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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING . 2. Drain the engine oil. 3. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD. 4. Remove the evaporator core housing. For additional information refer to CLIMATE CONTROL . NOTE: Only one retainer shown. 5. Disconnect the wiring harness retainers from the studs. 6. Remove the injection control pressure (ICP) sensor. 7. If equipped, remove the nut and position the transmission fluid and indicator aside. installation. 8. Remove the bolts, stud bolts and the valve cover. Clean and inspect the valve cover gasket. Install a new gasket if necessary. 9. Remove the high pressure oil rail-to-valve cover gasket. 10. Remove the crankcase-to-head tube assembly. Remove and discard the D-ring seals. 11. Remove the bolts and the high pressure oil rail. NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing. 12. If the crankcase-to-head tube separated, using the special tool, remove the lower crankcase-to-head tube. Remove and discard the D-ring seal.

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1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. If oil pump removal is necessary, remove the timing drive components. For additional information, refer to Timing Drive Components in this section. 3. Drain the engine oil. 4. If equipped, remove the skid plate. 5. Remove the bolts in sequence shown and remove the crossmember. 6. Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the listed steps: 7. To install, reverse the removal procedure. Item 1: Front Drive Axle Assembly Removal Note 1. Position a suitable hydraulic jack under the front axle. Securely strap the jack to the axle. 2. NOTE: Rotate the steering column so the pinch bolt for the steering column coupling allows clearance for the isolator bolt. Remove the upper front axle carrier mounting bushing bolt. 3. Remove the axle shaft housing carrier bushing bolt. 4. Remove the lower front axle carrier mounting bushing bolt. 5. Partially lower the front axle assembly. Item 4: Oil Pan Removal Note 1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These may cause scratches and gouges resulting in leak paths. Use a plastic scraper to clean the sealing surfaces. Remove and discard the oil pan gasket. Clean the sealing surfaces with silicone gasket remover and m etal surface prep. Follow the directions on the packaging. Inspect the mating surfaces. Items 6-10: Oil Pump, Oil Pump Screen and Pickup Tube and Bolts Removal Note 1. Remove the three bolts, the oil pump screen and pickup tube and the spacer.

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Some 1998-2003 E-Series, 1999-2003 Super Duty, 2000-2003 Excursion, and 2000-2003 F650/750 vehicles equipped with a 7.3L Diesel engine may exhibit an oil leak at the high pressure oil pump outlet fittings and/or end plug (see Figure 1). The leak may appear to be a rear main crankshaft seal, oil pan gasket, or other engine oil leak due to the drain hole machined in the crankcase valley which allows any oil in the valley to run down the back of the engine. ACTION High pressure oil pump leaks at the outlet fittings and/or end plug can be serviced without removing the pump assembly. Replace the O-rings on the fittings and the end plug using Kit 2C3Z-9G804-AA. All three (3) O-rings should be replaced. Apply liquid thread sealer (included in the kit) prior to reinstallation. Refer to the following Service Procedure for details.

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Vehicle Application: Customer Concern: Tests/Procedures: Potential Causes: 2003 Ford F-250 Super Duty 6.0L, DIESEL, Vin P, Turbo, Eng Cfg V8 2003 Ford F-350 Super Duty 6.0L, DIESEL, Vin P, Turbo, Eng Cfg V8 No start. The engine stalled while driving. 1. Check the engine oil level in the crankcase, verify it is full and top off if needed. If the oil level is OK, monitor the oil pressure gauge on the dash when cranking. It should rise and show oil pressure. If it does not, check for a mechanical oil pump problem. 2. If the oil pressure gauge comes up when cranking, monitor the Injection Control Pressure (ICP), Injection Pressure Regulator (IPR), RPM, and FICMSYNC readings on the scanner when cranking. The ICP needs to reach 500 PSI for the engine to start. RPM should show actual engine RPM based on the camshaft position sensor and crankshaft position sensor inputs. The FICMSYNC should change to YES when cranking if the cam and crank inputs are good and the Powertrain Control Module (PCM) and Fuel Injection Control Module (FICM) are communicating. 3. If the ICP is not building, but the IPR increases to 85% cranking, suspect a faulty IPR or ICP pump. 4. If the RPM is not showing a good reading, check the camshaft position sensor and crankshaft position sensor signals with a lab scope looking for good AC voltage sine waves on each sensor. 5. If all scan data looks OK, check the fuel pressure with a mechanical gauge. The pressure should be 50-60 PSI. If not, suspect a bad fuel pump. Camshaft Position Sensor (CMP) Crankshaft Position (CKP) Sensor Low Engine Oil Fuel Pump Injection Control Pressure Pump Injection Pressure Regulator (IPR)

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Exploded View Of Intake Manifold Components Removal
All vehicles 1. Remove the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND
CABLES . 2. Remove the cooling fan stator. For additional information, refer to ENGINE COOLING . 3. Remove the degas bottle. For additional information, refer to ENGINE COOLING . 4. Disconnect the upper radiator hose.