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Home >> Ford >> 2003 >> ZX2 Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1903 (Engine - 6.0L Diesel -- F250-F550 Super Duty 6.0L (99P F450/550)) >> Installation >> Engine >> Installation >> All vehicles

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WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
    2. Fig 1: Push & Drop Engine
    GF0005861Courtesy of FORD MOTOR CO.
  2. Raise the engine high enough to clear the No. 1 crossmember, then position the engine into the vehicle.


  1. Remove the Heavy Duty Floor Crane and the Diesel Engine Lifting Bracket.


Fig 1: Locating Engine Mount Retaining Nuts
G03921670Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  1. Install the 4 LH and 4 RH engine mount nuts.
    • Tighten to 103 Nm (76 lb-ft).
    2. Fig 2: Special Tool
    GF0005812Courtesy of FORD MOTOR CO.
  2. Remove the engine lifting eye from the right side cylinder head.
    3. Fig 3: Manufacturer's Lifting Eye
    GF0005811Courtesy of FORD MOTOR CO.
  3. Install the manufacturer's lifting bracket.
    4. Fig 4: Locating Engine Lift Adapters (303-D043-01)
    G04614140Courtesy of FORD MOTOR CO.
  4. Remove the 2 engine lift adapters.
    5. Fig 5: Securing Turbocharger Outlet Pipe
    GF0005810Courtesy of FORD MOTOR CO.
  5. Position the turbocharger outlet pipe.
    6. Fig 6: Transmission Cooler Tube Bracket Nut
    GF0005765Courtesy of FORD MOTOR CO.
  6. Install the transmission cooler tube bracket and nut.
    • Tighten to 10 Nm (89 lb-in).
    7. Fig 7: Left Rear Valve Cover Stud
    GF0005809Courtesy of FORD MOTOR CO.
  7. Install the left rear valve cover stud.
    • Tighten to 9 Nm (80 lb-in).
    8. Fig 8: Fuel Injector Control Module Mounting Bracket
    GF0005750Courtesy of FORD MOTOR CO.
  8. Install the fuel injector control module support bracket and the nuts.
    • Tighten to 8 Nm (71 lb-in).
    9. Fig 9: Exhaust Pressure (EP) Sensor Tube & Nut
    GF0005862Courtesy of FORD MOTOR CO.
  9. Connect the exhaust pressure (EP) sensor tube fitting to the exhaust manifold and install the EP sensor retaining nut.
    1. Tighten to 30 Nm (22 lb-ft).
    2. Tighten to 13 Nm (10 lb-ft).
    10. Fig 10: Heat Shield Bolts
    GF0005863Courtesy of FORD MOTOR CO.
  10. Install the heat shield and bolts.
    1. Tighten to 49 Nm (36 lb-ft).
    2. Tighten to 11 Nm (8 lb-ft).
    11. Fig 11: Exhaust Pipe Retaining Nuts
    GF0005760Courtesy of FORD MOTOR CO.
  11. Position the turbocharger adapter pipes. Install the gasket and bolts.
    • Tighten to 27 Nm (20 lb-ft).
    12. Fig 12: Turbocharger Adapter Pipe
    GF0005864Courtesy of FORD MOTOR CO.
  12. Position the turbocharger adapter pipe.
    13. Fig 13: Identifying Adapter Pipe Bolts
    G03899293Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
    NOTE: Do not tighten bolts at this time.
    NOTE: Apply anti-seize lubricant to the threads prior to installing the bolts.
  13. Install the bolts for the turbocharger adapter pipe.
  14. Position back the block heater and starter wiring.
    15. Fig 14: Identifying Block Heater Electrical Connector
    G03887446Courtesy of FORD MOTOR CO.
  15. If equipped, position back and connect the block heater electrical connector.
    16. Fig 15: Starter Wiring
    GF0005865Courtesy of FORD MOTOR CO.
  16. Connect the starter wiring and install the solenoid cap.
    1. Tighten to 6 Nm (53 lb-in).
    2. Tighten to 12 Nm (9 lb-ft).
    17. Fig 16: Right Rear Head Ground Strap
    GF0005804Courtesy of FORD MOTOR CO.
  17. Connect the ground strap to the RH cylinder head and install the bolt.
    • Tighten to 10 Nm (89 lb-in).


Fig 1: Locating CKP Sensor Electrical Connector
G03888387Courtesy of FORD MOTOR CO.
  1. Position back the wiring and connect the crankshaft position (CKP) sensor electrical connector.


Fig 1: Right Glow Plug Electrical Connector
GF0005800Courtesy of FORD MOTOR CO.
  1. Connect the RH glow plug electrical connector and wire retainer.
    2. Fig 2: Locating Injection Control Pressure (ICP) Electrical Connector And Glow Plug Connectors
    G03906822Courtesy of FORD MOTOR CO.
  2. Connect the glow plug module electrical connectors. Connect the pushpin retainer and the injection control pressure (ICP) sensor electrical connector.
    3. Fig 3: Wiring Harness Retainer
    GF0005743Courtesy of FORD MOTOR CO.
    NOTE: Only one retainer shown.
  3. Connect the wire retainers on the valve cover studs.
    4. Fig 4: Ground Cable, Stud & Nut
    GF0005799Courtesy of FORD MOTOR CO.
  4. Connect the ground cable and the ground stud.
    • Tighten to 47 Nm (35 lb-ft).
    5. Fig 5: Battery Cable Bracket & Nut
    GF0005714Courtesy of FORD MOTOR CO.
  5. Install the battery cable bracket and the nut.
    • Tighten to 47 Nm (35 lb-ft).
    6. Fig 6: Power Steering Pump Bolt
    GF0005798Courtesy of FORD MOTOR CO.
  6. Position the power steering pump and install the lower bolt.
    • Tighten to 25 Nm (18 lb-ft).
    7. Fig 7: Power Steering Pump Bolts
    GF0005713Courtesy of FORD MOTOR CO.
  7. Install the power steering pump upper bolts.
    • Tighten to 25 Nm (18 lb-ft).
    8. Fig 8: Stator Stand-Off
    GF0005797Courtesy of FORD MOTOR CO.
    NOTE: Only one stand-off shown.
  8. Install the stator stand-offs.
    • Tighten to 47 Nm (35 lb-ft).
    9. Fig 9: Fuel Tube Spring Lock Couplings
    GF0005796Courtesy of FORD MOTOR CO.
  9. Connect the fuel tube spring lock couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
    10. Fig 10: Locating Lower Radiator Hose
    G03921454Courtesy of FORD MOTOR CO.
  10. Install the lower radiator hose and clamp.
    11. Fig 11: Identifying Clamp And Heater Hose
    G03921453Courtesy of FORD MOTOR CO.
  11. Connect the heater hose at the front cover.
    12. Fig 12: Locating Camshaft Position Sensor Electrical Connector
    G03888384Courtesy of FORD MOTOR CO.
  12. Connect the camshaft position (CMP) sensor electrical connector.
    13. Fig 13: 12-Pin & 8-Pin Electrical Connectors
    GF0005795Courtesy of FORD MOTOR CO.
  13. Connect the 12-pin and 8-pin electrical connectors.
    14. Fig 14: Powertrain Control Module (PCM) Electrical Connectors
    GF0005794Courtesy of FORD MOTOR CO.
  14. Connect the powertrain control module (PCM) electrical connector.
    15. Fig 15: Left Glow Plug Electrical Connector
    GF0005793Courtesy of FORD MOTOR CO.
  15. Connect the LH glow plug electrical connector.
    16. Fig 16: Battery Tray Bolts
    GF0005792Courtesy of FORD MOTOR CO.
  16. Install the battery tray and bolts.
    • Tighten to 16 Nm (12 lb-ft).
  17. Install the intake manifold. For additional information, refer to Intake Manifold .
    18. Fig 17: Identifying Adapter Pipe Bolts
    G03899293Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
    NOTE: Alternately tighten the bolts to specification.
  18. Tighten the turbocharger adapter pipe at the flanges.
    • Tighten to 27 Nm (20 lb-ft).
    19. Fig 18: Exhaust Pipe Retaining Nuts
    GF0005760Courtesy of FORD MOTOR CO.
  19. Tighten the nuts at the turbocharger adapter pipe flange.
    • Tighten to 47 Nm (35 lb-ft).
    20. Fig 19: Upper Radiator Support Bolts
    GF0005791Courtesy of FORD MOTOR CO.
  20. Install the upper radiator support and bolts.
    • Tighten to 12 Nm (9 lb-ft).
    21. Fig 20: Body Feed Cable Nut
    GF0005790Courtesy of FORD MOTOR CO.
    NOTE: Cover position back for clarity.
  21. Connect the battery crossover cable and install the nut.
    • Tighten to 8 Nm (71 lb-in).
    22. Fig 21: Transmission Oil Cooler Bolts
    GF0005789Courtesy of FORD MOTOR CO.
  22. Install the transmission oil cooler.
    • Tighten to 8 Nm (71 lb-in).
    23. Fig 22: Transmission Oil Cooler Hoses
    GF0005788Courtesy of FORD MOTOR CO.
    NOTE: Remove the caps or plugs as needed.
  23. Connect the transmission cooler hoses.
    24. Fig 23: Power Steering Cooler Bolts
    GF0005787Courtesy of FORD MOTOR CO.
  24. Install the power steering cooler and bolts.
    • Tighten to 11 Nm (8 lb-ft).
    25. Fig 24: Power Steering Tubes Retaining Clip
    GF0005786Courtesy of FORD MOTOR CO.
  25. Position back the power steering cooler tubes and install the tubes in the retaining clip.
    26. Fig 25: Power Steering Cooler Hose Clamps
    GF0005785Courtesy of FORD MOTOR CO.
    NOTE: Remove the caps or plugs as needed.
  26. Connect the power steering hoses and tighten the clamps.
  27. Install the front bumper.
  28. Install the radiator grille opening panel reinforcement. For additional information, refer to FRONT END BODY PANELS article.


  1. Install the charge air cooler. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  2. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  3. Install the cooling fan stator. For additional information, refer to ENGINE COOLING article.


  1. Fill the motor with clean engine oil.
  2. Connect the LH and RH battery cables. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  3. Fill the cooling system. For additional information, refer to ENGINE COOLING article.
  4. Cycle the key 3 times prior to starting the vehicle to avoid the possibility of air lock in the fuel system.
  5. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION article.
  6. Check and fill the transmission.
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