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Section 1846 (Engine - 6.0L (99P F450/550) Diesel -- F250-F550 Super Duty): Installation: Engine: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Raise the engine high enough to clear the No. 1 crossmember, then position the engine into the vehicle.
    Fig 1: Positioning Engine Into Vehicle
    G04649089Courtesy of FORD MOTOR CO.

    3. Vehicles with automatic transmission 

  3. Align the torque converter studs with the holes in the engine flywheel, then lower the engine onto the engine mount towers.

    4. Vehicles with manual transmission 

  4. Lower the engine onto the engine mount towers.

    5. All vehicles 

  5. Remove the Heavy Duty Floor Crane and the Diesel Engine Lifting Bracket.

    6. Vehicles with automatic transmission 

  6. Remove the transmission jack.
  7. Install the transmission-to-engine mounting bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 2: Locating Transmission-To-Engine Mounting Bolts
      G04649090Courtesy of FORD MOTOR CO.
  8. Install the new torque converter-to-flywheel retaining nuts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 3: Locating Torque Converter-To-Flywheel Retaining Nuts
      G04649091Courtesy of FORD MOTOR CO.
  9. Install the flywheel housing cover.
    Fig 4: Locating Flywheel Housing Cover
    G04649092Courtesy of FORD MOTOR CO.

    10. All vehicles 

    NOTE: RH shown, LH similar.
  10. Install the 4 LH and 4 RH engine mount nuts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 5: Locating Engine Mount Retaining Nuts
      G03921670Courtesy of FORD MOTOR CO.
  11. Remove the engine lifting eye from the right side cylinder head.
    Fig 6: Identifying Engine Lifting Eye
    G04649094Courtesy of FORD MOTOR CO.
  12. Install the manufacturer's lifting bracket.
    Fig 7: Locating Manufacturer Lifting Bracket
    G04649095Courtesy of FORD MOTOR CO.
  13. Remove the 2 engine lift adapters.
    Fig 8: Locating Engine Lift Adapters (303-D043-01)
    G04614140Courtesy of FORD MOTOR CO.
  14. Position the turbocharger outlet pipe.
    Fig 9: Locating Turbocharger Outlet Pipe
    G04649097Courtesy of FORD MOTOR CO.
  15. Install the transmission cooler tube bracket and nut.
    • Tighten to 10 Nm (89 lb-in).
      Fig 10: Locating Transmission Cooler Tube Bracket Nut
      G04649098Courtesy of FORD MOTOR CO.
  16. Install the left rear valve cover stud.
    • Tighten to 9 Nm (80 lb-in).
      Fig 11: Locating Left Rear Valve Cover Stud
      G04649099Courtesy of FORD MOTOR CO.
  17. Install the fuel injector control module support bracket and the nuts.
    • Tighten to 8 Nm (71 lb-in).
      Fig 12: Locating Fuel Injector Control Module Support Bracket Nuts
      G04649100Courtesy of FORD MOTOR CO.
  18. Connect the exhaust pressure (EP) sensor tube fitting to the exhaust manifold and install the EP sensor retaining nut.
    1. Tighten to 30 Nm (22 lb-ft).
    2. Tighten to 13 Nm (10 lb-ft).
      Fig 13: Identifying EP Sensor Retaining Nut
      G04649101Courtesy of FORD MOTOR CO.
  19. Install the heat shield and bolts.
    1. Tighten to 49 Nm (36 lb-ft).
    2. Tighten to 11 Nm (8 lb-ft).
      Fig 14: Identifying Heat Shield And Bolts
      G04649102Courtesy of FORD MOTOR CO.
  20. Position the turbocharger adapter pipes. Install the gasket and bolts.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 15: Identifying Turbocharger Adapter Pipes
      G04649103Courtesy of FORD MOTOR CO.
  21. Position the turbocharger adapter pipe.
    Fig 16: Positioning Turbocharger Adapter Pipe
    G04649104Courtesy of FORD MOTOR CO.
    22. NOTE: LH shown, RH similar.
    NOTE: Do not tighten bolts at this time.
    NOTE: Apply anti-seize lubricant to the threads prior to installing the bolts.
    Fig 17: Locating Turbocharger Adapter Pipe Bolts
    G04649105Courtesy of FORD MOTOR CO.
  22. Install the bolts for the turbocharger adapter pipe.
  23. Position back the block heater and starter wiring.
  24. Connect the block heater electrical connector.
    Fig 18: Identifying Block Heater Electrical Connector
    G03887446Courtesy of FORD MOTOR CO.
  25. Connect the starter wiring and install the solenoid cap.
    1. Tighten to 6 Nm (53 lb-in).
    2. Tighten to 12 Nm (9 lb-ft).
      Fig 19: Identifying Starter Wiring
      G04649107Courtesy of FORD MOTOR CO.
  26. Connect the ground strap to the RH cylinder head and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 20: Locating Ground Strap
      G04649108Courtesy of FORD MOTOR CO.

    27. Vehicles with automatic transmission 

  27. Install the automatic transmission fluid indicator and tube.
    • Tighten to 8 Nm (71 lb-in).
      Fig 21: Identifying Transmission Fluid Indicator Retaining Nut
      G03899172Courtesy of FORD MOTOR CO.

    28. All vehicles 

  28. Position back the wiring and connect the crankshaft position (CKP) sensor electrical connector.
    Fig 22: Locating CKP Sensor Electrical Connector
    G03888387Courtesy of FORD MOTOR CO.

    29. Vehicles with A/C 

  29. Position the A/C compressor and install the bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 23: Locating A/C Compressor Bolts
      G04649111Courtesy of FORD MOTOR CO.
  30. Remove the cap or plug and install a new O-ring seal. Install the A/C hose and retaining nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 24: Locating A/C Hose And Retaining Nut
      G04649112Courtesy of FORD MOTOR CO.
  31. Connect the A/C high pressure switch and the clutch electrical connectors.
    Fig 25: Locating A/C high pressure Switch And Clutch Electrical Connectors
    G04649113Courtesy of FORD MOTOR CO.

    32. All vehicles 

  32. Connect the RH glow plug electrical connector and wire retainer.
    Fig 26: Locating RH Glow Plug Electrical Connector And Wire Retainer
    G04649114Courtesy of FORD MOTOR CO.
  33. Connect the glow plug module electrical connectors. Connect the pushpin retainer and the injection control pressure (ICP) sensor electrical connector.
    Fig 27: Locating Injection Control Pressure (ICP) Electrical Connector And Glow Plug Connectors
    G03906822Courtesy of FORD MOTOR CO.
    34. NOTE: Only one retainer shown.
    Fig 28: Locating Wire Retainers
    G04649116Courtesy of FORD MOTOR CO.
  34. Connect the wire retainers on the valve cover studs.
  35. Connect the ground cable and the ground stud.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 29: Locating Ground Cable And Ground Stud
      G04649117Courtesy of FORD MOTOR CO.
  36. Install the battery cable bracket and the nut.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 30: Locating Battery Cable Bracket Nut
      G04649118Courtesy of FORD MOTOR CO.
  37. Position the power steering pump and install the lower bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 31: Locating Power Steering Pump Lower Bolt
      G04649119Courtesy of FORD MOTOR CO.
  38. Install the power steering pump upper bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 32: Locating Power Steering Pump Upper Bolts
      G04649120Courtesy of FORD MOTOR CO.
    39. NOTE: Only one stand-off shown.
  39. Install the stator stand-offs.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 33: Locating Stator Stand-Off
      G04649121Courtesy of FORD MOTOR CO.
  40. Connect the fuel tube spring lock couplings. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
    Fig 34: Locating Fuel Tube Spring Lock Couplings
    G04649122Courtesy of FORD MOTOR CO.
  41. Install the lower radiator hose and clamp.
    Fig 35: Locating Lower Radiator Hose
    G03921454Courtesy of FORD MOTOR CO.
  42. Connect the heater hose at the front cover.
    Fig 36: Identifying Clamp And Heater Hose
    G03921453Courtesy of FORD MOTOR CO.
  43. Connect the camshaft position (CMP) sensor electrical connector.
    Fig 37: Locating Camshaft Position Sensor Electrical Connector
    G03888384Courtesy of FORD MOTOR CO.
  44. Connect the 12-pin and 8-pin electrical connectors.
    Fig 38: Locating 12-Pin And 8-Pin Electrical Connectors
    G04649126Courtesy of FORD MOTOR CO.
  45. Connect the powertrain control module (PCM) electrical connector.
    Fig 39: Locating Powertrain Control Module Electrical Connector
    G04649127Courtesy of FORD MOTOR CO.
  46. Connect the LH glow plug electrical connector.
    Fig 40: Locating LH Glow Plug Electrical Connector
    G04649128Courtesy of FORD MOTOR CO.
  47. Install the battery tray and bolts.
    • Tighten to 16 Nm (12 lb-ft).
      Fig 41: Locating Battery Tray Bolts
      G04649129Courtesy of FORD MOTOR CO.
  48. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
    49. NOTE: LH shown, RH similar.
    NOTE: Alternately tighten the bolts to specification.
  49. Tighten the turbocharger adapter pipe at the flanges.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 42: Identifying Adapter Pipe Bolts
      G03899293Courtesy of FORD MOTOR CO.
  50. Tighten the nuts at the turbocharger adapter pipe flange.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 43: Locating Turbocharger Adapter Pipe Flange Nuts
      G04649131Courtesy of FORD MOTOR CO.
  51. Install the upper radiator support and bolts.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 44: Locating Upper Radiator Support Bolts
      G04649132Courtesy of FORD MOTOR CO.
    52. NOTE: Cover position back for clarity.
  52. Connect the body feed cable and install the nut.
    • Tighten to 8 Nm (71 lb-in).
      Fig 45: Locating Body Feed Cable Nut
      G04649133Courtesy of FORD MOTOR CO.
  53. Install the transmission oil cooler.
    • Tighten to 8 Nm (71 lb-in).
      Fig 46: Locating Transmission Oil Cooler
      G04649134Courtesy of FORD MOTOR CO.
    54. NOTE: Remove the caps or plugs as needed.
    Fig 47: Locating Transmission Cooler Hoses
    G04649135Courtesy of FORD MOTOR CO.
  54. Connect the transmission cooler hoses.
  55. Install the power steering cooler and bolts.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 48: Locating Power Steering Cooler Bolts
      G04649136Courtesy of FORD MOTOR CO.
  56. Position back the power steering cooler tubes and install the tubes in the retaining clip.
    Fig 49: Locating Retaining Clip
    G04649137Courtesy of FORD MOTOR CO.
    57. NOTE: Remove the caps or plugs as needed.
    Fig 50: Locating Power Steering Hoses Clamps
    G04649138Courtesy of FORD MOTOR CO.
  57. Connect the power steering hoses and tighten the clamps.
  58. Install the front bumper.
  59. Install the radiator grille opening panel reinforcement. For additional information, refer to FRONT END BODY PANELS .

    60. Vehicles with A/C 

  60. Install the A/C condenser assembly. For additional information, refer to CLIMATE CONTROL .

    61. All vehicles 

  61. Install the charge air cooler. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  62. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  63. Install the cooling fan stator. For additional information, refer to ENGINE COOLING .
  64. Install the clutch disc and pressure plate. For additional information, refer to CLUTCH .
  65. Install the transmission. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED .

    66. All vehicles 

  66. Fill the motor with clean engine oil.
  67. Connect the LH and RH battery cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  68. Fill the cooling system. For additional information, refer to ENGINE COOLING .
  69. Cycle the key 3 times prior to starting the vehicle to avoid the possibility of air lock in the fuel system.
  70. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
  71. Check and fill the transmission.
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