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Home >> Ford >> 2003 >> Cutaway 7.3 F >> Repair and Diagnosis >> External Pages >> Different car >> Section 2804 (Engine Mechanical - 6.2L (2V) - F250-F350 Super Duty) >> Installation >> Engine

Section 2804 (Engine Mechanical - 6.2L (2V) - F250-F350 Super Duty): Installation: Engine

WARNING: This page is about a different car, the 2012 Ford Pickup and 2012 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
SPECIAL TOOLS CHART

G06138879
 Fan Clutch Nut Wrench
303-214 (T83T-6312-B)
G06138550
 Fan Pulley Holding Wrench
303-478 (T94T-6312-AH)
G06063978
 Installer, Power Steering Pump Pulley
211-185 (T91P-3A733-A)
G06126494
 Lifting Bracket, Engine
303-F047 (014-00073) or equivalent
G06518201
 Support Brackets, Engine
303-1507 or equivalent
G06139341
 Vehicle Communication Module (VCM) and Integrated Diagnostic System (IDS) software with appropriate hardware, or equivalent scan tool
MATERIAL SPECIFICATIONS

Item Specification
Motorcraft® SAE 5W-20 Premium Synthetic Blend Motor Oil (US); Motorcraft® SAE 5W-20 Super Premium Motor Oil (Canada)
XO-5W20-QSP (US); CXO-5W20-LSP12 (Canada)		 WSS-M2C945-A

All vehicles 

    NOTE: Clean the engine support insulator frame bracket-to-crossmember mating surfaces of any dirt or foreign material prior to engine installation.
  1. With the help of an assistant and using the floor crane, position the engine in the vehicle.

    Automatic transmission vehicles 

    2. NOTE: The torque converter must be installed in it's original orientation to the flexplate or engine damage may occur.
    Fig 1: Locating Sloted Holes And Index Mark On Torque Converter Stud
    G06518332Courtesy of FORD MOTOR CO.
  2. Check that the flexplate is positioned so that the 2 sloted holes are shown in illustration at the 6 o'clock position and the index marks are aligned.
    3. NOTE: The upper 2 transmission-to-engine bolts will be installed later.
    Fig 2: Locating Lower Transmission-To-Engine Bolts
    G07479668Courtesy of FORD MOTOR CO.
  3. Install the lower 5 engine-to-transmission bolts.
    • Tighten to 48 Nm (35 lb-ft).

    All vehicles 

    4. NOTE: The engine support insulator through bolts and transmission support insulator nuts can not be tightened until the support insulators are supporting the full weight of the engine and transmission assembly, or damage to the vehicle or engine support insulator may occur.
  4. Remove the the floor crane.
    5. NOTE: Only use hand tools when installing the engine support insulator through bolt or damage to the engine support insulator-to-cylinder block bracket can occur.
    NOTE: The engine support insulator through bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a tighten-to-yield design and cannot be reused.
    Fig 3: Locating LH Engine Support Insulator Through Bolt
    G07479669Courtesy of FORD MOTOR CO.
  5. Install a new LH engine support insulator through bolt finger tight.
    6. NOTE: The engine support insulator through bolt must be discarded and a new bolt installed, or damage to the vehicle or engine support insulator may occur.
    NOTE: Only use hand tools when installing the engine support through bolt or damage to the engine support insulator may occur.
    Fig 4: Locating RH Engine Support Insulator Through Bolt
    G07479670Courtesy of FORD MOTOR CO.
  6. Install a new LH engine support insulator through bolt.
    • Tighten to 350 Nm (258 lb-ft).
    7. NOTE: Only use hand tools when installing the engine support insulator through bolt or damage to the engine support insulator-to-cylinder block bracket can occur.
    NOTE: The engine support insulator through bolts must be discarded and new bolts installed or damage to the vehicle may occur. They are a tighten-to-yield design and cannot be reused.
    Fig 5: Locating LH Engine Support Insulator Through Bolt
    G07479669Courtesy of FORD MOTOR CO.
  7. Tighten the new LH engine support insulator through bolt.
    • Tighten to 350 Nm (258 lb-ft).

    Automatic transmission vehicles 

  8. Install the 4 new torque converter-to-flexplate nuts.
    • Tighten to 35 Nm (26 lb-ft).
    Fig 6: Locating Torque Converter-To-Flexplate Nut
    G06518331Courtesy of FORD MOTOR CO.
  9. Install the cylinder block opening cover.
    Fig 7: Locating Cylinder Block Opening Cover
    G06518330Courtesy of FORD MOTOR CO.
  10. Install the flexplate inspection cover and the 2 bolts.
    Fig 8: Locating Flexplate Inspection Cover And Bolts
    G07479664Courtesy of FORD MOTOR CO.
    11. NOTE: The transmission support insulator-to-crossmember nuts must be discarded and new nuts installed, or damage to the vehicle or transmission support insulator may occur.
    NOTE: The transmission support insulator studs may come out of the insulator while removing the nuts. Install new transmission support insulator studs if the studs come out of the insulator.
    Fig 9: Locating Transmission Support Insulator-To-Crossmember Nuts
    G06140674Courtesy of FORD MOTOR CO.
  11. Remove and discard the 2 transmission transmission support insulator nuts. Install 2 new transmission transmission support insulator nuts.
    • Tighten to 115 Nm (85 lb-ft).
    • If required, install new transmission support insulator stud(s) (W790019) and tighten to 75 Nm (55 lb-ft).
    12. NOTE: LH shown in illustration, RH similar.
    Fig 10: Locating Exhaust Y-Pipe Flange Nuts
    G06763170Courtesy of FORD MOTOR CO.
  12. Install the 4 exhaust manifold flange nuts.
    • Tighten to 40 Nm (30 lb-ft).
  13. Connect the 2 Heated Oxygen Sensor (HO2S) and Catalyst Monitor Sensor (CMS) electrical connectors.
    Fig 11: Locating Heated Oxygen Sensor And Catalyst Monitor Sensor Electrical Connectors
    G07479656Courtesy of FORD MOTOR CO.

    All vehicles 

  14. Position the oil cooler and install the threaded shaft.
    • Tighten to 58 Nm (43 lb-ft).
    Fig 12: Locating Engine Oil Cooler And Bolt
    G07479663Courtesy of FORD MOTOR CO.
  15. Connect the 2 oil cooler coolant hoses.
    Fig 13: Locating Oil Cooler Coolant Hoses With Clamps
    G07479662Courtesy of FORD MOTOR CO.
  16. Install a new engine oil filter.
    Fig 14: Locating Engine Oil Filter
    G07479661Courtesy of FORD MOTOR CO.
  17. Attach the starter motor wiring harness pin-type retainer to the oil pan.
    Fig 15: Locating Starter Motor Wiring Harness Pin-Type Retainer
    G07479657Courtesy of FORD MOTOR CO.
  18. Install the starter. For additional information, refer to STARTING SYSTEM - GASOLINE ENGINES .
  19. Remove the Engine Lifting Brackets.
    Fig 16: Removing Engine Lifting Brackets
    G07479672Courtesy of FORD MOTOR CO.

    Automatic transmission vehicles 

  20. Install the 2 upper engine-to-transmission bolts.
    • Tighten to 48 Nm (35 lb-ft).
    Fig 17: Locating Upper Transmission-To-Engine Bolts
    G06126529Courtesy of FORD MOTOR CO.
  21. Install the transmission fluid indicator tube and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
    Fig 18: Locating Transmission Fluid Level Indicator Tube And Bolts
    G07479655Courtesy of FORD MOTOR CO.
  22. Install the transmission fluid indicator.
    Fig 19: Locating Transmission Fluid Indicator
    G07479654Courtesy of FORD MOTOR CO.

    All vehicles 

  23. Connect the lower radiator hose to the block and install the clip.
    Fig 20: Locating Lower Radiator Hose Clip
    G07479653Courtesy of FORD MOTOR CO.
  24. Position the power steering pump and install the 3 bolts.
    Fig 21: Locating Power Steering Pump Bolts
    G07479652Courtesy of FORD MOTOR CO.
  25. Install the power steering pump pressure line and the bolt.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 22: Locating Power Steering Pump Pressure Line And Bolt
    G07479651Courtesy of FORD MOTOR CO.
  26. Using the Power Steering Pump Pulley Installer, install the power steering pump pulley.
    Fig 23: Installing Power Steering Pump Pulley
    G07479927Courtesy of FORD MOTOR CO.
  27. Install the transmission cooler lines and starter motor wiring harness brackets and nut.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 24: Locating Transmission Cooler Lines, Starter Motor Wiring Harness Brackets And Nut
    G07968911Courtesy of FORD MOTOR CO.
  28. Install the A/C compressor and 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    Fig 25: Locating A/C Compressor Bolts
    G06772875Courtesy of FORD MOTOR CO.
  29. Attach the wiring harness pin-type retainer to the RH valve cover.
    Fig 26: Locating Wiring Harness Pin-Type Retainer Of RH Valve Cover
    G07479647Courtesy of FORD MOTOR CO.
  30. Install the ground strap and bolt to the bulk head.
    • Tighten to 10 Nm (89 lb-in).
    Fig 27: Locating Ground Strap And Bolt
    G07479646Courtesy of FORD MOTOR CO.
  31. Connect the engine harness electrical connector and attach the pin-type retainer to the battery case.
    Fig 28: Locating Engine Harness Electrical Connector And Pin-Type Retainer
    G07479645Courtesy of FORD MOTOR CO.
  32. Connect the PCM electrical connector and attach the wiring harness retainer.
    Fig 29: Locating PCM Electrical Connector
    G07479644Courtesy of FORD MOTOR CO.
  33. Connect the A/C compressor electrical connector attach wiring harness retainer to A/C compressor stud bolt.
    Fig 30: Locating A/C Compressor Electrical Connector And Wiring Harness Retainer
    G07479619Courtesy of FORD MOTOR CO.
  34. Attach the generator wiring harness pin-type retainer.
    Fig 31: Locating Generator Wiring Harness Pin-Type Retainer
    G07479642Courtesy of FORD MOTOR CO.
  35. Using the Fan Pulley Holding Wrench and the Fan Clutch Nut Wrench, install the cooling fan.
    Fig 32: Installing Cooling Fan
    G06138552Courtesy of FORD MOTOR CO.

    36. All vehicles 

  36. Install the cooling module. For additional information, refer to ENGINE COOLING - GASOLINE ENGINES .
    37. NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
  37. Install the intake manifold. For additional information, refer to Intake Manifold .
  38. Rotate the accessory drive belt tensioner clockwise and install the accessory drive belt.
    Fig 33: Rotating Accessory Drive Belt Tensioner
    G07479937Courtesy of FORD MOTOR CO.
    39. NOTE: Align the index marks made during hood removal.
    Fig 34: Locating Hood Bolts
    G06126496Courtesy of FORD MOTOR CO.
  39. Position the hood and install the 4 bolts.
    • Tighten to 12 Nm (106 lb-in).
  40. Fill the crankcase with clean engine oil.
  41. Evacuate and charge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS .
  42. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM .
  43. If the engine was disassembled, use the scan tool to perform the Misfire Monitor Neutral Profile Correction procedure following the on-screen instructions.
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