Section 2107 (Engine - 6.8L (3V) -- F250-F550 Super Duty): Assembly: Engine: Assembly

WARNING: This page is about a different car, the 2008 Ford Pickup, 2008 Ford F550 Super Duty, 2008 Ford F450 Super Duty, and 2008 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Record the main bearing code found on the front of the engine block.

Fig 1: Identifying Main Bearing Code Found On Front Of Engine Block

Courtesy of FORD MOTOR CO.

Record the main bearing code found on the back of the crankshaft.

Fig 2: Identifying Main Bearing Code - Found On Back Of Crankshaft

Courtesy of FORD MOTOR CO.

Using the data recorded earlier and the Bearing Select Fit Chart, Standard Bearings, determine the required bearing grade for each main bearing.
- Read the first letter of the engine block main bearing code and the first letter of the crankshaft main bearing code.
- Read down the column below the engine block main bearing code letter, and across the row next to the crankshaft main bearing code letter, until the 2 intersect. This is the required bearing grade for the No. 1 crankshaft main bearing.
- As an example, if the engine block code letter is "F" and the crankshaft code letter is "D", the correct bearing grade for this main bearing is a "2".
- Repeat this process for the remaining 4 main bearings.

Fig 3: Bearing Select Fit Chart (Standard Bearings)

Courtesy of FORD MOTOR CO.

If oversize bearings are being used, use the procedure in the previous step and the Bearing Select Fit Chart, Oversize Bearings to determine the required bearing grade for each main bearing.

Fig 4: Bearing Select Fit Chart (Oversize Bearings)

Courtesy of FORD MOTOR CO.

NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

Install the 6 crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.

NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.

Install the crankshaft upper main bearings into the cylinder block and lubricate them with clean engine oil.

Fig 5: Installing Crankshaft Upper Main Bearings

Courtesy of FORD MOTOR CO.

Install the crankshaft into the cylinder block and onto the upper crankshaft main bearings.

Fig 6: Installing Crankshaft Into Cylinder Block And Upper Crankshaft Main Bearings

Courtesy of FORD MOTOR CO.

NOTE: If equipped, the oil groove on the thrust washer must face toward the crankshaft thrust surface.

Push the crankshaft rearward and install the rear upper crankshaft thrust washer at the back of the No. 6 main boss.

Fig 7: Installing Rear Crankshaft Upper Thrust Washer

Courtesy of FORD MOTOR CO.

NOTE: If equipped, the oil groove on the thrust washer must face toward the crankshaft thrust surface.

Push the crankshaft forward and install the front upper crankshaft thrust washer at the front of the No. 6 main boss.

Fig 8: Identifying Front Upper Crankshaft Thrust Washer

Courtesy of FORD MOTOR CO.

NOTE: To aid in assembly, apply petroleum jelly to the back of the crankshaft thrust washer.

NOTE: If equipped, the oil groove on the thrust washer must face toward the crankshaft thrust surface.

Install the lower crankshaft thrust washer to the back side of the No. 6 main bearing cap, with oil grooves facing the crankshaft surface, and install the No. 6 rear main bearing cap.

Fig 9: Installing Lower Crankshaft Thrust Washer To Back Side Of No 6 Main Bearing Cap

Courtesy of FORD MOTOR CO.

Install the No. 1 through No. 5 crankshaft lower main bearings into the main bearing caps. Locate the main bearing caps on the cylinder block and, keeping the cap as square as possible, alternately draw the cap down evenly using the cap fasteners.
Install the 12 bolts.

Fig 10: Installing No. 1 Through No. 5 Crankshaft Lower Main Bearings Bolts

Courtesy of FORD MOTOR CO.

Install the 12 dowel pins so that the flat sides face the crankshaft. Install the 12 cross-mounted bolts.

Fig 11: Installing Dowel Pins

Courtesy of FORD MOTOR CO.

Tighten fasteners 1 through 12 in 2 stages, in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.

Fig 12: Identifying Fasteners Tightening Sequence (1-12)

Courtesy of FORD MOTOR CO.

Tighten fasteners 13 through 24 in 2 stages, in the sequence shown.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 90 degrees.

Fig 13: Identifying Fasteners Tightening Sequence (13-24)

Courtesy of FORD MOTOR CO.

Check the piston-to-cylinder block and piston ring clearances. For additional information, refer to ENGINE SYSTEM - GENERAL INFORMATION article.
Assemble the 10 pistons. For additional information, refer to Piston .
Make sure the ring gaps (oil spacer-A, oil ring-B, compression ring-C) are correctly spaced around the circumference of the piston.

Fig 14: Identifying Piston Ring Gap Positioning

Courtesy of FORD MOTOR CO.

Make sure the dimple in the piston faces the front of the engine.

Fig 15: Making Sure Dimple In Piston Faces Front Of Engine

Courtesy of FORD MOTOR CO.

Using the Connecting Rod Installer and the Piston Ring Compressor, install the piston and connecting rod assembly.

Fig 16: Installing Piston And Connecting Rod Assembly

Courtesy of FORD MOTOR CO.

NOTE: Do not scratch the cylinder walls or crankshaft journals with the connecting rod, or engine damage may occur.

Once the connecting rod is seated on the crankshaft journal, remove the Connecting Rod Installer.

Fig 17: Identifying Special Tool (303-442)

Courtesy of FORD MOTOR CO.

NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

NOTE: The connecting rod caps are of the "cracked" design and must mate with the connecting rod ends. Excessive bearing clearance will result if not mated correctly.

Install the connecting rod bearings, position the connecting rod cap and loosely install the 2 new bolts.

NOTE: Be sure to tighten the bolts in 2 stages.

Tighten the connecting rod bolts in the sequence shown.
- Stage 1: Tighten to 43 Nm (32 lb-ft).
- Stage 2: Tighten an additional 105 degrees.

Fig 18: Tightening Connecting Rod Bolts In Sequence

Courtesy of FORD MOTOR CO.

Rotate the crankshaft and repeat the procedure to position each connecting rod at bottom dead center until all bolts are tightened to specification.
Position the oil pump and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 19: Locating Oil Pump Bolts

Courtesy of FORD MOTOR CO.

Install the oil pump screen and pickup tube spacer.
- Tighten to 25 Nm (18 lb-ft).

Fig 20: Installing Oil Pump Screen And Pickup Tube Spacer

Courtesy of FORD MOTOR CO.

NOTE: Make sure the O-ring is in place and not damaged. A missing or damaged O-ring can cause foam in the lubrication system, low oil pressure and severe engine damage.

NOTE: Clean and inspect the mating surfaces and install a new O-ring. Lubricate the O-ring with clean engine oil prior to installation.

Position the oil pump screen and pickup tube and install the 3 bolts.
- Tighten the oil pump screen and pickup tube-to-oil pump bolts to 10 Nm (89 lb-in).
- Tighten the oil pump screen and pickup tube-to-spacer bolt to 25 Nm (18 lb-ft).

Fig 21: Positioning Oil Pump Screen, Pickup Tube And Installing Bolts

Courtesy of FORD MOTOR CO.

Rotate the crankshaft to position the keyway at 12 o'clock.

Fig 22: Rotating Crankshaft To Position Keyway At 12 O'Clock

Courtesy of FORD MOTOR CO.

NOTE: Make sure all coolant residue and foreign material are cleaned from the block surface and cylinder bore, or engine damage may occur.

NOTE: The use of sealing aids (aviation cement, copper spray and glue) is not permitted. The gasket must be installed dry or engine damage may occur.

NOTE: The cylinder head bolts must be discarded and new bolts installed or engine damage may occur. They are a tighten-to-yield design and cannot be reused.

NOTE: Do not turn the crankshaft until instructed to do so.

NOTE: LH shown, RH similar.

Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the 24 cylinder head bolts loosely.

Fig 23: Installing Cylinder Head Bolts

Courtesy of FORD MOTOR CO.

NOTE: Be sure to tighten the bolts in 3 stages.

Tighten the bolts in the sequence shown.
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
- Stage 3: Tighten an additional 90 degrees.

Fig 24: Tightening Bolts In Sequence

Courtesy of FORD MOTOR CO.

Remove the Cylinder Head Remover/Installer from the LH cylinder head.

Fig 25: Identifying Special Tool (303-572) Onto Cylinder Head

Courtesy of FORD MOTOR CO.

Remove the Cylinder Head Remover/Installer from the RH cylinder head.

Fig 26: Identifying Special Tool (303-572) On Cylinder Head

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or engine damage may occur.

Install the hydraulic lash adjusters into the RH and LH cylinder heads.
- Lubricate the hydraulic lash adjusters with clean engine oil prior to installation.

Fig 27: Identifying Hydraulic Lash Adjusters

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or engine damage may occur.

NOTE: Camshaft shown installed to clarify camshaft roller follower position.

NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.

Install only the identified camshaft roller followers onto the RH cylinder head.

Fig 28: Installing Identified Camshaft Roller Followers Onto RH Cylinder Head

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or engine damage may occur.

NOTE: Camshaft shown installed to clarify camshaft roller follower position.

NOTE: Lubricate the camshaft roller followers with clean engine oil prior to installation.

Install only the identified camshaft roller followers onto the LH cylinder head.

Fig 29: Locating LH Camshaft Roller Followers

Courtesy of FORD MOTOR CO.

Install the LH and RH camshafts.
- Lubricate the camshaft and camshaft journals with clean engine oil prior to installation.
Install the 6 LH and 6 RH camshaft bearing caps in their original locations.
- Lubricate the camshaft bearing caps with clean engine oil.
- Position the 2 front camshaft bearing caps.
- Position the remaining 10 camshaft bearing caps.
- Install the 24 bolts loosely.
Tighten the 12 LH camshaft bearing cap bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.
- Stage 2: Tighten an additional 45 degrees.

Fig 30: Tightening LH Camshaft Bearing Cap Bolts In Sequence

Courtesy of FORD MOTOR CO.

Tighten the 12 RH camshaft bearing cap bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in) in the sequence shown.
- Stage 2: Tighten an additional 45 degrees.

Fig 31: Identifying RH Camshaft Bearing Cap Bolt Removal/Installation Sequence

Courtesy of FORD MOTOR CO.

Install the balance shaft drive gear onto the LH camshaft.
Install both camshaft sprockets and 2 camshaft sprocket bolts finger-tight.

NOTE: Timing chain procedures must be followed exactly or damage to valves and pistons will result.

NOTE: Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur.

Compress the tensioner plunger, using a vise.

Fig 32: Compressing Tensioner Plunger

Courtesy of FORD MOTOR CO.

Install a retaining clip on the tensioner to hold the plunger in during installation.

Fig 33: Identifying Retaining Clip on Tensioner

Courtesy of FORD MOTOR CO.

NOTE: There are 61 links in each timing chain.

If copper links are not visible, mark 2 links on one end and 1 link on the other end, and use as timing marks.

Fig 34: Locating Timing Chain Marks

Courtesy of FORD MOTOR CO.

Install the timing chain guides and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 35: Locating Timing Chain Guides Bolts

Courtesy of FORD MOTOR CO.

Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.

Fig 36: Positioning Crankshaft With Special Tool (303-448)

Courtesy of FORD MOTOR CO.

Position the camshafts.
- Rotate the LH camshaft until the timing mark is at approximately 12 o'clock.
- Rotate the RH camshaft until the timing mark is at approximately 11 o'clock.

Fig 37: Identifying LH And RH Camshaft Timing Mark Position

Courtesy of FORD MOTOR CO.

Install the crankshaft sprocket, making sure the flange faces forward.

Fig 38: Identifying Crankshaft Sprocket

Courtesy of FORD MOTOR CO.

Install the lower end of the LH timing chain, aligning the timing marks.

Fig 39: Aligning Timing Mark Of Crankshaft Sprocket With Single Copper Link On Chain

Courtesy of FORD MOTOR CO.

NOTE: Be sure the upper half of the timing chain is below the tensioner guide dowel.

Install the LH timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.

Fig 40: Aligning Timing Marks On Sprocket With Marked Chain Links

Courtesy of FORD MOTOR CO.

NOTE: The LH timing chain tensioner arm has a bump near the dowel hole for identification.

Position the LH timing chain tensioner arm on the dowel pin and install the LH timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 41: Identifying LH Timing Chain Tensioner & Tensioner Arm

Courtesy of FORD MOTOR CO.

NOTE: Be sure the chain link and crankshaft sprocket timing marks are aligned.

NOTE: The lower half of the timing chain must be positioned above the dowel.

Install the RH (outer) timing chain on the crankshaft sprocket.

Fig 42: Aligning Timing Mark On Crankshaft Sprocket With Single Copper Chain Link

Courtesy of FORD MOTOR CO.

Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.

Fig 43: Aligning Copper-Colored (Marked) Links With Camshaft Sprocket Timing Mark

Courtesy of FORD MOTOR CO.

Position the RH timing chain tensioner arm on the dowel pin and install the RH timing chain tensioner and the 2 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 44: Identifying RH Timing Chain Tensioner, Tensioner Arm And Bolts

Courtesy of FORD MOTOR CO.

Remove the retaining clips from the RH and LH timing chain tensioners.

Fig 45: Identifying Retaining Clip And Timing Chain Tensioner

Courtesy of FORD MOTOR CO.

Check for correct alignment of all timing marks.

Fig 46: Identifying Alignment Of All Timing Marks

Courtesy of FORD MOTOR CO.

Install the crankshaft sensor ring on the crankshaft.

Fig 47: View Of Crankshaft Sensor Ring At Crankshaft

Courtesy of FORD MOTOR CO.

NOTE: Only use hand tools to tighten the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.

Tighten the RH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.

Fig 48: Identifying Camshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

NOTE: Only use hand tools to tighten the camshaft sprocket bolt or damage to the camshaft or camshaft sprocket may occur.

Tighten the LH camshaft sprocket bolt in 2 stages:
- Stage 1: Tighten to 40 Nm (30 lb-ft).
- Stage 2: Tighten an additional 90 degrees.

Fig 49: Identifying LH Camshaft Sprocket Bolt

Courtesy of FORD MOTOR CO.

Rotate the crankshaft clockwise and position the crankshaft keyway at the 6 o'clock position.

Fig 50: Crankshaft Positioned With Keyway At 6 O'clock Position

Courtesy of FORD MOTOR CO.

Remove the 2 bolts and the middle balance shaft bearing support and camshaft bearing cap assembly.

Fig 51: Identifying Bolts And Camshaft Bearing Cap

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push the valve down while compressing the spring.

Using the Valve Spring Compressor, install the roller follower.
- Lubricate the camshaft roller follower with clean engine oil prior to installation.

Fig 52: Installing Roller Follower

Courtesy of FORD MOTOR CO.

Position the camshaft bearing cap and install the 2 bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.

Fig 53: Identifying Bolts And Camshaft Bearing Cap

Courtesy of FORD MOTOR CO.

Remove the 2 bolts and the rear balance shaft bearing support and camshaft bearing cap assembly.

Fig 54: Identifying Bolts And Camshaft Bearing Cap

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

NOTE: Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed.

NOTE: It may be necessary to push the valve down while compressing the spring.

Using the Valve Spring Compressor, install the roller follower.
- Lubricate the camshaft roller follower with clean engine oil prior to installation.

Fig 55: Installing Roller Follower

Courtesy of FORD MOTOR CO.

Position the camshaft bearing cap and install the 2 bolts in 2 stages:
- Stage 1: Tighten to 8 Nm (71 lb-in).
- Stage 2: Tighten an additional 45 degrees.

Fig 56: Identifying Bolts And Camshaft Bearing Cap

Courtesy of FORD MOTOR CO.

NOTE: If the components are to be reinstalled, they must be installed into their original locations or damage to the engine may occur.

Using the Valve Spring Compressor, install all of the remaining camshaft roller followers.
- Lubricate the camshaft roller followers with clean engine oil prior to installation.

Fig 57: Compressing Spring Using Special Tool (303-1039)

Courtesy of FORD MOTOR CO.

Rotate the crankshaft counterclockwise and position the crankshaft keyway at the 11 o'clock position.
Lubricate the balance shaft journals with clean engine oil.

NOTE: Camshaft sprocket removed from art for clarity.

Position the balance shaft on the journals and align the timing mark on the balance shaft with the camshaft timing mark as shown.

Fig 58: Positioning Balance Shaft On Journals & Aligning Timing Mark On Balance Shaft With Camshaft Timing Mark

Courtesy of FORD MOTOR CO.

NOTE: The balance shaft bearing caps must be installed into their original locations or engine damage may occur.

Install the 6 bolts and tighten in the sequence shown.
- Tighten to 10 Nm (89 lb-in).

Fig 59: Identifying Balance Shaft Bolt Loosening/Tightening Sequence

Courtesy of FORD MOTOR CO.

NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

NOTE: If the engine front cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and motorcraft metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

NOTE: Make sure that the engine front cover gasket is in place on the engine front cover before installation.

Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface at the locations shown.

Fig 60: Applying Bead Of Silicone Gasket And Sealant Along Cylinder Head-To-Cylinder Block Surface

Courtesy of FORD MOTOR CO.

Install a new engine front cover gasket on the engine front cover. Position the engine front cover onto the dowels. Install the 15 fasteners finger-tight.

Fig 61: Installing Engine Front Cover Gasket

Courtesy of FORD MOTOR CO.

Tighten the 15 engine front cover fasteners in sequence in 2 stages.

Stage 1: Tighten fasteners 1 through 15 to 25 Nm (18 lb-ft).

Stage 2: Tighten fasteners 6 and 7 to 48 Nm (35 lb-ft).

Item	Part Number	Description
1	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
2	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
3	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
4	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
5	N806177	Bolts, Hex Flange Head Pilot, M8 x 1.25 x 50
6	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
7	N808529	Stud, Hex Head Pilot, M10 x 1.5 x 1.5 x 103
8	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
9	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
10	N806177	Bolt, Hex Flange Head Pilot, M8 x 1.25 x 50
11	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
12	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
13	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
14	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 1.25 x 94
15	W709573	Stud and Washer, Hex Head Pilot, M8 x 1.25 x 56

Fig 62: Tightening Front Cover Fasteners In Sequence

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the O-ring seal with clean engine oil prior to installation.

Install the Camshaft Position (CMP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 63: Locating Camshaft (CMP) Sensor Bolt

Courtesy of FORD MOTOR CO.

NOTE: Do not rotate the coolant pump housing once the coolant pump has been positioned in the cylinder block. Damage to the O-ring seal will occur.

Position the coolant pump and install the bolts loosely.
- Lubricate the new O-ring seal using clean engine coolant and install the O-ring seal onto the coolant pump.

Fig 64: Identifying Coolant Pump

Courtesy of FORD MOTOR CO.

Tighten the 4 coolant pump bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 65: Coolant Pump Bolts

Courtesy of FORD MOTOR CO.

Lubricate the engine front cover and the crankshaft seal inner lip with clean engine oil.

Fig 66: Locating Crankshaft Front Seal

Courtesy of FORD MOTOR CO.

Using the Crankshaft Vibration Damper Installer, Front Cover Seal Installer and Crankshaft Front Oil Seal Installer, install a new crankshaft front seal.

Fig 67: Installing Crankshaft Front Seal Using Special Tools (303-102, 303-335, 303-635)

Courtesy of FORD MOTOR CO.

NOTE: If not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and motorcraft metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

Apply silicone gasket and sealant to the Woodruff key slot on the crankshaft pulley.

Fig 68: Applying Silicone Gasket And Sealant To Woodruff Key Slot On Crankshaft Pulley

Courtesy of FORD MOTOR CO.

Using the Crankshaft Vibration Damper Installer, install the crankshaft pulley.

Fig 69: Installing Crankshaft Pulley Using Special Tool (303-102)

Courtesy of FORD MOTOR CO.

Tighten the new crankshaft pulley bolt in 4 stages.
- Stage 1: Tighten to 90 Nm (66 lb-ft).
- Stage 2: Loosen 360 degrees.
- Stage 3: Tighten to 50 Nm (37 lb-ft).
- Stage 4: Tighten an additional 90 degrees.

Fig 70: Identifying Crankshaft Pulley Bolt Tightening Sequence

Courtesy of FORD MOTOR CO.

Position the Crankshaft Position (CKP) sensor and the bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 71: Locating Crankshaft Position (CKP) Sensor Bolt

Courtesy of FORD MOTOR CO.

Position the accessory drive belt tensioner and install the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 72: Identifying Accessory Drive Belt Tensioner Bolts

Courtesy of FORD MOTOR CO.

Install the accessory drive belt idler pulley, the coolant pump pulley and the 5 bolts.
- Tighten to 25 Nm (18 lb-ft).

Fig 73: Identifying Coolant Pump Pulley Bolts And Idler Pulley Bolt

Courtesy of FORD MOTOR CO.

NOTE: LH shown, RH similar.

Install the cylinder block drain plugs.
- Tighten to 24 Nm (18 lb-ft).

Fig 74: Locating Cylinder Block Drain Plug

Courtesy of FORD MOTOR CO.

NOTE: Clean and inspect the mating surfaces, and install a new gasket.

Position the oil filter adapter and install the 4 bolts and the nut.
- Tighten the bolts to 25 Nm (18 lb-ft).
- Tighten the nut to 48 Nm (35 lb-ft).

Fig 75: Positioning Oil Filter Adapter Bolts And Nut

Courtesy of FORD MOTOR CO.

NOTE: RH shown, LH similar.

Install 20 new exhaust manifold-to-cylinder head studs.
- Tighten to 12 Nm (106 lb-in).

Fig 76: Locating Exhaust Manifold-To-Cylinder Head Studs

Courtesy of FORD MOTOR CO.

Position 2 new gaskets, the LH exhaust manifold and tighten the 10 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).

Fig 77: Identifying Tightening Sequence For LH Exhaust Manifold Bolts

Courtesy of FORD MOTOR CO.

Position the exhaust manifold heat shield and install the 3 bolts.
- Tighten to 14 Nm (124 lb-in).

Fig 78: Locating Bolts On Exhaust Manifold Heat Shield

Courtesy of FORD MOTOR CO.

NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

NOTE: Clean the engine support insulator bracket mounting surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine support insulator damage.

NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.

Position the engine support insulator bracket and install 3 new bolts in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional minimum of 60 degrees.

Fig 79: Locating Engine Support Insulator Bracket Bolts

Courtesy of FORD MOTOR CO.

Position 2 new gaskets, the RH exhaust manifold and tighten the 10 new nuts in the sequence shown.
- Tighten to 25 Nm (18 lb-ft).

Fig 80: Identifying Tightening Sequence For RH Exhaust Manifold Bolts

Courtesy of FORD MOTOR CO.

Position the exhaust manifold heat shield and install the 2 bolts.
- Tighten to 14 Nm (124 lb-in).

Fig 81: Locating Bolts On Exhaust Manifold Heat Shield

Courtesy of FORD MOTOR CO.

NOTE: The engine support insulator bracket bolts must be discarded and new bolts installed. They are a tighten-to-yield design and cannot be reused.

NOTE: The engine support insulator bracket bolts must not be tightened more than 90 degrees after initial torque.

Position the engine support insulator bracket and install 3 new bolts in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional minimum of 60 degrees.

Fig 82: Locating Engine Support Insulator Bracket Bolts

Courtesy of FORD MOTOR CO.

NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the valve cover mating surface with silicone gasket remover and motorcraft metal surface prep. Follow the directions on the packaging.

NOTE: If the valve cover is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned with silicone gasket remover and motorcraft metal surface prep. Follow the directions on the packaging. Allow to dry until there is no sign of wetness, or 4 minutes, whichever is longer. Failure to follow this procedure may cause future oil leakage.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

Fig 83: Identifying Silicone Gasket And Sealant Application Points

Courtesy of FORD MOTOR CO.

Position the RH valve cover and new gasket on the cylinder head and tighten the 16 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).

Fig 84: Identifying Valve Cover Fasteners Loosening/Tightening Sequence

Courtesy of FORD MOTOR CO.

Clean the valve cover mating surface with silicone gasket remover and motorcraft metal surface prep. Follow the directions on the packaging.

Apply a bead of silicone gasket and sealant in 2 places where the engine front cover meets the cylinder head.

Fig 85: Identifying Silicone Gasket And Sealant Application Points

Courtesy of FORD MOTOR CO.

Position the LH valve cover and new gasket on the cylinder head and tighten the 17 fasteners in the sequence shown.
- Tighten to 10 Nm (89 lb-in).

Fig 86: Identifying Valve Cover Fasteners Tightening Sequence

Courtesy of FORD MOTOR CO.

NOTE: Do not reuse the O-ring seals.

NOTE: Lubricate the new O-ring seals with clean engine coolant prior to installation.

Slide the coolant tube forward with the new O-ring seals into the cylinder block.

Fig 87: Sliding Coolant Tube Forward With O-Ring Seals Into Cylinder Block

Courtesy of FORD MOTOR CO.

Install the coolant tube stud bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 88: Identifying Coolant Tube Stud Bolt

Courtesy of FORD MOTOR CO.

Install the 2 Knock Sensor (KS)s and the bolts.
- Tighten to 20 Nm (177 lb-in).

Fig 89: Identifying Knock Sensors (KS)

Courtesy of FORD MOTOR CO.

Install the oil level indicator tube and the front bolt.
- Tighten to 25 Nm (18 lb-ft).
- Install a new O-ring seal and lubricate with clean engine oil prior to installation.

Fig 90: Locating Front Oil Level Indicator Tube Bolt

Courtesy of FORD MOTOR CO.

Install the rear oil level indicator tube bolt.
- Tighten to 10 Nm (89 lb-in).

Fig 91: Locating Rear Oil Level Indicator Tube Bolt

Courtesy of FORD MOTOR CO.

Position the electrical harness on the engine assembly and connect the engine wiring harness retainers to the valve cover studs and the valve covers.
Connect the CKP sensor electrical connector.

Fig 92: Locating CKP Sensor Electrical Connector And Harness Retainer

Courtesy of FORD MOTOR CO.

NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.

NOTE: Apply a light coat of dielectric compound to the inside of the ignition coil boots prior to installation.

Install the 10 ignition coils and the 10 bolts.
- Tighten to 6 Nm (53 lb-in).

Fig 93: Locating Ignition Coils Bolts

Courtesy of FORD MOTOR CO.

Connect the 10 ignition coil electrical connectors.

Fig 94: Locating Ignition Coil Electrical Connectors

Courtesy of FORD MOTOR CO.

Install the LH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).

Fig 95: Identifying LH Radio Ignition Interference Capacitor And Stud Bolt

Courtesy of FORD MOTOR CO.

Connect the Engine Oil Pressure (EOP) switch electrical connector.

Fig 96: Identifying Engine Oil Pressure (EOP) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the Cylinder Head Temperature (CHT) sensor electrical connector.

Fig 97: Locating Cylinder Head Temperature (CHT) Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Install the RH radio ignition interference capacitor and the nut.
- Tighten to 25 Nm (18 lb-ft).

Fig 98: Identifying RH Radio Ignition Interference Capacitor Stud Bolt

Courtesy of FORD MOTOR CO.

Connect the CMP sensor electrical connector.

Fig 99: Identifying RH CMP Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

NOTE: The large clutch assembly nut has a RH thread and must be rotated clockwise to install it.

Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, install the engine cooling fan onto the cooling pump pulley.
- Tighten to 133 Nm (98 lb-ft).

Fig 100: Fan Clutch Assembly Nut - 6.8L

Courtesy of FORD MOTOR CO.

Using a suitable floor crane, remove the engine from the engine stand.
Lower and support the engine assembly on wood blocks.
Install the Engine Lifting Bracket.

Fig 101: Identifying Special Tool (303-F047)

Courtesy of FORD MOTOR CO.

Using a suitable floor crane, raise the engine.

NOTE: 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.

Inspect the crankshaft rear seal retainer plate. Clean the mating surface for the rear seal retainer plate with silicone gasket remover and motorcraft metal surface prep. Follow the directions on the packaging.

Apply a 4 mm (0.16 in) bead of silicone gasket and sealant around the crankshaft rear seal retainer sealing surface.

Fig 102: Applying Sealant Around Crankshaft Rear Seal Retainer Plate Sealing Surface

Courtesy of FORD MOTOR CO.

Install the crankshaft rear seal retainer plate and loosely install the 6 bolts.

Fig 103: Locating Crankshaft Rear Seal Retainer Plate Bolts

Courtesy of FORD MOTOR CO.

Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).

Fig 104: Tightening Bolts In Sequence

Courtesy of FORD MOTOR CO.

NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Inspect the oil pan. Clean the mating surface for the oil pan with silicone gasket remover and motorcraft metal surface prep. Follow the directions on the packaging.

Apply silicone gasket and sealant at the crankshaft rear seal retainer plate-to-cylinder block sealing surface.

Fig 105: Applying Silicone Gasket And Sealant

Courtesy of FORD MOTOR CO.

Apply silicone gasket and sealant at the engine front cover-to-cylinder block sealing surface.

Fig 106: Applying Sealant At Engine Front Cover-To-Cylinder Block Mating Surface

Courtesy of FORD MOTOR CO.

Install the oil pan gasket and the oil pan and loosely install the 18 bolts.
Tighten the bolts in 3 stages, in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 20 Nm (177 lb-in).
- Stage 3: Tighten an additional 60 degrees.

Fig 107: Identifying Tightening Sequence For Oil Pan Bolts

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the crankshaft rear seal with clean engine oil prior to installation.

Using the Crankshaft Rear Oil Seal Installers, install a new crankshaft rear seal.

Fig 108: Using Special Tools (303-516, 303-518) To Install New Crankshaft Rear Seal

Courtesy of FORD MOTOR CO.

NOTE: Lubricate the crankshaft oil slinger with clean engine oil prior to installation.

Using the Crankshaft Rear Oil Seal Installers and the Crankshaft Rear Oil Slinger Installer, install a new crankshaft oil slinger.

Fig 109: Installing Crankshaft Rear Oil Slinger Using Special Tools (303-516, 303-517, 303-518)

Courtesy of FORD MOTOR CO.

Install the flexplate or flywheel and the 8 bolts in the sequence shown.
- Tighten to 80 Nm (59 lb-ft).

Fig 110: Identifying Tightening Sequence For Flexplate Or Flywheel Bolts

Courtesy of FORD MOTOR CO.

Install the engine. For additional information, refer to Engine .