Hey guys, Im doing an EGR delete and oil cooler replacement on my truck, I caught up a little on this wiring harness that runs over the top of the motor. Is there a way to remove it? or do I just have to work around it? In the pictures im using as reference it doesn't appear to be on the motor, so Im assuming they removed it somehow. any help would be greatly appreciated, thanks guys

 

Jimmy, I've moved your thread to the 6.0L Powerstroke Diesel forum. You're more likely to get a quicker and more accurate response here.

 

I left Mine In Yes its a PIA But you can work around it and Most Folks do Cause that Crankshaft sensor is a BEAR to get at

Pull the Injector Harness to the Side though

I Ruined a Intake gasket because of it upon removal

I already had a New Gasket for the intake manafold

So I did a Full EGR Deleate so the Cooler was gone What I found that worked GRREAT for me was I slid the intake manafold in After I got it back in I Picked up Each side of the Intake and Slid the Intake gasket in

It worked Great

 

you can pull it to the passanger side by disconnecting the cam sensor and fishing that up. its just as easy to pull it foward though and work around it and less chance of causing cam sensor connector issues

 

hey thanks for the quick response guys, I got that harness moved out of the way and was cruising for a little while haha. I have one more bolt on the turbo (of course its the one in back) that doesn't want to come loose. tried some PB blaster and that hasn't done anything, also lost 2 wrenches, broke a universal joint and a wobble. So I think im just going to wait until next week and pick up one of those fancy air ratchet wrenches haha.thanks again

 

use a17mm striped bolt extractor

 

I use a couple bungee cords and pull it out of the way. It is easy to work around that way.

 

well got a compressor air ratchet and a bunch of other stuff, unfortunately the bolt still will not move. ive tried the 17mm stripped bolt extractor and a few other tricks I found online and havnt got anywhere with it. about the only progress that has been made is the vband clamp on the exhaust side haha. but im all out of ideas on that bolt...

 

I had the same hard time with mine. Ended up soaking the bolt over night with a lot of WD-40 on it, then got a 6 point box end, about a 3 foot long pipe, big hammer. Put the wrench on the bolt, then ran the pipe on the backside of turbo, keeping pressure on the wrench with the pipe and hit it with the hammer. It did work. Needed to get new bolts for it. Now this is to say if the bolt head is still good. If not have you tried a pipe wrench trick that DieselTechRon shows on a youtube video?

6.0 Stuck/ Stripped Turbo Bolt Powerstroke - YouTube

I picked up the smallest one I could find (8 in) just in case. Also when you put the bolts back in, use a anti-seize compound. It may or may not help next time.

Hope this helps!
Mark

 

I did the same thing, used a long pipe and hit it with a hammer.

The ford directions have you unhooking the harness from the drivers side. Looks like a pain in the ***

 

Removal

Disconnect the LH and RH battery ground cables. For additional information, refer to Section 414-01 .
Remove the LH battery. For additional information, refer to Section 414-01 .
Remove the air cleaner assembly. For additional information, refer to Section 303-12 .
Remove the cooling fan-blade, clutch and shroud, 6.0L diesel engine. For additional information, refer to Section 303-03 .
Remove the upper radiator hose.

Remove the coolant reservoir. For additional information, refer to Section 303-03 .
NOTE: Engine side shown, charge air cooler side similar.

Remove the turbocharger-to-charge air cooler tube.

NOTE: Engine side shown, charge air cooler side similar.

Remove the charge air cooler-to-engine tube.

Remove the accessory drive belt.

Position the boot back and disconnect the generator B+ wire and electrical connector.

Remove the three bolts and the generator.

Remove the turbocharger and the turbocharger pedestal. For additional information, refer to Section 303-04D .
Remove the bolts and position the heater hose tube aside.
Remove and discard the O-ring.

Disconnect the manifold absolute pressure (MAP) sensor hose.

Disconnect the engine coolant vent hose.

Remove the injector driver module. For additional information, refer to Section 303-14C .
Disconnect the powertrain control module (PCM) electrical connector.

Disconnect the 12-pin and 8-pin electrical connector.

Disconnect the wiring retainer, injector pressure regulator and injector control pressure (ICP) sensor electrical connector.

Disconnect the exhaust gas recirculation (EGR) valve electrical connector.

Disconnect the oil pressure sensor electrical connector.

Disconnect the oil temperature sensor electrical connector.

Disconnect the throttle position (TP) control module electrical connector, if equipped.

Disconnect the throttle position (TP) sensor electrical connector.

Disconnect the pin-type retainer and water temperature sensor.

Disconnect the intake air temperature (IAT) sensor electrical connector and wiring connector.

Disconnect the exhaust backpressure sensor and retaining clip.

Disconnect the camshaft position (CMP) sensor and position the engine wiring harness aside.

NOTE: Left side shown, right side similar.

Disconnect the eight fuel injectors. Remove the nut and the fuel injector wiring harness.

Disconnect the fuel line fittings.

NOTE: It is necessary to remove the filter and drain the housing.

Remove the four bolts and the oil filter housing.

Remove the bolt and the oil filter return tube.

Remove the fuel line.
Remove the bolt, and the banjo fitting from the fuel line.
Discard the sealing washers and remove the fuel line.

Remove the nuts and the turbocharger heat shield.

NOTE: Align the flat edge with the index feature located on the coolant supply port.

Twist the EGR cooler clamp and slide the EGR cooler hose down.

NOTE: Intake removed for clarity.

Remove the EGR cooler V-clamp and gasket.

Remove the bolts and the intake manifold.

Remove and discard the intake manifold gaskets.
Clean and inspect the sealing surfaces.

 

My back turbo bolt was a PIA too

Its safe to say my turbo will Never EVER have the rear bolt again
and the front 2 Bolts Got a Good Coat of Antiseize before they was installed

BTW no Problem from not having the rear bolt installed

 

ok, you can remove the intake without removing the harness, I had plenty of slack.

BE CAREFULL. while i was pulling the intake I hit the filter drainback valve. I hope the closest dealer has one, hour drive one way to them, if not I then it is a 2 hour one way drive
3C3Z-6800-a

 

I read somewhere that it is possible to remove the pedestal and rotate the turbo clockwise so you can see the bolt better, but im not sure if that was an 03 or not. the clearance around this motor is ridiculous hahaha. If I do get that bolt out I doubt I will install one back there again. im also curious, who manufactured the stock turbo? thanks for all the help everyone

 

garrett makes them