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Section 951 (Engine - 6.8L (3V) -- F250-F550 Super Duty): Installation: Engine

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS

G03886715
 Modular Engine Lift Bracket 303-F047 (014-00073) or equivalent
MATERIAL

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil XO-5W20-QSP (in Canada Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12) or equivalent WSS-M2C930-A
Motorcraft Premium Gold Engine Coolant VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-7-A) or equivalent (yellow color) WSS-M97B51-A1

    All vehicles 

  1. Using a suitable floor crane, position the engine assembly into the vehicle.
    2. CAUTION: Only use hand tools when installing the RH engine mount nut or damage to the engine mount can occur.
    NOTE: Align the engine-to-transmission dowels before installing the engine mount bolt.
    NOTE: RH shown, LH similar.
  2. Install the 4 engine mount nuts.
    • Tighten to 103 Nm (76 lb-ft).
      Fig 1: Identifying Engine Mount Nuts
      G03920590Courtesy of FORD MOTOR CO.
  3. Remove the special tool.
    Fig 2: Identifying Special Tool
    G03920205Courtesy of FORD MOTOR CO.

    4. Manual transmission vehicles 

  4. Install the clutch disc and pressure plate. For additional information, refer to CLUTCH .

    5. Automatic transmission vehicles 

    NOTE: The upper 2 transmission-to-engine bolts will be installed later.
  5. Install the lower 5 transmission-to-engine bolts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 3: Identifying Lower Transmission-To-Engine Bolts
      G03920193Courtesy of FORD MOTOR CO.
  6. Install 6 new torque converter-to-flexplate nuts.
    • Tighten to 35 Nm (26 lb-ft).
      Fig 4: Locating Torque Converter-To-Flexplate Nuts
      G03885557Courtesy of FORD MOTOR CO.
  7. Install the cylinder block opening cover.
    Fig 5: Identifying Access Plug
    G03908385Courtesy of FORD MOTOR CO.
  8. Install the flexplate inspection cover and the 2 bolts.
    • Tighten to 34 Nm (25 lb-ft).
      Fig 6: Locating Flexplate Inspection Cover Bolts
      G03885458Courtesy of FORD MOTOR CO.
  9. Install the starter. For additional information, refer to STARTING SYSTEM - GASOLINE ENGINES .
  10. Install the transmission filler tube. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - TORQSHIFT .

    11. All vehicles 

  11. Attach the wiring harness and retainer to the coolant tube support bracket and install the ground strap and the nut.
    • Tighten to 10 Nm (89 lb-in).
      Fig 7: Installing Ground Strap And Nut
      G03920908Courtesy of FORD MOTOR CO.
  12. Position a new oil cooler and install the threaded shaft.
    • Tighten to 58 Nm (43 lb-ft).
      Fig 8: Identifying Threaded Shaft
      G03920099Courtesy of FORD MOTOR CO.
  13. Connect the coolant hoses to the oil cooler.
    Fig 9: Connecting Coolant Hoses To Oil Cooler
    G03920297Courtesy of FORD MOTOR CO.
  14. Install a new oil filter.
    Fig 10: Locating Oil Filter
    G03920097Courtesy of FORD MOTOR CO.
  15. If equipped, connect the block heater electrical connector.
    Fig 11: Locating Block Heater Electrical Connector
    G03920195Courtesy of FORD MOTOR CO.
  16. Position the A/C compressor and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 12: Locating Bolt Access Holes For A/C Compressor
      G03919912Courtesy of FORD MOTOR CO.
  17. Position the starter electrical harness support bracket and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 13: Locating Starter Wiring Harness Support Bracket Bolt
      G03919905Courtesy of FORD MOTOR CO.
  18. Position the ground strap and install the stud bolt.
    • Tighten to 10 Nm (89 lb-in).
      Fig 14: Installing Stud Bolt
      G03905683Courtesy of FORD MOTOR CO.
  19. Install the 4 exhaust manifold flange nuts.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 15: Identifying Exhaust Manifold Flange Nuts
      G03885400Courtesy of FORD MOTOR CO.
  20. Connect the 2 heated exhaust gas oxygen sensor (HO2S) electrical connectors.
    Fig 16: Connecting Heated Exhaust Gas Oxygen Sensor (HO2S) Electrical Connectors
    G03920201Courtesy of FORD MOTOR CO.

    21. Automatic transmission vehicles 

  21. Install the transmission cooler tube support bracket and the nut.
    • Tighten to 10 Nm (89 lb-in).
      Fig 17: Identifying Transmission Cooler Tube Support Bracket And Nut
      G03905682Courtesy of FORD MOTOR CO.
  22. Install the upper 2 transmission-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 18: Installing Upper Transmission-To-Engine Bolts
      G03920204Courtesy of FORD MOTOR CO.

    23. All vehicles 

  23. Position the degas bottle support bracket and install the 3 nuts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 19: Installing Degas Bottle Nuts
      G03920186Courtesy of FORD MOTOR CO.
  24. Connect the heater hose at the rear of the engine.
    Fig 20: Connecting Heater Hose At Rear Of Engine
    G03905677Courtesy of FORD MOTOR CO.
  25. Connect the body wiring harness retainer to the degas bottle support bracket.
    Fig 21: Connecting Body Wiring Harness Retainer To Degas Bottle Support Bracket
    G03920185Courtesy of FORD MOTOR CO.
  26. Position the evaporative emissions (EVAP) canister purge valve and bracket assembly, and install the 3 nuts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 22: Positioning Evaporative Emissions (EVAP) Canister Purge Valve And Bracket Assembly
      G03919862Courtesy of FORD MOTOR CO.
  27. Connect the electrical connector and the EVAP tube quick connect couplings to the EVAP canister purge valve.
    Fig 23: Connecting Electrical Connector And EVAP Tube Quick Connect Couplings To EVAP Canister Purge Valve
    G03919866Courtesy of FORD MOTOR CO.
  28. Connect the engine wiring harness retainer to the EVAP canister purge valve bracket.
    Fig 24: Connecting Engine Wiring Harness Retainer To EVAP Canister Purge Valve Bracket
    G03919860Courtesy of FORD MOTOR CO.
  29. Connect the crankshaft position (CKP) sensor wiring harness retainer to the starter motor wiring harness.
    Fig 25: Connecting Crankshaft Position (CKP) Sensor Wiring Harness Retainer To Starter Motor Wiring Harness
    G03920181Courtesy of FORD MOTOR CO.
  30. Connect the generator wiring harness retainer to the RH cylinder head.
    Fig 26: Connecting Generator Wiring Harness Retainer To RH Cylinder Head
    G03920180Courtesy of FORD MOTOR CO.
  31. Connect the A/C compressor and the A/C high pressure cut-off switch electrical connectors.
    Fig 27: Connecting A/C Compressor And A/C High Pressure Cut-Off Switch Electrical Connectors
    G03920179Courtesy of FORD MOTOR CO.
  32. Connect the generator wiring harness retainer to the RH cylinder head.
    Fig 28: Connecting Generator Wiring Harness Retainer To RH Cylinder Head
    G03920178Courtesy of FORD MOTOR CO.
  33. Position the power steering pump and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 29: Identifying Power Steering Pump Bolts
      G03886436Courtesy of FORD MOTOR CO.
  34. Connect the 2 electrical connectors on the LH fender splash shield.
    Fig 30: Connecting Electrical Connectors On LH Fender Splash Shield
    G03920176Courtesy of FORD MOTOR CO.
  35. Connect the degas bottle coolant hose.
    Fig 31: Connecting Degas Bottle Coolant Hose
    G03920175Courtesy of FORD MOTOR CO.
  36. Position the accessory drive belt onto the engine.
  37. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  38. Install the radiator, fan shroud and engine cooling fan. For additional information, refer to ENGINE COOLING .
  39. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  40. Install the powertrain control module (PCM). For additional information, refer to ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES .
  41. Install the cowl vent grille. For additional information, refer to FRONT END BODY PANELS .
  42. Install the radiator grille support. For additional information, refer to FRONT END BODY PANELS .
  43. Install the A/C condenser core. For additional information, refer to AIR CONDITIONING .
  44. Install the hood.
  45. Fill the crankcase with clean engine oil.
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