303-04C-1 303-04C-1Fuel Charging and Controls — 6.0L Diesel

REMOVAL AND INSTALLATION

Oil Pump — Early Build

Special Tool(s)

Disconnect Tool, Quick ReleaseCoupling303-755

Dial Indicator with Bracketry100-002 (TOOL-4201-C) orequivalent

4. Remove the turbocharger heat shield.

Material

Item Specification

RTV Silicone Sealant -F5TZ-19G204-AB

Removal

1. Remove the intake manifold. For additional

information, refer to Section 303-01C.5. Remove the bolts and the high-pressure oil

2. Remove the turbocharger adapter pipe. 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 CompanyLast updated: 1/28/2004 2004 Excursion, F-Super Duty 250-550, 12/2004

303-04C-2 303-04C-2Fuel Charging and Controls — 6.0L Diesel

REMOVAL AND INSTALLATION (Continued)

6. Position the dial indicator with bracketry onto 9. Remove and discard the high-pressure pump

the oil pump drive and check the oil pump O-ring seal.

drive gear backlash.

10. Remove the bolts and the high-pressure oil

7. Remove the bolts from the high-pressure oil pump.

pump discharge pipe.

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-3 303-04C-3Fuel Charging and Controls — 6.0L Diesel

REMOVAL AND INSTALLATION (Continued)

Installation 4. Install the oil pump discharge pipe.

1. Install a new lower O-ring seal.

5. Install the bolts for the oil discharge pipe.

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

6. Position the dial indicator with bracketry onto

the oil pump drive and check the oil pump

drive gear backlash.3. Install the high-pressure pump O-ring seal.

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

303-04C-4 303-04C-4Fuel Charging and Controls — 6.0L Diesel

REMOVAL AND INSTALLATION (Continued)

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

discharge pipe.

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-5 303-04C-5Fuel Charging and Controls — 6.0L Diesel

REMOVAL AND INSTALLATION (Continued)

13. NOTE: Do not tighten the nuts and bolts until 14. Release and position the turbocharger outlet

after the turbocharger is installed and attached. pipe.

Loosely install the nuts and bolts in the adapter

pipe.

15. Install the intake manifold. For additional

information, refer to Section 303-01C.

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