Section 2471 (Engine Mechanical - 6.4L 99R Diesel -- F250-F550 Super Duty): Assembly: Engine: Assembly

All vehicles 

NOTE: Check alignment of the oil holes after installing the bearings.
Fig 1: Installing Camshaft Bearings
Courtesy of FORD MOTOR CO.
1. If removed, use the Camshaft Service Set to install the camshaft bearings.
NOTE: The patch bolt is unique. Do not substitute the patch bolt or engine damage may occur.
NOTE: Apply threadlock to the threads prior to installation.
2. Install the 8 piston cooling tubes and the 8 bolts.
   • Tighten to 13 Nm (115 lb-in).
     Fig 2: Locating Bolts And Piston Cooling Tubes

     Courtesy of FORD MOTOR CO.
NOTE: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage may occur.
NOTE: Apply clean engine oil to the camshaft prior to installing.
3. Install the camshaft and gear assembly and the 2 thrust plate mounting bolts.
   • Tighten to 31 Nm (23 lb-ft).
     Fig 3: Locating Thrust Plate Mounting Bolts

     Courtesy of FORD MOTOR CO.
4. Install the 4 new crankshaft upper bearings and the new crankshaft upper thrust bearing.
   • Apply clean engine oil to the crankshaft side of the bearings.
     Fig 4: Locating Crankshaft Upper Bearings And Crankshaft Upper Thrust Bearing

     Courtesy of FORD MOTOR CO.
NOTE: Make sure the 2 dowels on the back of the camshaft alignment tool insert into the holes in the camshaft gear.
Fig 5: Installing Camshaft Alignment Tool, Aligning Camshaft Timing Mark
Courtesy of FORD MOTOR CO.
5. Install the Camshaft Alignment Tool, aligning the camshaft timing mark as shown in the illustration.
NOTE: Apply clean engine oil to the crankshaft bearing journals prior to installing the crankshaft.
Fig 6: Installing Crankshaft With Crankshaft Timing Peg In Slot In Camshaft Alignment Tool, Over Camshaft Timing Mark
Courtesy of FORD MOTOR CO.
6. Install the crankshaft with the crankshaft timing peg in the slot in the Camshaft Alignment Tool, over the camshaft timing mark.
NOTE: Do not turn the crankshaft during the main bearing clearance check.
7. Position commercially available plastigage in the center of each main bearing cap.
NOTE: The locking tabs on the bearings shell are directional.
Fig 7: Locating Crankcase Lower Bearings In Lower Crankcase
Courtesy of FORD MOTOR CO.
8. Install the 5 new crankcase lower bearings into the lower crankcase.
NOTE: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.
NOTE: Lightly lubricate the new crankcase main bearing mounting bolt threads and flanges with clean engine oil.
9. Position the lower crankcase and install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in 3 stages in the sequence shown in the illustration.
   • Stage 1: Tighten to 149 Nm (110 lb-ft).
   • Stage 2: Tighten to 176 Nm (130 lb-ft).
   • Stage 3: Tighten to 231 Nm (170 lb-ft).
     Fig 8: Identifying Lower Crankcase Main Bearing Mounting Bolts Tightening Sequence

     Courtesy of FORD MOTOR CO.
10. Remove the 20 bolts and the lower crankcase.
    Fig 9: Locating Lower Crankcase Main Bearing Bolts

    Courtesy of FORD MOTOR CO.
11. Measure the clearances for the main bearings. Remove the plastigage.
    Fig 10: Measuring Clearances For Main Bearings

    Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the lower main bearings.
NOTE: Clean the groove and sealing surfaces of the upper and lower crankcase with metal brake parts cleaner or equivalent prior to applying the gasket maker.
NOTE: Make sure the gasket maker is used sparingly and spread to form a thin film on the surfaces.
Fig 11: Locating Lower Crankcase Seals And Crankshaft Lower Bearings
Courtesy of FORD MOTOR CO.
12. Apply a thin film of gasket maker to the bottom of the groove and the sealing surfaces of the lower crankcase. Install the new lower crankcase seals on the film of gasket maker in the grooves of the lower crankcase. Apply a thin film of gasket maker on the upper crankcase sealing surfaces.
NOTE: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.
13. Position the lower crankcase and install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in 3 stages in the sequence shown in the illustration.
    • Stage 1: Tighten to 149 Nm (110 lb-ft).
    • Stage 2: Tighten to 176 Nm (130 lb-ft).
    • Stage 3: Tighten to 231 Nm (170 lb-ft).
      Fig 12: Identifying Lower Crankcase Main Bearing Mounting Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Failure to remove the Camshaft Alignment Tool will result in incorrect readings.
Fig 13: Locating Bolt And Camshaft Alignment Tool
Courtesy of FORD MOTOR CO.
14. Remove the bolt and Camshaft Alignment Tool.
NOTE: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.
Fig 14: Measuring Crankshaft End Play
Courtesy of FORD MOTOR CO.
15. Using the Dial Indicator Gauge with Holding Fixture, measure the crankshaft end play.
16. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play.
    Fig 15: Measuring Camshaft End Play

    Courtesy of FORD MOTOR CO.
17. Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft gear backlash.
    Fig 16: Measuring Camshaft Gear Backlash

    Courtesy of FORD MOTOR CO.
18. Install the block heater.
    • Tighten to 41 Nm (30 lb-ft).
      Fig 17: Locating Block Heater

      Courtesy of FORD MOTOR CO.
19. Install the Camshaft Position (CMP) sensor and the bolt.
    • Tighten to 13 Nm (115 lb-in).
      Fig 18: Locating Bolt And CMP Sensor

      Courtesy of FORD MOTOR CO.
20. Install the Crankshaft Position (CKP) sensor and the bolt.
    • Tighten to 13 Nm (115 lb-in).
      Fig 19: Locating Bolt And CKP Sensor

      Courtesy of FORD MOTOR CO.
NOTE: The connecting rods are powdered metal cracked rods. Make sure the connecting rod and cap are installed as a set or engine damage may occur.
NOTE: Lubricate the connecting rod bearings with clean engine oil prior to installation.
Fig 20: Locating Connecting Rod Bearings
Courtesy of FORD MOTOR CO.
21. Install the new connecting rod bearings.
NOTE: Make sure the ring openings are 120 degrees from each other or engine damage may occur.
22. Install new piston rings.
    1. The top compression ring is identified with one indentation mark and a 15-degree keystone cross section. The ring must be installed with the indentation mark facing towards the piston crown (top).
    2. The intermediate ring is identified with 2 indentation marks and a rectangular profile. The ring must be installed with the indentation marks facing towards the piston crown (top).
    3. Install the oil control ring. Make sure the oil ring gap is 180-degrees from the spring wire latch.
       Fig 21: Identifying Piston Rings

       Courtesy of FORD MOTOR CO.
NOTE: The piston assembly must be installed with the words "Cam Side" toward the inside of the engine, along with the long side of the connecting rod big end split.
NOTE: Use care when installing the piston assembly to not damage the piston cooling tubes. If the tube is bent during installation of the piston assembly, install a new piston cooling tube.
NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.
23. Install the piston and rod assemblies.
    1. Coat the inside diameter of the Piston Ring Compressor with clean engine oil.
    2. Insert the piston into the Piston Ring Compressor. Position the piston, connecting rod and Piston Ring Compressor into the correct cylinder bore.
       • Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.
         Fig 22: Installing Piston And Rod Assemblies Into Cylinder Bore

         Courtesy of FORD MOTOR CO.
24. Position a piece of plastigage across the bearing surface.
    Fig 23: Positioning Piece Of Plastigage Across Bearing Surface

    Courtesy of FORD MOTOR CO.
NOTE: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage may occur.
25. Position the connecting rod cap and tighten the bolts in 2 stages.
    • Stage 1: Tighten to 45 Nm (33 lb-ft).
    • Stage 2: Tighten to 68 Nm (50 lb-ft).
      Fig 24: Locating Connecting Rod Caps Bolts

      Courtesy of FORD MOTOR CO.
26. Remove the bolts and the connecting rod cap.
27. Measure the clearances for the connecting rod cap. Remove the plastigage.
    Fig 25: Measuring Clearances For Connecting Rod Cap

    Courtesy of FORD MOTOR CO.
NOTE: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage may occur.
28. Position the connecting rod cap and tighten the bolts in 2 stages.
    • Stage 1: Tighten to 45 Nm (33 lb-ft).
    • Stage 2: Tighten to 68 Nm (50 lb-ft).
      Fig 26: Locating Connecting Rod Caps Bolts

      Courtesy of FORD MOTOR CO.
29. Using a Feeler Gauge Set, check for connecting rod side clearance.
    Fig 27: Checking For Connecting Rod Side Clearance

    Courtesy of FORD MOTOR CO.
NOTE: Upper oil pan gasket shown in the illustration.
Fig 28: Locating Upper Oil Pan Press-In-Place Upper And Lower Oil Pan Gasket
Courtesy of FORD MOTOR CO.
30. Install a new press-in-place upper and lower oil pan gasket into the upper oil pan.
31. Position the upper oil pan and install the 9 bolts.
    • Tighten to 13 Nm (115 lb-in).
      Fig 29: Locating Upper Oil Pan Bolts

      Courtesy of FORD MOTOR CO.
32. Install a new O-ring seal. Install the oil pump screen and pickup tube and the 2 bolts.
    • Tighten to 13 Nm (115 lb-in).
      Fig 30: Locating Bolts, Oil Pump Screen And Pickup Tube

      Courtesy of FORD MOTOR CO.
33. Install the oil pan and the 22 bolts.
    1. Install the 5 longer oil pan bolts.
    2. Install the 17 remaining oil pan bolts.
       • Tighten to 13 Nm (115 lb-in).
         Fig 31: Identifying Oil Pan Bolts

         Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original positions.
34. Apply clean engine oil to the valve tappets and install them into the valve tappet guides. Install the valve tappet guides and the 4 bolts.
    • Tighten to 13 Nm (115 lb-in).
      Fig 32: Locating Bolts And Valve Tappet Guides

      Courtesy of FORD MOTOR CO.
35. Install the 4 cylinder head dowels.
    Fig 33: Locating Cylinder Head Dowel Sleeves

    Courtesy of FORD MOTOR CO.
NOTE: Install a new cylinder head gasket with the part number facing up. Verify the top 5 bolt holes and the head gasket push rod holes line up.
NOTE: Use care to avoid scratching the blue compound on the cylinder head gaskets.
Fig 34: Locating Cylinder Head Gaskets
Courtesy of FORD MOTOR CO.
36. Place the 2 new cylinder head gaskets over the dowel sleeves and onto the crankcase.
37. Using the Cylinder Head Lifting Bracket, install the cylinder heads.
    Fig 35: Locating Cylinder Head Lifting Bracket

    Courtesy of FORD MOTOR CO.
38. Install the 5 outer bolts for each cylinder head.
    • Tighten finger-tight.
      Fig 36: Locating Cylinder Head Outer Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Using too much engine oil on the threads of the cylinder head bolts may cause damage to the threads and poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads may affect the true torque value of the bolts.
NOTE: Left cylinder head shown in the illustration, right cylinder head similar.
NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
39. Install the 10 cylinder head retaining bolts for each cylinder head.
    • Tighten finger-tight.
      Fig 37: Locating Cylinder Head Bolts

      Courtesy of FORD MOTOR CO.
NOTE: If bolt chatter occurs during Stage 4 or 5, loosen the bolt and repeat Stage 3.
40. Tighten the cylinder head bolts in 7 stages in the sequence shown in the illustration:
    • Stage 1: Tighten bolts 1 through 10 to 95 Nm (70 lb-ft).
    • Stage 2: Loosen bolts 1 through 10.
    • Stage 3: Tighten bolts 1 through 10 to 156 Nm (115 lb-ft).
    • Stage 4: Tighten bolts in sequence, 1 through 10, an additional 90 degrees.
    • Stage 5: Tighten bolts in sequence, 1 through 10, a second time, an additional 90 degrees.
    • Stage 6: Tighten bolts 11 through 15 to 24 Nm (18 lb-ft).
    • Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
      Fig 38: Identifying Cylinder Head Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Lubricate the seals with clean engine oil prior to installation.
Fig 39: Locating High-Pressure Fuel Rail Seal
Courtesy of FORD MOTOR CO.
41. If necessary, install the new seals for the high-pressure fuel rail.
42. Install the new press-in-place gaskets, the valve cover bases and the 22 bolts.
    • Tighten to 13 Nm (115 lb-in).
      Fig 40: Locating Bolts And Valve Cover Bases

      Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
NOTE: Install the copper ends of the push rods facing upward.
Fig 41: Locating Push Rods
Courtesy of FORD MOTOR CO.
43. Apply clean engine oil to each end of the push rods and insert them into their respective positions.
NOTE: Coat the end of each valve stem with clean engine oil.
Fig 42: Locating Valve Bridges
Courtesy of FORD MOTOR CO.
44. Install the 16 valve bridges.
45. Position the 2 rocker arm spacer bars.
    Fig 43: Locating Rocker Arm Spacer Bars

    Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the top center of each valve bridge and rocker arm ball socket.
46. Install the rocker arm assemblies and the 16 bolts in the following sequence.
    1. Position the crankshaft with the No. 1 and the No. 4 cylinders at approximately Top Dead Center (TDC) by observing the damper dowel pin and clocking it to the 10:30 position (as viewed from the front of the engine).
    2. Determine which cylinder is actually in the firing position by observing the push rods for No. 3 intake and No. 8 intake valves.
    3. If the No. 3 intake push rod shows cam lift, this is the No. 1 firing position. Tighten only fulcrum plates No. 1, 2, 7 and 8 per Substeps 4 through  6. If the No. 8 intake push rod shows cam lift, this is the No. 4 firing position. Tighten only fulcrum plates No. 3, 4, 5 and 6 per Substeps 4 through  6.
    4. Partially run down both M10 bolts until they contact the fulcrum plate.
    5. Fully run down and tighten the inboard (upper) bolt.
       • Tighten to 61 Nm (45 lb-ft).
    6. Fully run down and tighten the outboard (lower) bolt.
       • Tighten to 61 Nm (45 lb-ft).
    7. Rotate the crankshaft one revolution to position it at the alternate cylinder TDC  (dowel again at 10:30 position).
    8. Identify the remaining group of fulcrum plates per Substep  3 and tighten per Substeps  4 through  6.
    9. Verify that the pivot foot is centered on the valve bridge.
       Fig 44: Locating Rocker Arm Assemblies Bolts

       Courtesy of FORD MOTOR CO.
NOTE: The bead on the soft steel washer must be installed facing out.
NOTE: Lubricate the fuel injector and O-ring seal with clean engine oil.
Fig 45: Locating O-Ring Seal And Soft Steel Washer On Fuel Injector
Courtesy of FORD MOTOR CO.
47. Install a new O-ring seal and a soft steel washer on the fuel injector.
NOTE: Failure to tighten the fuel injector correctly can lead to engine failure.
NOTE: To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the fuel injector can dislodge and fall into the oil drain hole.
48. Install the fuel injector, the fuel injector hold down and bolt.
    • Tighten to 2 Nm (18 lb-in).
      Fig 46: Locating Fuel Injector Hold Down Bolt

      Courtesy of FORD MOTOR CO.
NOTE: RH shown in the illustration, LH similar.
49. Install the high-pressure fuel rails and 4 bolts.
    • Tighten hand-tight.
      Fig 47: Locating Bolts And High-Pressure Fuel Rails

      Courtesy of FORD MOTOR CO.
NOTE: Use a back-up wrench on the fuel injector fittings.
NOTE: Use a crowfoot wrench to aid in tightening the fuel injector supply tube.
50. Install the new fuel injector supply tubes in the following sequence.
    1. Remove the protective caps from the high-pressure fuel rails and fuel injectors one at a time prior to assembly of each tube.
    2. Position the 8 fuel injector supply tubes (one at a time) between the high-pressure fuel rail and fuel injectors, and fully hand start and seat the tube nuts onto the mating high-pressure fuel rail and fuel injector connectors. Snug the fuel injector supply tube nuts using the inside-out step sequence (2 inside tubes first, then 2 outside tubes).
       • Calculate the correct torque wrench setting for the following torque. Refer to the illustration   . See Fig 48.
         Fig 48: Torque Wrench Adapter Formulas

         
       • Tighten to 2 Nm (18 lb-in).
    3. Tighten the fuel injector hold-down clamp bolts.
       • Tighten to 38 Nm (28 lb-ft).
    4. Tighten the high-pressure fuel rail bolts.
       • Tighten to 31 Nm (23 lb-ft).
    NOTE: Pre-tighten the 8 fuel injector tube nuts at the fuel injectors first, then the 8 nuts at the high-pressure fuel rails.
    5. Pre-tighten the fuel injector tube nuts at the fuel injectors and at the high-pressure fuel rails.
       • Calculate the correct torque wrench setting for the following torque. Refer to the illustration   . See Fig 49.
         Fig 49: Torque Wrench Adapter Formulas

         
       • Tighten to 12 Nm (106 lb-in).
    NOTE: Place a visible mark with a permanent marker on the high-pressure fuel rail and fuel injector threaded connection. Turning the tube nuts one flat of the nut is equal to 60 degrees.
    6. Complete the tightening of the fuel injector tube nuts at the fuel injectors and at the high-pressure fuel rails.
       • Tighten the tube nuts 60 degrees.
         Fig 50: Locating Fuel Injector Supply Tubes

         Courtesy of FORD MOTOR CO.
NOTE: The terminals in the fuel charging harness plug are not serviced, install a new the fuel charging harness if damaged.
NOTE: Inspect the O-ring seals for damage or swelling prior to installing, install a new O-ring seal if necessary.
Fig 51: Locating Fuel Charging Harness Electrical Connectors
Courtesy of FORD MOTOR CO.
51. Install the 2 fuel charging harness electrical connectors into the valve cover bases.
NOTE: RH side shown in the illustration, LH side similar.
Fig 52: Locating High-Pressure Fuel Rail And Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
52. Position the fuel charging harness on the high-pressure fuel rail and connect the 8 fuel injector electrical connectors. Connect the Fuel Rail Pressure (FRP) sensor electrical connector.
53. Install the 8 glow plugs.
    • Tighten to 14 Nm (124 lb-in).
      Fig 53: Locating Glow Plugs

      Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, do not use air-powered tools when installing the valve cover.
NOTE: Alternate tightening the bolts to tighten evenly.
NOTE: RH shown in the illustration, LH similar.
54. Install new press-in-place gaskets. Install the valve covers, 6 bolts and 4 stud bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 54: Locating Stud Bolts, Bolts And Valve Covers

      Courtesy of FORD MOTOR CO.
55. Position the crankcase vent oil separator tube. Install the 2 bolts and nut.
    • Tighten the nut to 13 Nm (115 lb-in).
    • Tighten the bolts to 25 Nm (18 lb-ft).
      Fig 55: Locating Nut, Bolts And Crankcase Vent Oil Separator Tube

      Courtesy of FORD MOTOR CO.
56. Connect the crankcase vent oil separator tube at the crankcase.
    Fig 56: Locating Crankcase Vent Oil Separator Tube

    Courtesy of FORD MOTOR CO.
57. Position the LH valve cover bracket and the Exhaust Pressure (EP) tube assembly. Install the 4 retaining nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 57: Locating Retaining Nuts, LH Valve Cover Bracket And EP Sensor Tube Assembly

      Courtesy of FORD MOTOR CO.
NOTE: Only one glow plug connector shown in the illustration.
58. Install the glow plug harnesses and connect the retainers.
    • Make sure the seals are securely seated in the valve covers.
      Fig 58: Locating Glow Plug Seals, Valve Cover And Retainers

      Courtesy of FORD MOTOR CO.
NOTE: Install a new O-ring seal on the oil indicator and tube. Apply clean engine oil to the O-ring seal.
59. Install the oil indicator and tube. Install the bolt.
    • Tighten to 13 Nm (115 lb-in).
      Fig 59: Locating Oil Level Indicator Tube Bolt

      Courtesy of FORD MOTOR CO.
60. Install the retaining nut for the oil level indicator and tube.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 60: Locating Oil Level Indicator Tube Retaining Nut

      Courtesy of FORD MOTOR CO.
61. Apply a dime-sized bead of sealant at the back seam of the upper and lower crankcase.
    Fig 61: Locating Sealant At Back Seam Of Upper And Lower Crankcase

    Courtesy of FORD MOTOR CO.
NOTE: To prevent damage, replace damaged or missing dowel pins before installing the engine rear cover.
NOTE: Prior to installing the engine rear cover, check that the alignment dowels are centered so that 10 mm (0.39 in) of the dowel extends toward the engine and 10 mm (0.39 in) extends toward the transmission.
NOTE: Manual transmission shown in the illustration, automatic transmission similar.
62. Install a new press-in-place gasket, the engine rear cover and the bolts.
    1. For all vehicles, install the 8 bolts. Tighten to 31 Nm (23 lb-ft).
    2. For manual transmission vehicles, install the 3 additional bolts. Tighten to 62 Nm (46 lb-ft).
       Fig 62: Identifying Engine Rear Cover Bolts

       Courtesy of FORD MOTOR CO.
NOTE: A redesigned seal will have a flanged wear ring and pre-applied threadlock.
Fig 63: Locating Crankshaft Rear Seal And Wear Ring
Courtesy of FORD MOTOR CO.
63. Remove the new crankshaft rear seal and wear ring assembly and plastic step-up tool from the packing. Separate the plastic step-up tool (if installed on the crankcase rear seal) from the crankcase rear seal and wear ring assembly.
NOTE: The crankshaft rear seal and wear ring are one-piece and need to be installed as an assembly. Do not separate the wear ring from the crankshaft rear seal or damage to the seal may occur.
Fig 64: Locating Metal Face Of Wear Ring
Courtesy of FORD MOTOR CO.
64. Identify the metal face of the wear ring. This face must be installed so it is on the outside of the engine (facing the transmission).
NOTE: Lubricate the outer diameter of the rubber seal with a solution of dish soap and water (approximately 50/50 mix) prior to assembly. Do not use any other type of lubricant.
Fig 65: Locating Outer Diameter Of Rubber Seal
Courtesy of FORD MOTOR CO.
65. Lubricate the outer diameter of the rubber seal with a solution of dish soap and water.
NOTE: Make sure the crankshaft alignment dowel fits in the dowel recess hole in the Crankshaft Rear Seal and Wear Ring Installer base or engine damage may occur.
Fig 66: Identifying Crankshaft Rear Seal And Wear Ring Installer
Courtesy of FORD MOTOR CO.
66. Install the Crankshaft Rear Seal and Wear Ring Installer base and 2 bolts to the crankshaft flange.
NOTE: When positioning the crankshaft rear seal and wear ring assembly on the Crankshaft Rear Seal and Wear Ring Installer base, align it to the opening on the engine rear cover and manually start the crankcase rear seal installation.
Fig 67: Locating Crankshaft Rear Seal And Wear Ring Assembly
Courtesy of FORD MOTOR CO.
67. Position the crankshaft rear seal and wear ring assembly on the Crankshaft Rear Seal and Wear Ring Installer base.
NOTE: The plastic step-up tool increases the flat surface area of the Crankshaft Rear Seal and Wear Ring Installer. Failure to use the plastic step-up tool during installation will result in damage to the crankshaft rear seal and wear ring assembly.
Fig 68: Locating Crankshaft Rear Seal And Wear Ring Installer
Courtesy of FORD MOTOR CO.
68. Insert the plastic step-up tool into the Crankshaft Rear Seal and Wear Ring Installer with the step-edge toward the installer.
NOTE: The crankshaft rear seal face and the wear ring must be flush with the rear engine cover or damage to the crankshaft rear seal or wear ring may occur.
NOTE: Do not allow the engine to rotate during the installation of the crankshaft rear seal and wear ring assembly or damage to the crankshaft rear seal or wear ring may occur.
Fig 69: Installing Crankshaft Rear Seal And Wear Ring Installer
Courtesy of FORD MOTOR CO.
69. Using the Crankshaft Rear Seal and Wear Ring Installer, install the new crankshaft rear seal and wear ring assembly until the installation tool contacts the rear engine cover.
70. If equipped, install the flywheel front adapter.
    Fig 70: Locating Flywheel Front Adapter

    Courtesy of FORD MOTOR CO.
71. Position the flexplate or flywheel and install the 10 new bolts. Tighten the bolts in 2 stages, in the sequence shown in the illustration.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 94 Nm (69 lb-ft).
      Fig 71: Identifying Flexplate Bolts Tightening Sequence

      Courtesy of FORD MOTOR CO.
72. Apply a dime-sized bead of sealant at the front seam of the upper and lower crankcase.
    Fig 72: Locating Dime-Sized Bead Of Sealant At Front Seam Of Upper And Lower Crankcase

    Courtesy of FORD MOTOR CO.
NOTE: Failure to use guide pins to position the front cover gasket can lead to oil in the coolant.
NOTE: Use guide pins to aid in installation. Pins must be fabricated locally.
Fig 73: Locating Threaded Guide Pins
Courtesy of FORD MOTOR CO.
73. Position the new front cover gasket on the engine and install threaded guide pins to hold the gasket in position.
74. Position the engine front cover and loosely install the 10 bolts.
    Fig 74: Locating Bolts And Engine Front Cover

    Courtesy of FORD MOTOR CO.
75. Install a new O-ring seal. Install the coolant inlet port and bolt.
    • Tighten to 13 Nm (115 lb-in).
      Fig 75: Locating Bolt And Coolant Inlet Port

      Courtesy of FORD MOTOR CO.
NOTE: If reusing the original oil pump drive rotors, install the oil pump drive rotors with the marks pointing outward. Replacement oil pump drive rotors will have no marks and orientation is not necessary.
Fig 76: Locating Inner And Outer Oil Pump Drive Rotors
Courtesy of FORD MOTOR CO.
76. Lubricate the inner drive rotor with clean engine oil and install onto the crankshaft. Lubricate the outer drive rotor with clean engine oil and mesh with the inner drive rotor.
77. Install a new press-in-place gasket, the oil pump housing and the 11 bolts.
    • Tighten the 7 long bolts to 31 Nm (23 lb-ft).
    • Tighten the 4 short bolts to 22 Nm (16 lb-ft).
      Fig 77: Locating Bolts And Oil Pump Housing

      Courtesy of FORD MOTOR CO.
78. Tighten the 10 engine front cover bolts.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 78: Locating Engine Front Cover Bolts

      Courtesy of FORD MOTOR CO.
NOTE: Apply threadlock to the outer circumference of the leading edge of the crankshaft.
NOTE: The seal and wear sleeve must not be separated.
Fig 79: Installing Crankshaft Front Seal And Wear Sleeve Assembly Using Crankshaft Seal Installer
Courtesy of FORD MOTOR CO.
79. Using the Crankshaft Seal Installer, install a new crankshaft front seal and wear sleeve assembly.
NOTE: To prevent engine damage, always install 4 new bolts when installing the vibration damper.
NOTE: Apply a light coat of engine oil to the bolts prior to installing the bolts.
NOTE: Use the Strap Wrench to stop the engine from moving during tightening.
80. Install the crankshaft vibration damper and 4 new bolts. Tighten the bolts in 2 stages, in the sequence shown in the illustration.
    • Stage 1: Tighten to 68 Nm (50 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 80: Identifying Crankshaft Pulley Bolts Sequence

      Courtesy of FORD MOTOR CO.
NOTE: Install a new O-ring seal on the coolant pump.
81. Install the coolant pump and the 5 bolts.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 81: Locating Bolts And Coolant Pump

      Courtesy of FORD MOTOR CO.
82. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 82: Locating Bolts And Coolant Pump Pulley

      Courtesy of FORD MOTOR CO.
83. Install a new press-in-place gasket. Install the thermostat housing, collar and 4 bolts.
    • Tighten to 13 Nm (115 lb-in).
      Fig 83: Locating Bolts, Collar And Thermostat Housing

      Courtesy of FORD MOTOR CO.
84. Position the fuel supply and return tubes and install the bolt.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 84: Locating Bolt, Fuel Supply And Return Tubes

      Courtesy of FORD MOTOR CO.
NOTE: Install a new O-ring seal on the tube and a new clamp on the hose.
NOTE: Hand start both bolts prior to tightening the bolts.
85. Install the EGR cooler tube and install the 2 bolts.
    • Tighten to 13 Nm (115 lb-in).
      Fig 85: Locating Bolts And EGR Cooler Tube

      Courtesy of FORD MOTOR CO.
NOTE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps may result in hose joint failure.
86. Tighten the clamp for the EGR cooler hose.
    • Tighten to 4 Nm (35 lb-in).
      Fig 86: Locating EGR Cooler Hose Clamp

      Courtesy of FORD MOTOR CO.
NOTE: Install a new O-ring seal.
87. Install the LH heater tube and 2 bolts.
    • Tighten to 13 Nm (115 lb-in).
      Fig 87: Locating Bolts And LH Heater Return Tube

      Courtesy of FORD MOTOR CO.
NOTE: The protruding hub of the high-pressure fuel injection pump drive gear must be facing the high-pressure fuel injection pump. Failure to install the gear correctly will result in engine damage.
NOTE: The high-pressure fuel injection pump drive gear bolt is a LH thread.
NOTE: The bolt for the high-pressure fuel injection pump will not be tightened at this time.
Fig 88: Locating High-Pressure Fuel Injection Pump Drive Gear Bolt
Courtesy of FORD MOTOR CO.
88. If a new pump is being installed, install the high-pressure fuel injection pump drive gear and install the bolt finger-tight.
89. Install the high-pressure fuel injection pump and 3 bolts.
    • Tighten to 62 Nm (46 lb-ft).
      Fig 89: Locating Bolts And High-Pressure Fuel Injection Pump

      Courtesy of FORD MOTOR CO.
NOTE: The high-pressure fuel pump drive gear bolt has a LH thread.
NOTE: Use a tool such as a Snap-On FRDHM15 torque adapter, or equivalent, to tighten the bolt.
90. If a new high-pressure fuel pump has been installed, tighten the drive gear bolt.
    • Calculate the correct torque wrench setting for the following torque. Refer to the illustration   . See Fig 90.
      Fig 90: Torque Wrench Adapter Formulas

      
    • Tighten to 78 Nm (58 lb-ft).
      Fig 91: Locating Drive Gear Bolt

      Courtesy of FORD MOTOR CO.
91. Using the Dial Indicator Gauge with Holding Fixture, check the high-pressure fuel injection pump drive gear backlash.
    Fig 92: Checking High-Pressure Fuel Injection Pump Drive Gear Backlash

    Courtesy of FORD MOTOR CO.
92. Clean the cover mounting surface and apply a dime-sized bead of sealant at the seams.
    Fig 93: Locating Bead Of Sealant At Seams

    Courtesy of FORD MOTOR CO.
NOTE: Inspect the volume control valve and the pressure control valve electrical connectors for damage or obstructions at the connector and mating high-pressure fuel injection pump connector. Verify that the connectors are completely latched to the valve housings or engine damage may occur.
Fig 94: Locating Pressure Control Valve, Volume Control Valve Electrical Connectors And High-Pressure Fuel Injection Pump Cover Gasket
Courtesy of FORD MOTOR CO.
93. Install a new gasket for the high-pressure fuel injection pump cover. Connect the pressure control valve and volume control valve electrical connectors.
94. Install a new press-in-place gasket in the high-pressure fuel injection pump cover.
    Fig 95: Locating High-Pressure Fuel Injection Pump Cover Press-In-Place Gasket

    Courtesy of FORD MOTOR CO.
NOTE: Do not remove the Fuel System Caps from the high-pressure fuel pump until the fuel rail supply tubes are ready to be installed.
95. Install the high-pressure fuel injection pump cover and 5 bolts.
    • Tighten to 13 Nm (115 lb-in).
      Fig 96: Locating Bolts And High-Pressure Fuel Injection Pump Cover

      Courtesy of FORD MOTOR CO.
NOTE: In the event of a catastrophic engine failure, always install a new oil cooler cover assembly (with oil cooler). Foreign material cannot be removed from the oil cooler and engine damage may occur.
96. Install a new press-in-place gaskets, the oil cooler assembly and the 8 bolts.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 97: Locating Bolts And Oil Cooler Assembly

      Courtesy of FORD MOTOR CO.
NOTE: The old oil cooler cover screws or new self-tapping screws must be used to cut the threads in the new oil cooler cover.
97. Install the new press-in-place gaskets, the oil filter base and the 10 screws.
    • On a new oil cooler cover, tighten to 10 Nm (89 lb-in).
    • On a used oil cooler cover, tighten to 7 Nm (62 lb-in).
      Fig 98: Locating Bolts And Oil Filter Base

      Courtesy of FORD MOTOR CO.
98. Install new O-ring seal and gasket in the oil filter base.
    • Apply clean engine oil to the O-ring seal and gasket.
      Fig 99: Locating Oil Filter Base O-Ring Seal And Gasket

      Courtesy of FORD MOTOR CO.
99. Install the oil filter return tube assembly and screw.
    • On new oil return tubes, tighten to 7 Nm (62 lb-in).
    • On used oil return tubes, tighten to 5 Nm (44 lb-in).
      Fig 100: Locating Oil Filter Return Tube Screw

      Courtesy of FORD MOTOR CO.
100. Install the oil filter housing and the 4 bolts.
     • Tighten to 22 Nm (16 lb-ft).
       Fig 101: Locating Oil Filter Housing Bolts

       Courtesy of FORD MOTOR CO.
NOTE: Install a new O-ring on the oil filter cap and apply clean engine oil.
101. Install a new oil filter element and the oil filter housing cap.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 102: Locating Oil Filter Cap And Element

       Courtesy of FORD MOTOR CO.
NOTE: The 2 shoulder bolts go in the center holes on the sides.
102. Install a new press-in-place gasket, the turbocharger pedestal and 7 bolts.
     • Tighten to 62 Nm (46 lb-ft).
       Fig 103: Locating Bolts And Turbocharger Pedestal

       Courtesy of FORD MOTOR CO.
NOTE: The locating tabs on the gaskets must be up and positioned toward the center of the engine or a leak will occur.
Fig 104: Locating Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.
103. Install the intake manifold gaskets.
104. Install the intake manifold and bolts and tighten in 2 stages, in the sequence shown in the illustration.
     • Stage 1: Loosely assemble all bolts in the sequence shown in the illustration.
     • Stage 2: Tighten to 11 Nm (97 lb-in).
       Fig 105: Identifying Intake Manifold Bolts Tightening Sequence

       Courtesy of FORD MOTOR CO.
NOTE: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the high-pressure fuel injection pump.
105. Position the fuel injector return tube. Install the banjo bolts and new sealing washers at the cylinder heads.
     • For Viton® sealing washers, tighten to 25 Nm (18 lb-ft).
     • For copper sealing washer, tighten to 38 Nm (28 lb-ft).
       Fig 106: Locating Fuel Injector Return Tube Banjo Bolts And Sealing Washers

       Courtesy of FORD MOTOR CO.
106. Position the retainers and install the 2 bolts for the fuel injector return tube.
     • Tighten to 13 Nm (115 lb-in).
       Fig 107: Locating Fuel Injector Return Tube Retainer Bolts

       Courtesy of FORD MOTOR CO.
107. Install the nut on the fuel injector return tube.
     • Tighten to 11 Nm (97 lb-in).
       Fig 108: Locating Fuel Injector Return Tube Bracket Nut

       Courtesy of FORD MOTOR CO.
108. Install the fuel filter module and 3 bolts.
     • Tighten to 13 Nm (115 lb-in).
       Fig 109: Locating Fuel Filter Module Bolts

       Courtesy of FORD MOTOR CO.
NOTE: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the high-pressure fuel injection pump.
109. Install the banjo fittings and new sealing washers at the fuel filter module.
     • For M14 banjo bolt with Viton® sealing washers, tighten to 28 Nm (21 lb-ft).
     • For M14 banjo bolt with copper sealing washer, tighten to 47 Nm (35 lb-ft).
     • For M12 banjo bolt with Viton® sealing washers, tighten to 25 Nm (18 lb-ft).
     • For M12 banjo bolt with copper sealing washer, tighten to 38 Nm (28 lb-ft).
       Fig 110: Locating Fuel Supply Banjo Bolts And Fuel Filter Module Return Tubes

       Courtesy of FORD MOTOR CO.
110. Install the bolt for the fuel supply and return tube retainer.
     • Tighten to 31 Nm (23 lb-ft).
       Fig 111: Locating Fuel Supply And Return Tube Retainer Bolt

       Courtesy of FORD MOTOR CO.
NOTE: Do not bend or flex the heater supply tube or damage to the tube may occur.
NOTE: Install a new O-ring seal.
111. Install the RH heater supply tube, bolt and nut.
     • Tighten to 13 Nm (115 lb-in).
       Fig 112: Locating Nut, Bolt And RH Heater Supply Tube

       Courtesy of FORD MOTOR CO.
112. Install the glow plug module bracket and 3 bolts.
     • Tighten to 13 Nm (115 lb-in).
       Fig 113: Locating Glow Plug Module Bracket Bolts

       Courtesy of FORD MOTOR CO.
NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in FUEL CHARGING AND CONTROLS - 6.4L DIESEL .
NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.
NOTE: Remove the protective caps from the high-pressure fuel pump.
113. Install new sealing washers, fuel injection pump supply tube, fuel injection pump-to-fuel cooler return tube and 2 nuts at the high-pressure fuel injection pump.
     • For Viton® sealing washers, tighten to 25 Nm (18 lb-ft).
     • For copper sealing washer, tighten to 38 Nm (28 lb-ft).
       Fig 114: Locating High-Pressure Fuel Injection Pump Nuts And Sealing Washers

       Courtesy of FORD MOTOR CO.
114. Install the 2 retaining nuts for the fuel injection pump supply tube.
     • Tighten to 11 Nm (97 lb-in).
       Fig 115: Locating Fuel Injection Pump Supply Tube Retaining Nuts

       Courtesy of FORD MOTOR CO.
NOTE: Remove the protective caps or plugs from the fuel tubes.
NOTE: Use a crowfoot wrench to aid in tightening the fitting.
115. Connect the fuel injector return tube at the check valve.
     • Calculate the correct torque wrench setting for the following torque. Refer to the illustration   . See Fig 116.
       Fig 116: Torque Wrench Adapter Formulas

       
     • Tighten to 28 Nm (21 lb-ft).
       Fig 117: Locating Fuel Injector Return Tube At Check Valve

       Courtesy of FORD MOTOR CO.
116. Position and connect the high-pressure fuel injection pump electrical connector. Connect the pushpin retainer.
     Fig 118: Locating Pushpin Harness And High-Pressure Fuel Pump Harness

     Courtesy of FORD MOTOR CO.
NOTE: Use a back-up wrench to prevent the fittings in the high-pressure fuel injection pump from turning. If the fittings move, the high-pressure fuel injection pump fittings must be retightened. Refer to Fuel Injection Pump Fitting Re-Torque in FUEL CHARGING AND CONTROLS - 6.4L DIESEL .
NOTE: It will be necessary to use a thin or low profile wrench to hold the fittings on the high-pressure fuel injection pump.
NOTE: Use a crowfoot wrench to aid in tightening the fuel rail supply tube.
NOTE: LH side shown in the illustration, RH side similar.
117. Install the new fuel rail supply tubes in the following sequence.
     1. Remove the Fuel System Caps from the fuel rail supply tube openings.
     NOTE: Support the tubes while hand snugging the nut to make sure of assembly of the joints.
     2. Position the fuel rail supply tubes between the high-pressure fuel injection pump and high-pressure fuel rail. Fully hand start and seat the tube nuts onto the high-pressure fuel injection pump and high-pressure fuel rail.
     3. Snug the tube nuts.
        • Calculate the correct torque wrench setting for the following torque. Refer to the illustration   . See Fig 119.
          Fig 119: Torque Wrench Adapter Formulas

          
        • Tighten to 2 Nm (18 lb-in).
     4. Pre-tighten the high-pressure fuel injection pump and high-pressure fuel rail tube nuts.
        • Calculate the correct torque wrench setting for the following torque. Refer to the illustration   . See Fig 120.
          Fig 120: Torque Wrench Adapter Formulas

          
        • Tighten to 12 Nm (106 lb-in).
     NOTE: Place a visible mark with a permanent marker on the high-pressure fuel rail and high-pressure fuel pump threaded connection. Turning the tube nuts one flat of the nut is equal to 60 degrees.
     5. Final-tighten the fuel rail supply tube nuts.
        • Tighten the tube nuts 60 degrees.
          Fig 121: Locating Fuel Rail Supply Tubes

          Courtesy of FORD MOTOR CO.
118. Install the 2 bolts for the fuel rail supply tube retainers.
     • Tighten to 13 Nm (115 lb-in).
       Fig 122: Locating Fuel Rail Supply Tube Retainers Bolts

       Courtesy of FORD MOTOR CO.
NOTE: Failure to correctly install the high-pressure fuel injection pump heat shield may result in engine damage.
119. Install the high-pressure fuel injection pump heat shield, fuel tube bracket and ground strap. Install the 5 retaining nuts and bolt.
     • Tighten the fuel tube bracket nuts to 8 Nm (71 lb-in).
     • Tighten the remaining fasteners to 13 Nm (115 lb-in).
       Fig 123: Locating High-Pressure Fuel Injection Pump Heat Shield Bolt And Retaining Nuts

       Courtesy of FORD MOTOR CO.
120. Position the engine wiring harness on the engine. Install the bolt.
     • Tighten to 13 Nm (115 lb-in).
       Fig 124: Locating Heater Supply Tube Bolt

       Courtesy of FORD MOTOR CO.
121. Connect the glow plug module and high-pressure fuel injection pump electrical connectors. Connect the pushpin retainers.
     Fig 125: Locating Glow Plug Module Electrical Connectors And Pin-Type Retainers

     Courtesy of FORD MOTOR CO.
NOTE: Use a socket to aid in installing the pushnuts.
Fig 126: Locating Glow Plug Module Heat Shield Pushnuts
Courtesy of FORD MOTOR CO.
122. Position the glow plug module heat shield. Install the 3 new pushnuts.
123. Connect the RH fuel charging harness electrical connector. Connect the Manifold Absolute Pressure (MAP) sensor and Intake Air Temperature 2 (IAT2) sensor electrical connectors.
     Fig 127: Locating Manifold Absolute Pressure Sensor And Intake Air Temperature 2 Sensor Electrical Connectors

     Courtesy of FORD MOTOR CO.
124. Connect the glow plug harness electrical connector and retainer on the RH valve cover.
     Fig 128: Locating Glow Plug Harness Electrical Connector And Retainer

     Courtesy of FORD MOTOR CO.
125. Connect the CKP  sensor and retainer.
     Fig 129: Locating Crankshaft Position Sensor Electrical Connector And Pushpin Retainer

     Courtesy of FORD MOTOR CO.
126. Connect the pushpin retainers to the oil drain back tube brackets.
     Fig 130: Locating Crankcase Vent Oil Separator Tube Pin-Type Retainer

     Courtesy of FORD MOTOR CO.
NOTE: Make sure the harness is positioned on the stud at the fuel filter prior to installing the bolt.
Fig 131: Locating Engine Oil Temperature And Engine Oil Pressure Electrical Connectors
Courtesy of FORD MOTOR CO.
127. Install the bolt for the engine harness. Connect the Engine Oil Pressure (EOP) switch and the Engine Oil Temperature (EOT) sensor electrical connectors.
128. Connect the Engine Coolant Temperature (ECT) sensor electrical connector and wire retainer.
     Fig 132: Locating ECT Sensor Electrical Connector And Wire Retainer

     Courtesy of FORD MOTOR CO.
129. Connect the fuel temperature sensor electrical connector.
     Fig 133: Locating Fuel Temperature Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
130. Connect the LH fuel charging harness electrical connector. Position the harness in the retaining clip and connect the pushpin retainers.
     Fig 134: Locating LH Fuel Charging Harness Electrical Connector And Pushpin Retainers

     Courtesy of FORD MOTOR CO.
131. Connect the CMP  sensor electrical connector and pushpin retainer.
     Fig 135: Locating Camshaft Position Sensor Electrical Connector And Pushpin Retainer

     Courtesy of FORD MOTOR CO.
132. Connect the glow plug harness electrical connector and pushpin retainers.
     Fig 136: Locating Glow Plug Electrical Connector And Pushpin Retainers

     Courtesy of FORD MOTOR CO.
133. Connect the Exhaust Pressure (EP) sensor electrical connector and retaining clip.
     Fig 137: Locating Exhaust Pressure Sensor Electrical Connector And Retaining Clip

     Courtesy of FORD MOTOR CO.
134. Install a new press-in-place gasket. Install the intake throttle adapter and loosely install the 4 bolts.
     Fig 138: Locating Intake Throttle Adapter Bolts

     Courtesy of FORD MOTOR CO.
135. Connect the EGR valve and Throttle Body (TB) electrical connectors.
     Fig 139: Locating EGR Valve And Throttle Body Electrical Connectors

     Courtesy of FORD MOTOR CO.
NOTE: Install a new horizontal EGR cooler gasket prior to installing the vertical EGR cooler.
Fig 140: Locating Vertical EGR Cooler Assembly Bolts
Courtesy of FORD MOTOR CO.
136. Position the vertical EGR cooler assembly and loosely install the 5 bolts.
137. Install a new vertical EGR cooler gasket and the stud.
     • Tighten to 17 Nm (150 lb-in).
       Fig 141: Locating Vertical EGR Cooler Stud

       Courtesy of FORD MOTOR CO.
138. Install the nut and bolt for the EGR cooler.
     • Tighten to 31 Nm (23 lb-ft).
       Fig 142: Locating Vertical EGR Cooler Nut And Bolt

       Courtesy of FORD MOTOR CO.
139. Connect the coolant hose to the vertical EGR cooler.
     Fig 143: Locating Vertical EGR Cooler Coolant Hose Clamp

     Courtesy of FORD MOTOR CO.
140. Connect the EGRT  sensor electrical connector.
     Fig 144: Locating Exhaust Gas Recirculation Temperature Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
NOTE: Do not bend or twist the Exhaust Gas Recirculation (EGR) cooler bellows or damage to the EGR cooler may occur.
NOTE: Inspect the corrugation of the vertical EGR cooler inlet to make sure that the corrugation ribs are not touching and are not damaged.
141. Install the 2 nuts for the vertical EGR cooler.
     • Tighten to 31 Nm (23 lb-ft).
     • Inspect the corrugation of the EGR cooler inlet to make sure that the corrugation ribs are not touching and are not damaged.
       Fig 145: Locating Vertical EGR Cooler Retaining Nuts

       Courtesy of FORD MOTOR CO.
NOTE: The coolant hose clamps used on this engine are constant tension worm gear clamps. Standard worm gear clamps cannot be used. Failure to use the correct coolant hose clamps could result in a hose joint failure.
NOTE: Install a new clamp on the EGR cooler hose.
142. Connect the EGR cooler hose and tighten the clamp.
     • Tighten to 4 Nm (35 lb-in).
       Fig 146: Locating EGR Cooler Hose Clamp

       Courtesy of FORD MOTOR CO.
NOTE: Do this step only if the horizontal EGR cooler was removed from the mounting bracket.
143. Tighten the clamps for the horizontal EGR cooler.
     • Tighten to 10 Nm (89 lb-in).
     • Loosen the clamps 720 degrees.
     • Tighten to 8 Nm (71 lb-in).
       Fig 147: Locating Horizontal EGR Cooler Clamps Nut

       Courtesy of FORD MOTOR CO.
NOTE: Do this step only if the vertical EGR cooler was removed from the mounting bracket.
144. Tighten the clamps for the vertical EGR cooler.
     • Tighten to 9 Nm (80 lb-in).
     • Loosen the clamps 720 degrees.
     • Tighten to 7 Nm (62 lb-in).
       Fig 148: Locating Vertical EGR Cooler Clamps Nuts

       Courtesy of FORD MOTOR CO.
145. Tighten the 5 vertical EGR cooler mounting bracket bolts.
     • Tighten the M8 bolts to 31 Nm (23 lb-ft).
     • Tighten the M10 bolt to 62 Nm (46 lb-ft).
       Fig 149: Locating Vertical EGR Cooler Assembly Bolts

       Courtesy of FORD MOTOR CO.
NOTE: Vertical EGR cooler removed for clarity.
146. Tighten the 4 bolts for the intake throttle adapter.
     • Tighten to 10 Nm (89 lb-in).
       Fig 150: Locating Intake Throttle Adapter Bolts

       Courtesy of FORD MOTOR CO.
NOTE: RH heater tube removed for clarity.
NOTE: Install a new O-ring seal.
147. Install the vertical EGR cooler tube and bolt.
     • Tighten to 10 Nm (89 lb-in).
       Fig 151: Locating EGR Cooler Coolant Tube Bolt

       Courtesy of FORD MOTOR CO.
148. Install the new low-pressure turbocharger drain tube in the turbocharger.
     Fig 152: Locating Low-Pressure Turbocharger Drain Tube

     Courtesy of FORD MOTOR CO.
NOTE: Install new O-ring seals and apply clean engine oil prior to installing the high-pressure turbocharger drain tube.
Fig 153: Locating High-Pressure Turbocharger Drain Tube
Courtesy of FORD MOTOR CO.
149. Install the high-pressure turbocharger drain tube.
NOTE: Failure to use the turbocharger lifting bracket during removal, handling or installation of the turbocharger could result in damage to the low pressure-to-high pressure turbocharger seal.
NOTE: Make sure the turbocharger assembly is kept level to the engine during removal or installation. Failure to follow these instructions may result in damage to the high-pressure oil drain tube.
Fig 154: Identifying Turbocharger Lifting Bracket
Courtesy of FORD MOTOR CO.
150. Using the Turbocharger Lifting Bracket, install the turbocharger assembly.
NOTE: The top bolt holes remain open on the turbocharger.
151. Remove the Turbocharger Lifting Bracket.
152. Install the 2 turbocharger hold downs and 2 retaining bolts.
     • Tighten to 201 Nm (148 lb-ft).
       Fig 155: Locating Bolts And Hold Downs For Turbocharger

       Courtesy of FORD MOTOR CO.
153. Install the turbocharger heat shield and 5 bolts.
     • Tighten to 11 Nm (97 lb-in).
       Fig 156: Locating Turbocharger Heat Shield Bolts

       Courtesy of FORD MOTOR CO.
NOTE: Rear bolts shown in the illustration, front bolts similar.
154. Install the 4 bolts for the turbocharger crossover tube.
     • Tighten to 31 Nm (23 lb-ft).
       Fig 157: Locating Turbocharger Crossover Tube Bolts

       Courtesy of FORD MOTOR CO.
155. Connect the turbocharger actuator electrical connector and pushpin retainer.
     Fig 158: Locating Turbocharger Actuator Electrical Connector And Pushpin Retainer

     Courtesy of FORD MOTOR CO.
NOTE: Install a new O-ring seal and apply clean engine oil.
156. Install the turbocharger oil feed tube and bolt.
     • Tighten to 13 Nm (115 lb-in).
       Fig 159: Locating Turbocharger Oil Supply Tube Bolt

       Courtesy of FORD MOTOR CO.
157. Prelubricate the oil inlet holes of the turbocharger assembly with clean oil and spin the compressor wheel several times to coat the bearings with oil.
NOTE: Only use banjo bolts with a green hex head. The green-headed bolts do not contain a check valve. When viewed from the inner end, the correct bolt will appear open. Failure to install the correct banjo bolt may result in damage to the turbochargers.
NOTE: Do not lean on, pull on or use the turbocharger oil supply tube as a handle or damage to the turbocharger oil supply tube may occur.
NOTE: Use a back-up wrench to prevent the fittings from turning.
158. Install new sealing washers and banjo bolts on the turbocharger oil feed fittings.
     • For Viton® sealing washers, tighten to 25 Nm (18 lb-ft).
     • For copper sealing washer, tighten to 38 Nm (28 lb-ft).
     • Move the turbocharger actuator linkage through the full range of motion and verify that the turbocharger oil supply tube does not contact the turbocharger actuator linkage.
       Fig 160: Locating Turbocharger Oil Supply Tube Banjo Bolts And Sealing Washers

       Courtesy of FORD MOTOR CO.
159. Install a new press-in-place gasket. Position the crankcase vent oil separator on the right valve cover. Install the 4 bolts.
     • Tighten to 13 Nm (115 lb-in).
       Fig 161: Locating Crankcase Vent Oil Separator Bolts

       Courtesy of FORD MOTOR CO.
160. Connect the crankcase vent oil separator drain tube.
     Fig 162: Locating Crankcase Vent Oil Separator Drain Tube Clamp

     Courtesy of FORD MOTOR CO.
NOTE: Do not bend or twist the turbocharger inlet pipe or damage to the turbocharger inlet pipe may occur.
Fig 163: Locating Turbocharger Inlet Pipes Bracket Bolts
Courtesy of FORD MOTOR CO.
161. Install new gaskets for the exhaust manifolds. Install the turbocharger inlet pipes, bracket, new turbocharger gaskets and loosely install the 6 new bolts.
NOTE: LH side shown in the illustration, RH side similar.
Fig 164: Locating Turbocharger Inlet Pipes Retaining Nuts
Courtesy of FORD MOTOR CO.
162. Loosely install the 6 new nuts for the turbocharger inlet pipes.
163. Tighten the 3 LH turbocharger inlet pipe bolts and 3 nuts.
     1. Tighten the bolts to 25 Nm (18 lb-ft).
     2. Tighten the nuts to 31 Nm (23 lb-ft).
        Fig 165: Locating LH Turbocharger Inlet Pipe Bolts And Nuts

        Courtesy of FORD MOTOR CO.
164. Tighten the 3 RH turbocharger inlet pipe bolts and 3 nuts.
     1. Tighten the bolts to 25 Nm (18 lb-ft).
     2. Tighten the nuts to 31 Nm (23 lb-ft).
        Fig 166: Locating RH Turbocharger Inlet Pipe Bolts And Nuts

        Courtesy of FORD MOTOR CO.
NOTE: Make sure the correct bolts are installed in the bracket or damage to the bracket can occur.
NOTE: Turbocharger side shown in the illustration, exhaust manifold side similar.
Fig 167: Locating EGR-OC Pipe Bolts And EGR-OC-To-Turbocharger Bracket Bolts
Courtesy of FORD MOTOR CO.
165. Position the EGR-Oxidation Catalytic Converter (OC) pipe and loosely install the 2 new bracket bolts. Install new gaskets and loosely install the 4 new bolts.
166. Install the bracket, washers and 2 new bolts for the EGR- OC  pipe.
     • Tighten finger-tight.
       Fig 168: Locating EGR-OC Pipe Bracket-To-Bracket Bolt And Washer

       Courtesy of FORD MOTOR CO.
167. Tighten the 2 bolts at the EGR cooler.
     • Tighten the bolts to 31 Nm (23 lb-ft).
       Fig 169: Locating EGR Cooler Bolts

       Courtesy of FORD MOTOR CO.
168. Tighten the 2 EGR- OC  -to-RH turbocharger inlet pipe bolts.
     • Tighten to 31 Nm (23 lb-ft).
       Fig 170: Locating EGR-OC Pipe Bolts At RH Turbocharger Inlet Pipe

       Courtesy of FORD MOTOR CO.
169. Tighten the 2 bolts for the EGR- OC  pipe bracket at the turbocharger.
     • Tighten to 31 Nm (23 lb-ft).
       Fig 171: Locating EGR-OC Pipe Bolts

       Courtesy of FORD MOTOR CO.
NOTE: Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe support bolt will result in damage to the horizontal EGR cooler and possible engine damage.
170. Tighten the bolt and nut for the EGR- OC  pipe bracket.
     • Tighten to 31 Nm (23 lb-ft).
       Fig 172: Locating EGR-OC Pipe Bracket Bolt

       Courtesy of FORD MOTOR CO.
NOTE: Failure to install and correctly tighten the Exhaust Gas Recirculation (EGR)-Oxidation Catalytic Converter (OC) pipe support bolt will result in damage to the horizontal EGR cooler and possible engine damage.
171. Tighten the bolt for the EGR- OC  pipe bracket.
     • Tighten to 62 Nm (46 lb-ft).
       Fig 173: Locating EGR-OC Pipe Bracket Bolt

       Courtesy of FORD MOTOR CO.
172. Connect the EGRT  sensor electrical connector.
     Fig 174: Locating EGRT Sensor Electrical Connector

     Courtesy of FORD MOTOR CO.
173. Connect the EP  sensor tube.
     • Tighten to 20 Nm (177 lb-in).
       Fig 175: Locating Exhaust Pressure Sensor Tube

       Courtesy of FORD MOTOR CO.
NOTE: LH shown in the illustration, RH similar.
NOTE: Lightly lubricate the O-ring seal with clean engine oil prior to installing.
174. Install the 2 cylinder block coolant drain plugs.
     • Tighten to 20 Nm (177 lb-in).
       Fig 176: Locating Cylinder Block Coolant Drain Plugs

       Courtesy of FORD MOTOR CO.
175. Using the Heavy Duty Floor Crane, remove the engine from the Car/Truck Engine Stand.
NOTE: The engine mount bracket bolts must be discarded and new bolts installed, or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.
NOTE: The engine mount bracket bolts must not be tightened more than 90 degrees after initial torque or damage to the bolts may occur.
NOTE: Clean the engine mount mating surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine mount bracket or engine mount damage.
NOTE: Place a visible mark on the engine mount bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.
176. Install the LH engine mount bracket and 4 new bolts. Tighten in 2 stages:
     • Stage 1: Tighten to 30 Nm (22 lb-ft).
     • Stage 2: Tighten a minimum of an additional 60 degrees.
       Fig 177: Locating LH Engine Mount Bracket Bolts

       Courtesy of FORD MOTOR CO.
NOTE: Lower radiator hose shown in the illustration, upper radiator hose similar.
Fig 178: Locating Upper And Lower Radiator Hoses Clips
Courtesy of FORD MOTOR CO.
177. Install the upper and lower radiator hoses. Install the clips.
178. Install the engine fill hose.
     Fig 179: Locating Engine Fill Hose

     Courtesy of FORD MOTOR CO.
179. Install the 2 stator stand offs.
     • Tighten to 47 Nm (35 lb-ft).
       Fig 180: Locating Stator Stand Offs

       Courtesy of FORD MOTOR CO.
NOTE: The engine mount bracket bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a torque-to-yield design and cannot be reused.
NOTE: The engine mount bracket bolts must not be tightened more than 90 degrees after initial torque or damage to the bolts may occur.
NOTE: Clean the engine mount mating surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine mount bracket or engine mount damage.
NOTE: Place a visible mark on the engine mount bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.
180. Install the RH engine mount bracket and 4 new bolts. Tighten in 2 stages:
     • Stage 1: Tighten to 30 Nm (22 lb-ft).
     • Stage 2: Tighten a minimum of an additional 60 degrees.
       Fig 181: Locating RH Engine Mount Bracket Bolts

       Courtesy of FORD MOTOR CO.
NOTE: Only use hand tools when installing the center bolt or damage to the center bolt may occur.
181. Install the RH engine mount and new center bolt.
     • Tighten to 350 Nm (258 lb-ft).
       Fig 182: Locating RH Engine Mount Center Bolt

       Courtesy of FORD MOTOR CO.

     Vehicles with A/C 

182. Install the A/C compressor and 3 bolts.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 183: Locating Bolts And A/C Compressor

       Courtesy of FORD MOTOR CO.
183. Connect the A/C compressor clutch electrical connector and wire retainer.
     Fig 184: Locating A/C Clutch Electrical Connector And Wire Retainer

     Courtesy of FORD MOTOR CO.
184. Connect the A/C pressure switch electrical connector.
     Fig 185: Locating A/C Pressure Switch Electrical Connector

     Courtesy of FORD MOTOR CO.

     All vehicles 

185. Install the Front End Accessory Drive (FEAD) assembly, 2 nuts and 2 bolts.
     • Tighten to 47 Nm (35 lb-ft).
       Fig 186: Locating Nuts, Bolts And Front End Accessory Drive Assembly

       Courtesy of FORD MOTOR CO.
186. Connect the wire retainer and the plug for the generator. Install the nut for the generator wiring and position the boot back.
     • Tighten to 8 Nm (71 lb-in).
       Fig 187: Locating Wiring Boot And Generator Wiring

       Courtesy of FORD MOTOR CO.
187. Install the accessory drive belt idler pulley and bolt.
     • Tighten to 47 Nm (35 lb-ft).
       Fig 188: Locating Accessory Drive Belt Idler Pulley

       Courtesy of FORD MOTOR CO.
NOTE: When installing the pump, raise the supply tube up to clear the ECT  sensor connector.
NOTE: Make sure the power steering pressure tube retainer is on the retaining stud prior to tightening the bolts for the power steering pump.
188. Install the power steering pump and 3 bolts. Secure the hose on the engine.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 189: Locating Power Steering Pump Bolts

       Courtesy of FORD MOTOR CO.
189. Install the retaining nut for the power steering hose and tube.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 190: Locating Power Steering Hoses Retaining Nut

       Courtesy of FORD MOTOR CO.

     Vehicles with A/C 

190. Install the A/C drive belt.
     Fig 191: Locating A/C Drive Belt

     Courtesy of FORD MOTOR CO.

     All vehicles 

191. Install the accessory drive belt.
     Fig 192: Locating Accessory Drive Belt

     Courtesy of FORD MOTOR CO.
192. Install the engine cooling fan stator, 2 nuts and 2 bolts.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 193: Locating Engine Cooling Fan Stator Nuts And Bolts

       Courtesy of FORD MOTOR CO.
NOTE: The cooling fan has LH threads.
193. Using the Fan Clutch Nut Wrench and Fan Hub Nut Wrench, install the engine cooling fan.
     • Tighten to 150 Nm (111 lb-ft).
       Fig 194: Installing Engine Cooling Fan Using Fan Clutch Nut Wrench And Fan Hub Nut Wrench

       Courtesy of FORD MOTOR CO.
194. Install the cooling fan electrical connector into the stator. Connect the electrical connector for the engine cooling fan.
     Fig 195: Locating Engine Cooling Fan Electrical Connector And Tabs

     Courtesy of FORD MOTOR CO.
195. Install the starter and 3 bolts.
     • Tighten to 25 Nm (18 lb-ft).
       Fig 196: Locating Bolts And Starter

       Courtesy of FORD MOTOR CO.