303-04C-1

Fuel Charging and Controls 6.0L Diesel

303-04C-1

REMOVAL AND INSTALLATION

Oil Pump Early Build
Special Tool(s) Disconnect Tool, Quick Release Coupling 303-755

Dial Indicator with Bracketry 100-002 (TOOL-4201-C) or equivalent

4.

Remove the turbocharger heat shield.

Material Item RTV Silicone Sealant F5TZ-19G204-AB Specification -

Removal
1. Remove the intake manifold. For additional information, refer to Section 303-01C. 5. 2. Remove the turbocharger adapter pipe. Remove the bolts and the high-pressure oil pump cover. Use a thin gasket scraper to separate the cover from the crankcase. Remove and discard the press-in-place gasket.

3.

Secure the turbocharger outlet pipe.

Copyright 2003, Ford Motor Company

Last updated: 1/28/2004

2004 Excursion, F-Super Duty 250-550, 12/2004

303-04C-2

Fuel Charging and Controls 6.0L Diesel

303-04C-2

REMOVAL AND INSTALLATION (Continued)

6. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash. 9. Remove and discard the high-pressure pump O-ring seal.

7.

Remove the bolts from the high-pressure oil pump discharge pipe.

10. Remove the bolts and the high-pressure oil pump.

11. Remove and discard the lower O-ring seal. 8. Using the special tool, disconnect and remove the high-pressure oil pump discharge pipe. Remove and discard the D-shaped O-ring seal.

2004 Excursion, F-Super Duty 250-550, 12/2004

303-04C-3

Fuel Charging and Controls 6.0L Diesel

303-04C-3

REMOVAL AND INSTALLATION (Continued)

Installation 1. Install a new lower O-ring seal. 4. Install the oil pump discharge pipe.

5. 2. Install the high-pressure oil pump and bolts.

Install the bolts for the oil discharge pipe.

6. 3. Install the high-pressure pump O-ring seal.

Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.

2004 Excursion, F-Super Duty 250-550, 12/2004

303-04C-4

Fuel Charging and Controls 6.0L Diesel

303-04C-4

REMOVAL AND INSTALLATION (Continued)

7. Install a new D-ring seal on the high-pressure discharge pipe. 10. Install the high-pressure pump cover and bolts.

11. Install the turbocharger heat shield. 8. Install a new press-in-place gasket in the high-pressure pump cover.

12. Position the turbocharger adapter pipe. 9. Clean the cover mounting surface and apply sealer at the seams.

2004 Excursion, F-Super Duty 250-550, 12/2004

303-04C-5

Fuel Charging and Controls 6.0L Diesel

303-04C-5

REMOVAL AND INSTALLATION (Continued)

13. NOTE: Do not tighten the nuts and bolts until after the turbocharger is installed and attached. Loosely install the nuts and bolts in the adapter pipe. 14. Release and position the turbocharger outlet pipe.

15. Install the intake manifold. For additional information, refer to Section 303-01C.

2004 Excursion, F-Super Duty 250-550, 12/2004