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Section 2512 (Engine - 6.0L (99P E-Series) Diesel): Installation: Engine: Installation

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
    2. NOTE: The engine must be to the left of the center line to install.
  2. Raise the engine high enough to clear the No. 1 crossmember and position the engine into the vehicle.
    3. Fig 1: Installing Engine
    GF0011904Courtesy of FORD MOTOR CO.
    NOTE: Left side shown, right side similar.
  3. Position the engine mounts in the vehicle.
    4. Fig 2: Left Engine Mount
    GF0011905Courtesy of FORD MOTOR CO.
  4. Align the torque converter studs with the holes in the flywheel and push the engine in. Install the top engine-to-transmission bolts.
    • Tighten to 47 Nm (35 lb-ft).
    5. Fig 3: Top Engine-To-Transmission Bolts
    GF0011893Courtesy of FORD MOTOR CO.
  5. Lower the engine until it is just above the motor mounts and install the 4 RH engine mount bolts.
    • Tighten to 80 Nm (59 lb-ft).
    6. Fig 4: Right Engine Mount Bolts
    GF0011895Courtesy of FORD MOTOR CO.
  6. Install the 4 LH engine mount bolts.
    • Tighten to 80 Nm (59 lb-ft).
    7. Fig 5: Left Engine Mount Bolts
    GF0011894Courtesy of FORD MOTOR CO.
  7. Remove the transmission jack.
  8. Install a new O-ring seal on the oil pickup tube and position the oil pickup tube in the oil pan.
    9. Fig 6: Locating Oil Pickup Tube O-Ring Seal
    G03887262Courtesy of FORD MOTOR CO.
  9. Install a new press-in-place gasket into the upper oil pan.
    10. Fig 7: Oil Pan Gasket
    GF0005767Courtesy of FORD MOTOR CO.
  10. Position the oil pan in the vehicle.
  11. Install the oil pickup tube and bolts.
    • Tighten to 13 Nm (10 lb-ft).
    12. Fig 8: Locating Oil Pickup Tube Bolts
    G03887261Courtesy of FORD MOTOR CO.
  12. Position the oil pan and install the bolts.
    1. Install the 5 longer oil pan bolts.
    2. Install the remaining oil pan bolts.
    3. Tighten to 13 Nm (10 lb-ft).
    13. Fig 9: Longer Oil Pan Bolts
    GF0005768Courtesy of FORD MOTOR CO.
  13. Clean and inspect the oil pan drain plug and gasket. Install new, if necessary.
    14. Fig 10: Oil Pan Drain Plug & Gasket
    GF0005769Courtesy of FORD MOTOR CO.
  14. Install the oil pan drain plug.
    • Tighten to 44 Nm (32 lb-ft).
    15. Fig 11: Locating Oil Pan Drain Plug
    G03887254Courtesy of FORD MOTOR CO.
  15. Lower the engine into place and remove the special tools.
    16. Fig 12: Engine Lifting Attachment & Lifting Crane
    GF0005813Courtesy of FORD MOTOR CO.
  16. Install the factory engine lifting bracket.
    17. Fig 13: Factory-Installed Engine Lifting Bracket
    GF0011892Courtesy of FORD MOTOR CO.
  17. Position the ground strap and install the bolt.
    • Tighten to 12 Nm (9 lb-ft).
    18. Fig 14: Ground Strap Bolt
    GF0011891Courtesy of FORD MOTOR CO.
  18. Loosely install the turbocharger exhaust pipe.
    19. NOTE: Remove the plug or cap as needed.
  19. Install the injection control pressure (ICP) sensor.
    • Tighten to 12 Nm (9 lb-ft).
    20. Fig 15: Injection Control Pressure (ICP) Sensor
    GF0011890Courtesy of FORD MOTOR CO.
    NOTE: Remove the protective covering from the cylinder head.
  20. Install the LH valve cover gasket, valve cover and bolts.
    • Tighten to 9 Nm (80 lb-in).
    21. Fig 16: Left Valve Cover & Bolts
    GF0011889Courtesy of FORD MOTOR CO.
  21. Install the glow plug module mounting bracket and the nuts.
    • Tighten to 8 Nm (71 lb-in).
    22. Fig 17: Glow Plug Module Mounting Bracket & Nuts
    GF0011888Courtesy of FORD MOTOR CO.
  22. Install the glow plug module and the nuts.
    • Tighten to 8 Nm (71 lb-in).
    23. Fig 18: Glow Plug Module & Nuts
    GF0011887Courtesy of FORD MOTOR CO.
  23. Connect the exhaust pressure tube to the exhaust manifold.
    • Tighten to 30 Nm (22 lb-ft).
    24. Fig 19: Exhaust Pressure Tube At Exhaust Manifold
    GF0011886Courtesy of FORD MOTOR CO.
    NOTE: Install a new O-ring seal and lubricate with clean engine oil prior to installation.
  24. Position the oil indicator and tube, install the retaining nut and connect the glow plug wire retainer.
    • Tighten to 8 Nm (71 lb-in).
    25. Fig 20: Glow Plug Wire Retainer & Oil Indicator Tube Nut
    GF0011885Courtesy of FORD MOTOR CO.
  25. Position the fuel tubes and install the mounting bolts for the fuel tube bracket.
    26. Fig 21: Lifting Bracket Mounting Bolts
    GF0011884Courtesy of FORD MOTOR CO.
  26. Install the lower engine-to-transmission bolts.
    • Tighten to 47 Nm (35 lb-ft).
    27. Fig 22: Locating Lower Engine-To-Transmission Bolts
    GF0044577Courtesy of FORD MOTOR CO.
    NOTE: Left side shown, right side similar.
    NOTE: The top retaining nut must be tightened first.
  27. Install the 4 engine mount-to-crossmember nuts.
    • Tighten to 90 Nm (66 lb-ft).
    28. Fig 23: Identifying Engine Mount Nuts
    G03887256Courtesy of FORD MOTOR CO.
  28. Install the starter motor, stud bolt and bolts.
    • Tighten to 25 Nm (18 lb-ft).
    29. Fig 24: Starter Motor Bolts
    GF0011882Courtesy of FORD MOTOR CO.
  29. Connect the starter motor electrical connection.
    • Tighten to 14 Nm (10 lb-ft).
    30. Fig 25: Starter Motor Electrical Connection
    GF0011906Courtesy of FORD MOTOR CO.
  30. Connect the starter motor electrical connection.
    • Tighten to 6 Nm (53 lb-in).
    31. Fig 26: Starter Motor Electrical Connection
    GF0011907Courtesy of FORD MOTOR CO.
  31. Install the starter motor solenoid protective cap.
    32. Fig 27: Identifying Starter Motor Solenoid Protective Cap
    G03887448Courtesy of FORD MOTOR CO.
  32. Position the battery cable bracket and install the nut.
    • Tighten to 22 Nm (16 lb-ft).
    33. Fig 28: Battery Cable Bracket Nut
    GF0011880Courtesy of FORD MOTOR CO.
  33. Connect the block heater electrical connector.
    34. Fig 29: Identifying Block Heater Electrical Connector
    G03887446Courtesy of FORD MOTOR CO.
  34. Install new torque converter nuts.
    • Tighten to 35 Nm (26 lb-ft).
    35. Fig 30: Torque Converter Nuts
    GF0011879Courtesy of FORD MOTOR CO.
  35. Install the torque converter cover.
    36. Fig 31: Torque Converter Access Plug
    GF0011878Courtesy of FORD MOTOR CO.
  36. Position the transmission cooler tube support bracket on the stud and install the nut.
    • Tighten to 12 Nm (9 lb-ft).
    37. Fig 32: Transmission Cooling Tubes Support Bracket Nut
    GF0011875Courtesy of FORD MOTOR CO.
  37. Install the engine-to-transmission bolt for the transmission cooler tubes.
    • Tighten to 47 Nm (35 lb-ft).
    38. Fig 33: Locating Engine-To-Transmission Bolt
    GF0044576Courtesy of FORD MOTOR CO.
  38. Install the oil filter assembly and the bolts.
    • Tighten to 24 Nm (18 lb-ft).
    39. Fig 34: Oil Filter Assembly & Bolts
    GF0011874Courtesy of FORD MOTOR CO.
    NOTE: Fully seat the PCM electrical connectors prior to latching the electrical connectors or damage to the connector pins may occur.
  39. Position the engine wiring harness and connect the PCM electrical connectors.
    40. Fig 35: PCM Electrical Connectors
    GF0011873Courtesy of FORD MOTOR CO.
  40. Connect the 2 engine-to-vehicle electrical connectors.
    41. Fig 36: Engine-To-Vehicle Electrical Connectors
    GF0011872Courtesy of FORD MOTOR CO.
  41. Connect the LH glow plug electrical connector.
    42. Fig 37: Left Glow Plug Electrical Connector
    GF0011871Courtesy of FORD MOTOR CO.
  42. Connect the pushpin retainer and exhaust pressure sensor electrical connector.
    43. Fig 38: Identifying Exhaust Pressure Sensor Electrical Connector and Retainer
    G03887203Courtesy of FORD MOTOR CO.
  43. Connect the electrical connector and wire retainers at the transmission.
    44. Fig 39: Electrical Connector & Wire Retainers
    GF0011870Courtesy of FORD MOTOR CO.
  44. Connect the glow plug module electrical connectors.
    45. Fig 40: Glow Plug Module Electrical Connectors
    GF0011844Courtesy of FORD MOTOR CO.
  45. Connect the camshaft position sensor electrical connector and retaining clips.
    46. Fig 41: Camshaft Position (CMP) Sensor Electrical Connector & Retaining Clips
    GF0011869Courtesy of FORD MOTOR CO.
  46. Position the wiring and connect the glow plug and ICP sensor electrical connectors.
    47. Fig 42: Injection Control Pressure (ICP) Sensor Electrical Connector, Glow Plug Electrical Connector & Wire Retainers
    GF0011868Courtesy of FORD MOTOR CO.
  47. Connect the crankshaft position (CKP) sensor electrical connector and retaining clips.
    48. Fig 43: Crankshaft Position (CKP) Sensor Electrical Connector & Retaining Clip
    GF0011867Courtesy of FORD MOTOR CO.
  48. Connect the fuel tube spring lock couplings and install the retaining clips. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
    49. Fig 44: Fuel Tube Spring Lock Couplings
    GF0011866Courtesy of FORD MOTOR CO.
  49. Install the lower radiator hose.
    50. Fig 45: Identifying Lower Radiator Hose Clamp
    G03887303Courtesy of FORD MOTOR CO.
  50. Position the power steering pump and install the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    51. Fig 46: Identifying Power Steering Pump Bolts
    G03887253Courtesy of FORD MOTOR CO.
  51. Install the LH fan stator stand-off.
    • Tighten to 47 Nm (35 lb-ft).
    52. Fig 47: Identifying LH Fan Stator Stand-Off
    G03887252Courtesy of FORD MOTOR CO.
  52. Install the 2 power steering upper mounting bolts.
    • Tighten to 25 Nm (18 lb-ft).
    53. Fig 48: Identifying Power Steering Pump Upper Mounting Bolts
    G03887251Courtesy of FORD MOTOR CO.
    NOTE: The stud bolt behind the pulley is accessed through one of the holes in the pulley.
  53. Position the vacuum pump and install the 3 stud bolts.
    • Tighten to 47 Nm (35 lb-ft).
    54. Fig 49: Vacuum Pump & Stud Bolts
    GF0011865Courtesy of FORD MOTOR CO.
  54. Connect the vacuum pump hose.
    55. Fig 50: Vacuum Pump Hose
    GF0011864Courtesy of FORD MOTOR CO.
  55. Connect the engine coolant fill hose and tighten the clamp.
    56. Fig 51: Engine Coolant Fill Hose & Clamp
    GF0011850Courtesy of FORD MOTOR CO.
    NOTE: The nut behind the pulley is accessed through one of the holes in the pulley.
  56. Position the coolant hose shield and install the nuts.
    • Tighten to 6 Nm (53 lb-in).
    57. Fig 52: Coolant Hose Shield & Nuts
    GF0011849Courtesy of FORD MOTOR CO.
  57. Install the idler pulley and bolt.
    • Tighten to 47 Nm (35 lb-ft).
    58. Fig 53: Identifying Idler Pulley Bolt
    G03887298Courtesy of FORD MOTOR CO.
  58. Connect the heater hose.
    59. Fig 54: Identifying Heater Hose
    GF0044575Courtesy of FORD MOTOR CO.
  59. Install the A/C compressor and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    60. Fig 55: A/C Compressor Bolts
    GF0011862Courtesy of FORD MOTOR CO.
  60. Connect the A/C pressure switch electrical connector and install the bolt.
    • Tighten to 28 Nm (21 lb-ft).
    61. Fig 56: Locating Bolt & A/C Pressure Switch Electrical Connector
    GF0044574Courtesy of FORD MOTOR CO.
    NOTE: Remove the caps or plugs as needed. Install new O-ring seal and gasket. Lubricate O-ring seal and gasket with PAG oil.
  61. Connect the A/C fitting and install the nut.
    • Tighten to 15 Nm (11 lb-ft).
    62. Fig 57: Locating Nut & A/C Fitting
    GF0044573Courtesy of FORD MOTOR CO.
  62. Connect the A/C compressor electrical connector.
    63. Fig 58: Locating A/C Electrical Connector
    GF0044572Courtesy of FORD MOTOR CO.
  63. Position back the cable and install the bolt. Install the RH fan stator stand-off.
    • Tighten both to 47 Nm (35 lb-ft).
    64. Fig 59: Identifying Cable and RH Fan Stator Stand-Off
    G03887257Courtesy of FORD MOTOR CO.
  64. Install the intake manifold. For additional information, refer to Intake Manifold .
    65. NOTE: LH shown, RH similar.
  65. Install the lower radiator support and 12 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    66. Fig 60: Identifying Lower Radiator Support Bolts
    G03886640Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  66. Position back the power steering cooler. Position back the side deflectors and install the pushpin retainers.
    67. Fig 61: Locating Pushpins & Side Shields
    GF0044571Courtesy of FORD MOTOR CO.
  67. Position the headlamp wire harness and connect the pushpin retainers. Install the bolt for the ground wire.
    68. Fig 62: Locating Bolt For Ground Wire & Pushpin Retainers
    GF0044570Courtesy of FORD MOTOR CO.
  68. Connect the front impact severity sensor electrical connector.
    69. Fig 63: Locating Front Impact Severity Sensor Electrical Connector
    GF0044569Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  69. Install the radiator upper support and the 8 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    70. Fig 64: Locating Bolts & Radiator Upper Support
    GF0044568Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  70. Install the radiator upper support brackets and 4 bolts.
    • Tighten to 12 Nm (9 lb-ft).
    71. Fig 65: Locating Bolts & Radiator Upper Support Brackets
    GF0044567Courtesy of FORD MOTOR CO.
  71. Connect the horn electrical connector.
    72. Fig 66: Locating Horn Electrical Connector
    GF0044566Courtesy of FORD MOTOR CO.
  72. Position the transmission cooler and loosely install a bolt.
    • Connect the transmission cooler hose and the pushpin retainers.
    73. Fig 67: Locating Pushpin Retainers & Transmission Cooler Hose
    GF0044565Courtesy of FORD MOTOR CO.
  73. Position the hood latch and install the 2 bolts. Connect the cable retainer.
    • Tighten to 12 Nm (9 lb-ft).
    74. Fig 68: Locating Cable Retainer, Bolts & Positioning Hood Latch Aside
    GF0044564Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  74. Position the side shields and install the pushpin retainers.
    75. Fig 69: Locating Pushpin Retainers & Side Shields
    GF0044563Courtesy of FORD MOTOR CO.
  75. Install the radiator grille support. For additional information, refer to FRONT END BODY PANELS article.
  76. Install the front bumper shields and pushpin retainers.
    77. Fig 70: Locating Pushpin Retainers & Front Bumper Shields
    GF0044562Courtesy of FORD MOTOR CO.
  77. Install the front bumper. For additional information, refer to BUMPERS article.
  78. Install the cooling module. For additional information, refer to ENGINE COOLING article.
  79. Fill the engine with clean engine oil.
  80. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  81. Check and top off the transmission fluid level.
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