
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28. fO(E: Clean all exhaust connections before assembly.

Install a new RH turbocharger inlet pipe gasket.
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29. fO(ICE: Do noM bend oq Mxi)M Mhe Mmqboahlqgeq inTeM cice) oq dltlge Mo Mhe beTTox) on Mhe Mmqboahlqgeq inTeM cice) tly oaamq.
Install the RH turbocharger inlet pipe, the new turbocharger clamp and the new nuts.
Torque:
Stage 1: Tighten the clamp nut to: : 106 lb.in (12 Nm)
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Stage 2: Tighten the nuts to: : 18 lb.ft (25 Nm)
Stage 3: Tighten the nuts a second time to: : 18 lb.ft (25 Nm)
Stage 4: Loosen the clamp nut : 1 turn(s)
Stage 5: Tighten the clamp nut to: : 159 lb.in (18 Nm)
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30. Install the TC heat shield and bolts.

Torque: 89 lb.in (10 Nm)
31. Install the lower intake manifold and the bolts.
Torque: 18 lb.ft (24 Nm)

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32. Tighten the lower intake manifold clamp.

Torque: 31 lb.in (3.5 Nm)
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33. Connect the crankcase vent oil separator hose to the lower intake manifold.
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34. If removed, install the new upper intake manifold gaskets.

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35. fO(ICE: Do noM )Tide Mhe mcceq inMlke tlniSoTd laqo)) Mhe Toxeq inMlke tlniSoTd dmqing in)MlTTlMion. FliTmqe Mo SoTTox Mhi) tly qe)mTM in dltlge Mo Mhe
mcceq inMlke tlniSoTd gl)keM). co
Remove the cover or tape from the valve covers and lower intake manifold prior to installing the upper intake manifold.
Install the upper intake manifold and tighten the retainers.
Torque:
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Stage 1: Tighten bolts 1 thru 8 to: : 89 lb.in (10 Nm)
Stage 2: Tighten bolts 1 thru 8 to: : 98 °
Stage 3: Tighten bolt 9 to: : 18 lb.ft (24 Nm)
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36. Using new gaskets, install the EGR cooler outlet tube and the bolts.
Torque: 89 lb.in (10 Nm)
37. Connect the EGRT sensor electrical connector and the wire retainer.

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38. Connect the TB (throttle body) electrical connector.

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39. Position back the engine oil level indicator tube, install the nut and the bolt.
Torque: 89 lb.in (10 Nm)
40.
1. Install the EP (exhaust pressure) sensor tube assembly and nut. Tighten the EP sensor tube assembly.
Torque: 133 lb.in (15 Nm)
2. Tighten the nut.
Torque: 89 lb.in (10 Nm)
3. Tighten the EP sensor tube assembly.
Torque: 177 lb.in (20 Nm)

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41.
Connect the MAP sensor, EP sensor, EGRT sensor and the turbocharger actuator electrical connectors.
Connect the wiring harness retainers.
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42. Install the intake manifold support and the bolts.

Torque: 89 lb.in (10 Nm)
43. Position back the coolant hose and connect the retainer on the frame. Connect the coolant hose to the transmission oil cooler coolant tube.

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44. Install the new power steering tube O-ring seals.
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45. Position back the power steering hose and install the bolt.
Torque: 18 lb.ft (25 Nm)
46. Install the retainer to the power steering line bracket.
Torque: 44 lb.in (5 Nm)

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47. Install the upper radiator hose.

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48. Install the CAC outlet pipe.

49. Install the ACL (air cleaner) outlet pipe and tighten the clamp.
Torque: 44 lb.in (5 Nm)

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50. fO(ICE: FmeT in1eaMion eumictenM i) tlnmSlaMmqed Mo veqy cqeai)e MoTeqlnae) lnd Sine aTelqlnae). (o cqevenM SmeT )y)Met dltlge, iM i) e))enMilT MhlM
lb)oTmMe aTelnTine)) i) ob)eqved xhen xoqking xiMh Mhe)e aotconenM).
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Position back the fuel tubes and connect the tubes.

Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 6.7L Power Stroke Diesel) .
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51. Install the fuel tube bracket bolts to the transmission bellhousing.
Torque: 46 lb.ft (63 Nm)
52. Install the fuel tube bracket bolt.
Torque: 18 lb.ft (25 Nm)

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53. If equipped, connect the retainer for the transmission/ transfer case vent tubes.
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54. Connect the heater hose retainer to the frame. Connect the heater hose to the retainers.
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55. Install the cooling fan stator and nuts.

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Torque: 159 lb.in (18 Nm)

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56.
Install the coolant hoses and connect.
Use the General Equipment: Hose Clamp Remover/Installer
Connect the vacuum hose connectors.
Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 6.7L Power Stroke Diesel) .
57. Position back the wire harness and connect the wire retainer. Install the bracket bolt and the ground wire bolt.
Torque: 22 lb.ft (30 Nm)

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58. fO(E: Using the crankshaft pulley bolts, turn the engine clockwise.
Install the new torque converter nuts.
Torque: 41 lb.ft (55 Nm)
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59. Install the access cover and the retainers.

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60. Install the starter motor and the bolts.

Torque: 18 lb.ft (25 Nm)
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61. Position back the starter cables and install the nuts.
Torque:
Large nut : 106 lb.in (12 Nm)
Small nut : 53 lb.in (6 Nm)
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62. Install the starter cable cover.

63. If equipped, connect the block heater electrical connector.

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64. Install the exhaust downpipe and the new nuts.

Torque: 22 lb.ft (30 Nm)
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65. Tighten the clamp for the exhaust downpipe.
Torque: 41 lb.ft (55 Nm)
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66. Install the new exhaust downpipe bolts.

Torque: 26 lb.ft (35 Nm)

67. Lubricate the rubber seal with clean engine oil and install the new oil filter.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Torque:
 Stage 1: 44 lb.in (5 Nm)
Stage 2: 230 °

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68. Fill the engine with the correct engine oil for the climate.
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Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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fO(E: Carry out the following 4 steps if installing a new engine, long block or short block to remove any contaminants from the radiator and heater core.
69. Remove the primary cooling system radiator.

Refer to: Radiator (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Removal and Installation).
70. fO(ICE: 3ldilMoq inMeqnlT cqe))mqe tm)M noM e8aeed P20 kRl sHw c)i/. Dltlge Mo Mhe qldilMoq aln qe)mTM.
fO(E: Dispose of old coolant and flushing water contaminated with antifreeze and cleaning chemicals in accordance with local, state or federal laws.
Backflush the radiator using a garden hose with the radiator rotated so the lower radiator hose location is at the top.
Use a garden hose in the lower hose location and backflush.
71. fO(ICE: jelMeq aoqe inMeqnlT cqe))mqe tm)M noM e8aeed P20 kRl sHw c)i/. Dltlge Mo Mhe helMeq aoqe aln qe)mTM.
fO(E: Dispose of old coolant and flushing water contaminated with antifreeze and cleaning chemicals in accordance with local, state or federal laws.
Backflush the heater core using a garden hose in the heater core outlet hose.

72. Install the primary cooling system radiator.

Refer to: Radiator (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Removal and Installation).
73. Install the following items:
1. Install the body.
Refer to: Body - 6.7L Power Stroke Diesel (502-02 Full Frame and Body Mounting, Removal and Installation).
2. Install the transmission fluid cooler.
Refer to: Transmission Fluid Cooler - 6.7L Power Stroke Diesel (307-02 Transmission Cooling - 6.7L Power Stroke Diesel) .
74. Bleed the fuel system.

Refer to: Fuel System Bleeding (310-00B Fuel System - General Information - 6.7L Power Stroke Diesel, General Procedures).
75. Start the engine and check the exhaust for leaks.

76. Check the transmission fluid level.

Refer to: Transmission Fluid Level Check (307-01B Automatic Transmission, Transfer Case and Power Transfer Unit - 10-Speed Automatic Transmission – 10R140,
General Procedures).

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303-01B Engine - 6.7L Power Stroke Diesel 2020 F-250-550 Super Duty
Installation Procedure revision date: 01/7/2020

Engine - Body On
Special Tool(s) / General Equipment

205-036 (T70P-4067-A)
Wrench

303-050 (T70P-6000)
Lifting Bracket, Engine

303-1518
Bracket, Engine Removal
TKIT-2009C-F
TKIT-2009C-ROW
303-214 (T83T-6312-B)
Wrench, Fan Clutch Nut

307-346 (T97T-7902-A)
Retainer, Torque Converter

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TKIT-1998-LM (NavigatoR)
TKIT-1997-F/FLM/LT

Floor Crane
Transmission Jack
Hose Clamp Remover/Installer
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Materials

Name Specification
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Motorcraft® Multi-Purpose Grease Spray ESB-M1C93-B

XL-5-A
Motorcraft® PAG Refrigerant Compressor Oil WSH-M1C231-B
YN-12-D
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NOTICE: Change the engine oil any time the turbocharger is removed from the engine. The passages in the block, located underneath the turbocharger, are
direct passages to the lubrication system. Debris and/or coolant may enter the lubrication system and engine damage may occur.
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NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body was removed, refer to Engine — Body Off in this section.
NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel openings to prevent the ingress of dirt or
other contamination. Remove caps, tape and other protective materials prior to installation.
NOTE: For EXPORT ONLY vehicles (outside US/Canada), an Export Supplement is provided and should be referenced to identify differences that can impact
service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US
EPA or CARB Regulations."
NOTE: Carry out the following 5 steps if installing a new engine, long block or short block to remove any contaminants from the radiator and heater core.
1. NOTICE: Failure to inspect the components for debris may result in repeat failures.
NOTE: It may be necessary to use a borescope to inspect the components.
When an engine or turbocharger is replaced due to a failure, inspect the following components for potential metal debris. If evidence of debris is found, clean or replace
the components as needed.
CAC and the CAC tubes
Intake air system
Exhaust manifolds
EGR cooler and pipes
Diesel Oxidation Catalyst (DOC)
Turbocharger (on engine failure only)
2. Remove the primary cooling system radiator.

Refer to: Radiator (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Removal and Installation).
3. NOTICE: Radiator internal pressure must not exceed 138 kPa (20 psi). Damage to the radiator can result.
NOTE: Dispose of old coolant and flushing water contaminated with antifreeze and cleaning chemicals in accordance with local, state or federal laws.
 Backflush the radiator using a garden hose with the radiator rotated so the lower radiator hose location is at the top.
Use a garden hose in the lower hose location and backflush.
4. NOTICE: Heater core internal pressure must not exceed 138 kPa (20 psi). Damage to the heater core can result.
NOTE: Dispose of old coolant and flushing water contaminated with antifreeze and cleaning chemicals in accordance with local, state or federal laws.
Backflush the heater core using a garden hose in the heater core outlet hose.

5. Install the primary cooling system radiator.

Refer to: Radiator (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Removal and Installation).
6. Remove Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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7. NOTICE: Prior to installation of the engine, lubricate the torque converter pilot hub or damage to the torque converter or the engine crankshaft can
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occur.
Lubricate the torque converter pilot hub with multi-purpose grease and align the paint dot on the torque converter in the 12 o'clock position.
Material: Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)
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8. NOTICE: During installation of the engine, the engine oil cooler will pass very close to the frame crossmember. Install the engine slowly, continually
checking to make sure the engine oil cooler does not hit the frame crossmember, or component damage may occur.
NOTE: Use caution to make sure the torque converter studs align with the holes in the flexplate while joining the engine to the transmission.
Position the engine in the vehicle. Allowing the engine to roll forward, install the engine.
Use the General Equipment: Floor Crane
Once the engine has cleared the crossmember. Install a ratchet strap.
Using the ratchet strap, level the engine.
Install the engine to the transmission.
 9. Install the RH bellhousing bolts.
Torque: 46 lb.ft (63 Nm)

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10. Install the LH bellhousing stud bolt and the bolt.

Torque: 46 lb.ft (63 Nm)
11. Remove the transmission jack.
Use the General Equipment: Transmission Jack
12. Install the lower engine bellhousing bolts and the stud bolt.
Torque: 46 lb.ft (63 Nm)

13.
Lower the engine into position.
Remove the ratchet strap.
Remove the floor crane.

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Use the General Equipment: Floor Crane

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14. Install the transmission heat shield and the nuts.

Torque: 80 lb.in (9 Nm)

15. Position back the valve and install the nuts.

Torque: 106 lb.in (12 Nm)
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16. Connect the electrical connector and the retainers.

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17. NOTICE: Failure to replace the engine mount cross bolts may result in engine mount damage.
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NOTICE: Only use hand tools when installing the engine mount cross bolts or damage to the engine mount cross bolts may occur.
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Install the LH engine mount cross bolt.

Torque: 258 lb.ft (350 Nm)
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18. NOTICE: Failure to replace the engine mount cross bolts may result in engine mount damage.
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NOTICE: Only use hand tools when installing the engine mount cross bolts or damage to the engine mount cross bolts may occur.
Install the RH engine mount cross bolt.
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Torque: 258 lb.ft (350 Nm)

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19. NOTICE: Failure to replace the transmission support insulator nuts may result in transmission support insulator damage.
Remove and discard the transmission support insulator nuts.
20. Tighten the transmission support insulator studs.

Torque: 66 lb.ft (90 Nm)

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21. NOTICE: Failure to replace the transmission support insulator nuts may result in transmission support insulator damage.
NOTICE: Only use hand tools when installing the transmission support insulator nuts or damage to the transmission support insulator may occur.
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Install new transmission support insulator nuts.
Torque: 85 lb.ft (115 Nm)
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22.
Remove Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.
Torque: 18 lb.ft (25 Nm)
23. Remove Special Service Tool: 303-1518 Bracket, Engine Removal.

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24. Install new O-ring seals on the oil level indicator tube and lubricate with clean engine oil.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
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25. NOTE: Verify that the oil level indicator tube is bottomed in the engine rear cover.
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Install the oil level indicator tube.
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26. NOTE: Using the crankshaft pulley bolts, turn the engine clockwise.
Install the new torque converter nuts.
Torque: 41 lb.ft (55 Nm)
27. Install the access cover and the retainers.

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28. Install the starter motor.

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Refer to: Starter Motor (303-06B Starting System - 6.7L Power Stroke Diesel, Removal and Installation).
29. If equipped, connect the block heater electrical connector.
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30. Lubricate the rubber seal with clean engine oil and install the new oil filter.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
Torque:
Stage 1: 44 lb.in (5 Nm)
Stage 2: 230 °
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31. Remove and discard the TC oil supply filter.

32. Install a new TC oil supply filter.

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33. Install a new TC mounting gasket.

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34. Install the TC and the new bolts.

Torque:
Stage 1: 133 lb.in (15 Nm)
Stage 2: 41 lb.ft (55 Nm)
35. Connect the TC actuator electrical connector.

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36. Install a new O-ring seal on the heater supply tube and lubricate with clean engine coolant.
Refer to: Specifications (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Specifications).
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37. Install the heater supply tube and the bolts.
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Torque: 89 lb.in (10 Nm)
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38. Lubricate the O-ring with clean engine coolant. Position back the TC coolant outlet tube and install the new bolt.

Refer to: Specifications (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Specifications).
Torque:
Stage 1: 106 lb.in (12 Nm)
Stage 2: 30 °
39. NOTE: Clean all exhaust connections before assembly.
Install a new LH turbocharger inlet pipe gasket.

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40. NOTICE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.
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Install the LH turbocharger inlet pipe, the new turbocharger clamp and the new nuts.
Torque:
Stage 1: Tighten the clamp nut to: : 106 lb.in (12 Nm)
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Stage 2: Tighten the nuts to: : 18 lb.ft (25 Nm)

Stage 3: Tighten the nuts a second time to: : 18 lb.ft (25 Nm)
Stage 4: Loosen the clamp nut : 1 turn(s)
Stage 5: Tighten the clamp nut to: : 159 lb.in (18 Nm)
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41. Install the exhaust downpipe.

42. NOTE: Clean all exhaust connections before assembly.

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Install a new RH turbocharger inlet pipe gasket.
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43. NOTICE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.
Install the RH turbocharger inlet pipe, the new turbocharger clamp and the new nuts.
Torque:
Stage 1: Tighten the clamp nut to: : 106 lb.in (12 Nm)
Stage 2: Tighten the nuts to: : 18 lb.ft (25 Nm)
Stage 3: Tighten the nuts a second time to: : 18 lb.ft (25 Nm)
Stage 4: Loosen the clamp nut : 1 turn(s)
Stage 5: Tighten the clamp nut to: : 159 lb.in (18 Nm)
44. Install the TC heat shield and bolts.
Torque: 89 lb.in (10 Nm)

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45. Install the lower intake manifold and the bolts.

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Torque: 18 lb.ft (24 Nm)

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46. Tighten the lower intake manifold clamp.
Torque: 31 lb.in (3.5 Nm)
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47. Install the crankcase vent oil separator.

Refer to: Crankcase Vent Oil Separator (303-08B Engine Emission Control - 6.7L Power Stroke Diesel, Removal and Installation).
48. If removed, install the new upper intake manifold gaskets.
49. NOTICE: Do not slide the upper intake manifold across the lower intake manifold during installation. Failure to follow this may result in damage to the
upper intake manifold gaskets.

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Remove the cover or tape from the valve covers and lower intake manifold prior to installing the upper intake manifold.
Install the upper intake manifold and tighten the retainers.
Torque:
Stage 1: Tighten bolts 1 thru 8 to: : 89 lb.in (10 Nm)
Stage 2: Tighten bolts 1 thru 8 to: : 98 °
Stage 3: Tighten bolt 9 to: : 18 lb.ft (24 Nm)
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50. Connect the TB (throttle body) electrical connector.

51. Install the EGR cooler.

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Refer to: Exhaust Gas Recirculation (EGR) Cooler (303-08B Engine Emission Control - 6.7L Power Stroke Diesel, Removal and Installation).
52. Position back the engine oil level indicator tube, install the nut and the bolt.
Torque: 89 lb.in (10 Nm) co
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53.
1. Install the EP (exhaust pressure) sensor tube assembly and nut. Tighten the EP sensor tube assembly.
Torque: 133 lb.in (15 Nm)
2. Tighten the nut.
Torque: 89 lb.in (10 Nm)
3. Tighten the EP sensor tube assembly.
Torque: 177 lb.in (20 Nm)
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54.
Connect the MAP sensor, EP sensor and the EGRT sensor electrical connectors.
Connect the wiring harness retainers.
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55. Install the intake manifold support and the bolts.

Torque: 89 lb.in (10 Nm)
56. Connect the heater hose at the heater supply tube.

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57. Connect the heater hose retainer to the frame. Connect the heater hose to the retainers.
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58. Connect the heater hose.

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59. NOTICE: Only use the specified material to lubricate the seals.
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Install a new O-ring seal and lubricate with clean PAG refrigerant oil.
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Material: Motorcraft® PAG Refrigerant Compressor Oil / YN-12-D (WSH-M1C231-B)
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60. Position the evaporator-to-compressor suction tube fitting and install the nut.
Torque: 159 lb.in (18 Nm)
61. Install the PCM and the nuts.
Torque: 80 lb.in (9 Nm)

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62. Install the PCM cover.

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63.
Position the wire harnesses back and connect the retainers.
Install the ground cable nut.
Torque: 106 lb.in (12 Nm)
64.
Position back the wire harness and connect the retainer.
Connect the PCM electrical connectors and the electrical connector.

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Position back and connect the PCM electrical connector and the electrical connectors.
Connect the retainer.
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66. Position back the wire harness and connect the retainer. Install the bracket bolt and the ground wire bolt.
Torque: 22 lb.ft (30 Nm)
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67.
If equipped with dual generators, connect the electrical connector.
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Position back the harness and install the nut

Torque: 106 lb.in (12 Nm)
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68.
Position back the battery harness and install the bolt.
Torque: 106 lb.in (12 Nm)
Connect the electrical connectors and the harness retainer.
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69.
Connect the cable to the power distribution box and install the nut.
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Torque: 106 lb.in (12 Nm)

Connect the cable to the battery harness and install the nut.
Torque: 80 lb.in (9 Nm)
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70.
Install the power distribution cover.
Position back the battery cable cover.
71. Position back the ground strap and install the retainer.
Torque: 106 lb.in (12 Nm)

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72. NOTICE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that
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absolute cleanliness is observed when working with these components.

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Position back the fuel tubes and connect the tubes.

Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 6.7L Power Stroke Diesel) .
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73. Install the fuel tube bracket bolts to the transmission bellhousing.
Torque: 46 lb.ft (63 Nm)
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74. If equipped, connect the retainer for the transmission/ transfer case vent tubes.
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75. Install the lower radiator hose and install the clip.
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76. Connect the coolant hose and install the clip.

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77. Position back the lower radiator hose and install the bolts.
Torque: 80 lb.in (9 Nm)
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78. Position back the coolant hose and connect the retainer on the frame. Connect the coolant hose to the transmission oil cooler coolant tube.

79. Position back the power steering pump and bolts.

Torque: 18 lb.ft (25 Nm)
80. Install the retainer to the power steering line bracket.
Torque: 44 lb.in (5 Nm)

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81. Install the upper radiator hose.
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82. If equipped with single generator, install the accessory drive belt.

83. If equipped with dual generator, install the accessory drive belt.
84. Using the special tools, install the fan clutch.
Use Special Service Tool: 205-036 (T70P-4067-A) Wrench. , 303-214 (T83T-6312-B) Wrench, Fan Clutch Nut.
Torque: 98 lb.ft (133 Nm)

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Install the fan clutch electrical connector bolt.

Torque: 18 lb.ft (25 Nm)
Connect the fan clutch electrical connector and the retainer.
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86. Install the cooling fan stator and nuts.

Torque: 159 lb.in (18 Nm)
87.
Position back the coolant hoses and connect.
Use the General Equipment: Hose Clamp Remover/Installer
Connect the vacuum hose connector.
Refer to: Quick Release Coupling (310-00 Fuel System - General Information - 6.7L Power Stroke Diesel) .

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88. Fill the engine with the correct engine oil for the climate.
Refer to: Specifications (303-01B Engine - 6.7L Power Stroke Diesel, Specifications).
89. Install the following items:
1. Install the cowl panel grille
Refer to: Cowl Panel Grille (501-02 Front End Body Panels, Removal and Installation).
2. Install the RH and LH battery trays.
Refer to: Battery Tray (414-01 Battery, Mounting and Cables, Removal and Installation).
3. Install the CAC
Refer to: Charge Air Cooler (CAC) (303-12B Intake Air Distribution and Filtering - 6.7L Power Stroke Diesel, Removal and Installation).
4. Install the CAC outlet pipe.

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Refer to: Charge Air Cooler (CAC) (303-12B Intake Air Distribution and Filtering - 6.7L Power Stroke Diesel, Removal and Installation).
5. Install the CAC intake pipe.
Refer to: Charge Air Cooler (CAC) (303-12B Intake Air Distribution and Filtering - 6.7L Power Stroke Diesel, Removal and Installation).
6. Install the cooling module.

90. Bleed the fuel system.

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Refer to: Cooling Module (303-03B Engine Cooling - 6.7L Power Stroke Diesel, Removal and Installation).

Refer to: Fuel System Bleeding (310-00B Fuel System - General Information - 6.7L Power Stroke Diesel, General Procedures).
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91. Start the engine and check the exhaust for leaks.
92. Check the transmission fluid level.
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Refer to: Transmission Fluid Level Check (307-01B Automatic Transmission, Transfer Case and Power Transfer Unit - 10-Speed Automatic Transmission – 10R140,
General Procedures).
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