1. Disconnect both battery ground cables. Loosen the clamps and remove the air cleaner outlet tube.
2. Remove the air intake tube and adapter. Loosen the air intake tube clamp. See Fig. 5.
Remove the air intake tube adapter bolts. Lift the tube and adapter, disconnect the wastegate pressure hose, and remove the tube and adapter from the vehicle.
3. Partially drain the cooling system. See COOLING SYSTEM BLEEDING. Remove the wing bolt and lug wrench. Squeeze the clamp and remove the overflow hose.
4. Remove the degas bottle retaining bolts. See Fig. 6. Squeeze the clamp and remove the degas bottle supply hose. Remove the degas bottle.
5. On vehicles equipped with A/C, recover the refrigerant. Discharge A/C system, using approved refrigerant recovery/recycling equipment. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.
6. Remove the radiator grille, and the radiator grille opening panel. See RADIATOR GRILLE (EXCURSION & “F” SERIES). Remove the bolts and position the hood latch aside. Remove the right side air deflector push pins. See Fig. 7.
7. Remove the air charge cooler retainers. See Fig. 8. Remove the radiator bolts and the brackets. See Fig. 9. Detach the battery cable retainers and position the battery cables aside.
8. Remove the 8 radiator upper support bolts and the radiator upper support. See Fig. 10. Remove the radiator sight shield. See Fig. 11.
9. On vehicles equipped with A/C, disconnect the A/C condenser core inlet and outlet tubes. See Fig. 12. Remove the A/C condenser.
10. On all vehicles, loosen the inlet and outlet duct clamps and remove the inlet and outlet ducts from the charge air cooler. See Fig. 13. Detach the ducts from the air charge cooler.
11. Remove the air charge cooler. Disconnect the upper radiator hose from the radiator.
Remove the bolts and position the fan shroud on the fan. See Fig. 14.
12. Raise and support the vehicle. Disconnect the degas supply and lower radiator hoses from the radiator. Lower the vehicle. Remove the radiator and fan shroud.
13. Using the Fan Pulley Holding Wrench (303-478, T94T-6312-AH) and Fan Clutch Nut Wrench (303-214, T83T- 6312-B), remove the fan and the fan clutch from the water pump pulley. Rotate the belt tensioner counterclockwise and remove the drive belt.
14. Disconnect the Manifold Absolute Pressure (MAP) sensor hose from the turbocharger compressor manifold. See Fig. 15. Remove the engine ground cable from the right side of the engine block. Remove the ground cable nut. See Fig. 16. Remove the starter wire retaining bracket. Remove the engine ground cable.
15. On vehicles equipped with A/C, disconnect the A/C compressor electrical connector.
Disconnect the A/C manifold from the A/C compressor.
16. On all vehicles, disconnect the power steering hoses from power steering pump. Disconnect the generator electrical connectors.
17. Remove the generator mounting bracket bolts. See Fig. 17. Remove the generator mounting bracket. Remove the bolt from the left front of the engine block. See Fig. 18.
18. Disconnect the engine control sensor wiring electrical connector. See Fig. 19.
19. On vehicles equipped with dual generators, disconnect the lower generator electrical connectors.
20. Remove the fusible link retaining nuts. See Fig. 20. Disconnect the cable and the fusible link. Disconnect the ground strap. See Fig. 21. Disconnect the heater return hose. See Fig 22.
21. Disconnect the heater supply hose. See Fig. 23. Remove the turbocharger. See TURBOCHARGER. Using the Fuel Line Tool (310-5039, T90T-9550-S), disconnect the fuel lines. See Fig. 24.
22. Remove the fuel line retaining bolt. See Fig. 25. Remove the idler pulley bolt and remove the idler pulley. See Fig. 26.
23. Remove the nuts and position the glow plug and intake air heater relays aside. See Fig. 27.
Remove the bolts and the water outlet tube. See Fig. 28. Install 2 engine lift adapters. See Fig. 29. Install the Lifting Eye (303-D099, D94T-6000-C) on the right side cylinder head. See Fig. 30.
24. On vehicles equipped with an automatic transmission, raise and support the vehicle.
Disconnect the starter electrical connector nuts. See Fig. 31. Remove the battery cable.
Remove the starter solenoid wire.
25. Remove the 3 bolts and the starter. See Fig. 32. Remove the torque converter housing cover. Mark one stud and the flex plate for assembly reference and remove the torque converter-to-flex plate nuts.
26. On vehicles equipped with manual transmissions, remove the transmission. See CLUTCHES article for 2002 models or MANUAL TRANSMISSION for 2003 models.
27. On all vehicles, remove the oil filter and disconnect the block heater electrical connector. See Fig. 33. Remove the engine mount nuts. See Fig. 34.
28. On vehicles equipped with an automatic transmission. Remove the transmission-to-engine bolts. Lower the vehicle. Use a wood block and a suitable jack to support the transmission.
See Fig. 35. Remove the transmission oil level indicator tube. See Fig. 36.
29. On all vehicles, install the Heavy Duty Floor Crane (014-00071) and the Diesel Engine Lifting Bracket (303- D043, D83T-6000-B) on the engine. See Fig. 37. Raise the engine high enough to clear the No. 1 crossmember and pull the engine forward out of the vehicle.
Remove the engine lifting equipment from the engine.
1. Remove the power steering reservoir cap. Check the fluid level. Raise the front wheels off the floor. Tightly insert the stopper of the Vacuum Pump Kit (416-D002, D95L-7559-A) into the reservoir. See Fig. 4.
2. Apply and maintain maximum vacuum. Cycle the steering wheel fully to the left and right 10 times. Release the vacuum and remove the vacuum pump.
3. Fill the power steering reservoir. Start the engine. Reinstall the vacuum pump. Apply and maintain maximum vacuum.
4. Cycle the steering wheel fully to the left and right 10 times. Stop the engine, release the vacuum, and remove the vacuum pump.
5. Lower the vehicle. Install the power steering reservoir cap. Check for fluid leaks at all of the connections. If the power steering fluid shows signs of air, repeat this procedure.
1. Release the pressure in the cooling system. Make sure the engine is cool. Wrap a thick cloth around the coolant pressure relief cap on the coolant reservoir. Slowly turn the cap counterclockwise (left) until the pressure begins to release. Step back while the pressure releases. When you are sure all the pressure has been released, use the cloth to turn and remove the cap.
2. Place a suitable container below the radiator draincock. If equipped, disconnect the coolant return hose at the oil cooler.
3. Open the radiator draincock. Remove the cylinder drain plug, if equipped, and drain the coolant from the cylinder block into a suitable container.
4. When the coolant is drained, make sure drain plugs are installed and tight.
5. Close the radiator draincock when finished.
1. Add the correct engine coolant mixture to the degas bottle.
2. Move the temperature blend selector to the full warm position.
3. Run the engine until it reaches operating temperature.
4. Add the proper engine coolant mixture to the degas bottle until the coolant level is between the “COOLANT FILL LEVEL” marks.
5. Turn off the engine and allow the cooling system to cool.
6. Repeat steps 1-5 until the degas bottle level is okay.
1. Select the maximum heater temperature and blower motor speed settings.
2. Position the control to discharge air at A/C vents in instrument panel.
3. Start the engine and allow to idle. While engine is idling, feel for hot air at A/C vents.
4. Shut the engine off and allow to cool.
5. Check the engine for coolant leaks.
6. Check the engine coolant level in degas bottle and fill as necessary.
The 7.3L diesel engine is a 4-cycle turbo-charged V-8 with overhead valves, separated into 2 banks. The right bank cylinders are numbered 1, 3, 5, 7 and the left bank cylinders are numbered 2, 4, 6, 8. On “F” series models, the 7.3L diesel engine is rated at 250 horsepower for automatic transmission and 275 horsepower for manual transmission. On “E” series models the 7.3L diesel engine is rated at 215 horsepower.
The cylinder block has been designed to withstand the loads of diesel operations by using 4 bolt main bearing caps, internal piston cooling oil jets, a forged steel crankshaft and heavy-duty forged steel connecting rods.
The pistons are made of aluminum alloy, fitted with an upper keystone compression ring, a lower rectangular compression ring and oil control rings.
The piston pins are a free-floating type permitting the piston pin to move/float freely in the piston pin bore. Piston pins are retained in the piston and rings by piston pin retainers.
On “F” series and Excursion models, the camshaft is a roller design. On all models the camshaft is supported by 5 insert-type camshaft bearings and driven by the crankshaft through the use of the crankshaft gear and the camshaft gear.
HYDRAULIC VALVE TAPPETS
The hydraulic valve tappets minimize engine noise by maintaining zero valve lash. The hydraulic valve tappets incorporate camshaft follower guides and a roller follower design that reduces camshaft wear.
The cylinder heads are designed with integral high pressure oil galleries to incorporate electronically controlled/hydraulically actuated fuel injectors. The fuel injectors are located in the center of the combustion chambers between the rocker arms.
GLOW PLUG SYSTEM
The glow plug system is mounted directly into the cylinder heads, controlled by the Engine Control Module (ECM) and designed to preheat the cylinders for faster cold weather starts and smoke reduction.
BLOCK HEATER (OPTIONAL)
The optional block heater is designed to heat the engine coolant and oil for improved cold weather starts. The optional block heater is located near the oil filter in the oil cooler and powered by a 120-volt external power source. The optional block heater is not repairable, a NEW block heater must be installed.
FUEL INJECTION SYSTEM
The fuel injection system is controlled by the Powertrain Control Module (PCM) and utilizes an electric in-line fuel pump. The fuel circulates through a combination fuel filter, fuel heater and water separator assembly and uses 8 electronically controlled/hydraulically actuated fuel injectors. The fuel injection system maintains operating pressures between 40-65 psi (2.8-4.5 Kg/Cm ).
ENGINE LUBRICATION SYSTEM
The engine lubrication system is divided into 2 systems. The low pressure system lubricates the engine, and the high pressure system actuates the fuel injectors. The engine lubrication low pressure system maintains pressures of 0-60 psi (0-4.21 Kg/Cm ). The high pressure system maintains pressures of 600-3,000 psi (42-211 Kg/Cm ). The engine lubrication system is cooled by an engine oil cooler and utilizes an oil pressure sensor and an oil pressure regulator. For more information on low and high pressure oiling systems, see ENGINE OILING.
• The fuel injector is controlled by an extremely precise piezo electric actuator that can accomplish multiple injections per combustion event.
NOTE: Never unplug a fuel injector while the engine is running, serious engine damage could occur!
• The glow plug is used to heat the air in the cylinder.
• The glow plug utilizes a system of sending voltage through a resistance coil to create heat.
NOTE: The 6.4L glow plug is very similar to the glow plug used on the 6.0L Power Stroke® Diesel, but they are
different. The glow plugs must not be interchanged!
NOTE: The 6.4L glow plug uses a green isolator.
• The GPCM is a unit that controls the glow plugs in order to warm the air in the cylinders.
• The GPCM uses a glow plug enable signal to turn the glow plugs on for a time controlled by the ECM.
• The GPCM is capable of diagnosing a problem with one glow plug and then sending a diagnostic signal to the ECM.
• It also has the ability to turn off one glow plug if a short is detected in that circuit.
• Each bank of glow plugs is connected to the engine wiring harness via a glow plug harness, either left bank or right bank.
• The glow plug harness has four connectors that supply power to the glow plugs and seal oil from escaping through the glow plug access holes.
• The glow plug system is used to warm the air in the cylinders to enhance cold weather startability and reduce start up smoke.
• The glow plug system is ECM controlled, and powered by the GPCM.
• The ECM, which is mounted behind the engine on the passenger side cowl, uses sensor inputs to control actuators and send fueling commands to the fuel inectors.
• The ECM controls the fuel and air management system on the 6.4L Power Stroke® Diesel.
• The throttle body is operated by a stepper motor controlled by the ECM and assists with the exhaust aftertreatment system.