Section 654 (Engine - 6.8L - Excursion & F250-F550 Super Duty): Installation: Engine: Installation

All vehicles 

1. Attach the Modular Engine Lift Bracket.
2. Remove the engine from the engine stand.
CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
3. Clean and inspect the mating surfaces of the cylinder block and the retainer plate.
NOTE: If not secured within four minutes, sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Fig 1: Applying A Bead Of Silicone Gasket And Sealant
Courtesy of FORD MOTOR CO.
4. Apply a bead of silicone gasket and sealant around the rear oil seal retainer sealing surface.
5. Install the retainer plate. Tighten the bolts in two stages.
   • Stage 1: Tighten the retainer plate bolts to 10 Nm (89 lb-in), in the sequence shown.
   • Stage 2: Tighten the oil pan bolts to 20 Nm (15 lb-ft), then tighten an additional 60 degrees.
     Fig 2: Tightening Retainer Plate Bolts

     Courtesy of FORD MOTOR CO.
6. Use the two crankshaft rear oil seal installers to install the crankshaft rear oil seal.
   Fig 3: Installing Crankshaft Rear Oil Seal

   Courtesy of FORD MOTOR CO.
7. Using the two crankshaft rear oil seal installers and the crankshaft rear oil slinger installer, install the crankshaft rear oil slinger.
8. Install the flywheel.
   Fig 4: Installing Flywheel

   Courtesy of FORD MOTOR CO.
9. Position the engine in the vehicle and remove the Modular Engine Lift Bracket and the jack supporting the transmission.
10. Install and tighten the nuts.
    Fig 5: Installing And Tighten Nuts

    Courtesy of FORD MOTOR CO.
11. Install the heater water tube and the two studs.
    Fig 6: Installing Heater Water Tube And Two Studs

    Courtesy of FORD MOTOR CO.
12. On automatic transmission-equipped vehicles, install the transmission oil level indicator tube and the ground strap on all vehicles.
    Fig 7: Installing Transmission Oil Level Indicator Tube

    Courtesy of FORD MOTOR CO.
13. Raise and support the vehicle.

    Automatic transmission vehicles 

14. Install the lower transmission to engine bolts.
    Fig 8: Installing Lower Transmission To Engine Bolts

    Courtesy of FORD MOTOR CO.
15. Install the access plug.
    Fig 9: Installing Access Plug

    Courtesy of FORD MOTOR CO.
16. Install and tighten the four new nuts retaining the torque converter.
    Fig 10: Tightening Four New Nuts

    Courtesy of FORD MOTOR CO.
17. Install the flywheel inspection cover.

    All vehicles 

18. Install the wiring bracket.
    Fig 11: Installing Wiring Bracket

    Courtesy of FORD MOTOR CO.

    Automatic transmission vehicles 

19. Install the starter motor. Refer to STARTERS .

    All vehicles 

20. Install the oil cooler to the oil filter adapter and install the oil bypass filter.
    Fig 12: Installing Oil Cooler To Oil Filter Adapter

    Courtesy of FORD MOTOR CO.

    Manual transmission vehicles 

21. Install the clutch and transmission. Refer to CLUTCH .

    All vehicles 

22. Install and tighten the nuts.
    Fig 13: Installing Nuts

    Courtesy of FORD MOTOR CO.
23. Install the ground strap.
    Fig 14: Installing Ground Strap

    Courtesy of FORD MOTOR CO.

    Automatic transmission vehicles 

24. Install the transmission cooler line bracket.
    Fig 15: Installing Transmission Cooler Line Bracket

    Courtesy of FORD MOTOR CO.

    All vehicles 

25. Install the A/C compressor. Refer to AIR CONDITIONING .
26. Lower the vehicle.
27. Position back and install the heater hose at the rear of the engine.
    Fig 16: Installing Heater Hose At Rear Of Engine

    Courtesy of FORD MOTOR CO.

    Automatic transmission vehicles 

28. Install the remaining transmission-to-engine bolts and fuel line bracket.
    Fig 17: Installing Remaining Transmission-To-Engine Bolts

    Courtesy of FORD MOTOR CO.

    All vehicles 

29. Connect the transmission wiring harness and the LH and RH heated exhaust gas oxygen sensor connectors.
    Fig 18: Connecting Transmission Wiring Harness

    Courtesy of FORD MOTOR CO.
30. Install the suction line to the accumulator.
    Fig 19: Installing Suction Line To Accumulator

    Courtesy of FORD MOTOR CO.
31. Connect the A/C cycling switch.
    Fig 20: Connecting A/C Cycling Switch

    Courtesy of FORD MOTOR CO.
32. Connect the connector and position the harness aside.
    Fig 21: Connecting Connector And Positioning Harness Aside

    Courtesy of FORD MOTOR CO.
33. Install the power steering pump.
    Fig 22: Installing power steering pump

    Courtesy of FORD MOTOR CO.
34. Position back and connect the lower radiator hose at the oil cooler water inlet.
    Fig 23: Positioning Back And Connect Lower Radiator Hose

    Courtesy of FORD MOTOR CO.
35. Install the intake manifold. Refer to INTAKE MANIFOLD .
36. Install the harness mounting bracket and connect the 42-pin and 16-pin connectors.
    Fig 24: Installing Harness Mounting Bracket

    Courtesy of FORD MOTOR CO.
37. Install the radiator. Refer to ENGINE COOLING .
38. Install the A/C condenser core. Refer to AIR CONDITIONING .
39. Install the radiator grille support. Refer to FRONT END BODY PANELS .
40. Fill all fluids to the correct levels.
41. Connect the battery ground cable.
42. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
43. Evacuate and recharge the A/C system. Refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION .