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Section 57 (Engine - 6.0L Diesel -- F250-F550 Super Duty): Assembly: Engine: Assembly

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

    CAUTION: Install new D-ring seals on the crankcase-to-head tube. It requires several hours after installation for the D-ring seals to relax back to their original size. If the tube assembly is installed before the D-ring seals have relaxed, damage to the D-ring seals can occur.
    NOTE: Late build shown, early build similar.
    Fig 1: Installing New D-Ring Seals
    G03899308Courtesy of FORD MOTOR CO.
  1. Install new D-ring seals on the crankcase-to-head tube assemblies.
    2. NOTE: Check alignment of the oil holes after installing the bearings.
    Fig 2: Installing Camshaft Bearings
    G03887632Courtesy of FORD MOTOR CO.
  2. If removed, install the camshaft bearings.
    3. CAUTION: The patch bolt is unique. Do not substitute or engine damage can occur.
    NOTE: Apply High Strength Threadlocker to the threads prior to installation.
    Fig 3: Installing Piston Cooling Tubes And Bolts
    G03887633Courtesy of FORD MOTOR CO.
  3. Install the eight piston cooling tubes and bolts.
    4. CAUTION: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage can occur.
    NOTE: Apply clean engine oil to the camshaft prior to installing.
    Fig 4: Installing Camshaft And Gear Assembly
    G03887634Courtesy of FORD MOTOR CO.
  4. Install the camshaft and gear assembly. Install the thrust plate mounting bolts.
    5. NOTE: Apply clean engine oil to each bearing.
    Fig 5: Installing Crankshaft Upper Bearings
    G03887601Courtesy of FORD MOTOR CO.
  5. Install the crankshaft upper bearings and the crankshaft upper thrust bearing.
  6. Using the special tool, align the camshaft timing mark as shown.
    Fig 6: Aligning Camshaft Timing Mark Using Special Tool
    G03887636Courtesy of FORD MOTOR CO.
  7. With the timing peg in the special tool over the camshaft timing mark, install the crankshaft.
    Fig 7: Installing Crankshaft
    G03887637Courtesy of FORD MOTOR CO.
    8. NOTE: Do not turn the crankshaft during the main bearing clearance check.
  8. Position commercially available plastigage in the center of each main bearing bolt cap.
  9. Install the lower bearings into the lower crankcase.
    Fig 8: Installing Lower Bearings
    G03887638Courtesy of FORD MOTOR CO.
    10. CAUTION: 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.
  10. Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in three stages in the sequence shown.
    • Stage 1: Tighten to 122 Nm (90 lb-ft).
    • Stage 2: Tighten again to 163 Nm (120 lb-ft).
    • Stage 3: Tighten to 231 Nm (170 lb-ft).
      Fig 9: Tightening Lower Crankcase Bolts
      G03887639Courtesy of FORD MOTOR CO.
  11. Install eight M8 x 30 bolts around the outside of the lower crankcase.
    • Tighten bolts to 31 Nm (23 lb-ft) in the sequence shown.
      Fig 10: Installing Outside Lower Crankcase Bolts
      G03887640Courtesy of FORD MOTOR CO.
  12. Remove the 28 bolts and the lower crankcase.
    Fig 11: Removing Lower Crankcase
    G03887598Courtesy of FORD MOTOR CO.
  13. Measure the clearances for the main bearings. Remove the plastigage.
    Fig 12: Measuring Clearances For Main Bearings
    G03887642Courtesy of FORD MOTOR CO.
    14. NOTE: Apply clean engine oil to the lower main bearings.
    Fig 13: Installing Lower Crankcase Seals
    G03887599Courtesy of FORD MOTOR CO.
  14. Install new lower crankcase seals.
    15. CAUTION: 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.
  15. Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in three stages in the sequence shown.
    • Stage 1: Tighten bolts to 122 Nm (90 lb-ft).
    • Stage 2: Tighten bolts again to 163 Nm (120 lb-ft).
    • Stage 3: Tighten bolts to 231 Nm (170 lb-ft).
      Fig 14: Installing Lower Crankcase Bolts
      G03887639Courtesy of FORD MOTOR CO.
  16. Install eight M8 x 30 bolts around the outside of the lower crankcase.
    • Tighten bolts to 31 Nm (23 lb-ft) in the sequence shown.
      Fig 15: Installing Outside Lower Crankcase Bolts
      G03887640Courtesy of FORD MOTOR CO.
    17. CAUTION: 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 16: Measuring Crankshaft End Play
    G03887646Courtesy of FORD MOTOR CO.
  17. Install the special tool and measure the crankshaft end play.
  18. Install the special tool and measure the camshaft end play.
    Fig 17: Measuring Camshaft End Play
    G03887593Courtesy of FORD MOTOR CO.
  19. Install the special tool and measure the camshaft gear backlash.
    Fig 18: Measuring Camshaft Gear Backlash Using Special Tool
    G03887592Courtesy of FORD MOTOR CO.
  20. Install the block heater.
    Fig 19: Installing Block Heater
    G03887649Courtesy of FORD MOTOR CO.
  21. Install the camshaft position (CMP) sensor and the bolt.
    Fig 20: Installing Camshaft Position (CMP) Sensor And Bolt
    G03887650Courtesy of FORD MOTOR CO.
  22. Install the crankshaft position (CKP) sensor and the bolt.
    Fig 21: Installing Crankshaft Position (CKP) Sensor And Bolt
    G03887651Courtesy of FORD MOTOR CO.
    23. NOTE: Lubricate with clean engine oil.
    Fig 22: Installing Connecting Rod Bearings
    G03887591Courtesy of FORD MOTOR CO.
  23. Install the connecting rod bearings.
    24. NOTE: Make sure the ring openings are 120 degrees from each other, or engine damage can occur.
  24. Install new piston rings.
    1. The top compression ring is identified with one indentation mark and a 15-degree keystone profile.
    2. The intermediate compression ring is identified with two indentation marks and a square profile.
    3. Install the oil control ring.
      Fig 23: Installing Piston Rings
      G03887590Courtesy of FORD MOTOR CO.
    25. NOTE: Cam V8 is toward the inside of the engine.
    NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.
  25. Install the piston and rod assemblies.
    1. Coat the inside diameter of the ring compressor with clean engine oil.
    2. Insert the piston into the special tool. Position the piston, connecting rod and special tool 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 24: Installing Connecting Rod And Piston Assembly
        G03887654Courtesy of FORD MOTOR CO.
  26. Position a piece of plastigage across the bearing surface.
    Fig 25: Positioning Piece Of Plastigage Across Bearing Surface
    G03900006Courtesy of FORD MOTOR CO.
  27. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
    1. Tighten to 45 Nm (33 lb-ft).
    2. Tighten to 68 Nm (50 lb-ft).
      Fig 26: Identifying Connecting Rod Cap Bolts
      G03887588Courtesy of FORD MOTOR CO.
  28. Remove the bolts and the connecting rod cap.
  29. Measure the clearances for the connecting rod cap. Remove the plastigage.
    Fig 27: Measuring Clearances For Connecting Rod Cap
    G03887657Courtesy of FORD MOTOR CO.
  30. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
    1. Tighten to 45 Nm (33 lb-ft).
    2. Tighten to 68 Nm (50 lb-ft).
      Fig 28: Identifying Connecting Rod Cap Bolts
      G03887588Courtesy of FORD MOTOR CO.
  31. Using a feeler gauge, check for connecting rod side clearance.
    Fig 29: Measuring Connecting Rod Side Clearance Using Feeler Gauge
    G04519326Courtesy of FORD MOTOR CO.
    32. NOTE: Install a new press-in-place gasket.
    Fig 30: Installing Upper Oil Pan Bolts
    G03887279Courtesy of FORD MOTOR CO.
  32. Install the upper oil pan and bolts.
  33. Install the oil pickup tube and screen.
    • Install a new O-ring seal.
    • Install the oil pickup tube and screen.
    • Install the bolts.
      Fig 31: Installing Oil Pickup Tube
      G03907459Courtesy of FORD MOTOR CO.
    34. NOTE: Install a new press-in-place gasket.
  34. Position the oil pan and install the bolts.
    1. Install the longer oil pan bolts.
    2. Install the remaining bolts.
      • Tighten the bolts to 13 Nm (10 lb-ft).
        Fig 32: Installing Oil Pan Bolts
        G03887267Courtesy of FORD MOTOR CO.
    35. CAUTION: To prevent engine damage, keep the cam followers in the order in which they were removed. Install all cam followers back in their original positions.
    NOTE: Only the front guides use bolts.
    Fig 33: Installing Roller Follower Guide And Bolts
    G03887661Courtesy of FORD MOTOR CO.
  35. Apply clean engine oil to the hydraulic cam followers and install into the roller follower guide. Install the roller follower guide and the bolts.
    36. NOTE: RH side shown, LH side similar.
  36. Install the rear engine tube assembly and bolts.
    • Position the rear engine tube assembly and install the right side bolt hand tight.
    • Install the left side bolt hand tight.
    • Tighten both rear engine tube assembly bolts.
      Fig 34: Installing Rear Engine Tube Assembly And Bolts
      G03887662Courtesy of FORD MOTOR CO.
  37. Install the four cylinder head dowels.
    Fig 35: Identifying Cylinder Head Dowels
    G03887582Courtesy of FORD MOTOR CO.
    38. NOTE: Install a new cylinder head gasket with the part number facing up. Verify the top five 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 36: Cleaning And Inspecting Gasket Sealing Surfaces
    G03887503Courtesy of FORD MOTOR CO.
  38. Place the new cylinder head gasket over the dowel sleeves and onto the crankcase.
  39. Using the special tool, install the cylinder heads.
    1. Install the lifting brackets.
    2. Install the bolts.
      • Install the cylinder heads.
        Fig 37: Installing Cylinder Heads Using Special Tool
        G03887502Courtesy of FORD MOTOR CO.
  40. Install the 5 outer bolts for each cylinder head (finger tight).
    Fig 38: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
    41. CAUTION: 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: Higher mileage engines require push rods to be cleaned so the copper-colored end of the push rod can be identified.
    NOTE: If a push rod has been replaced, it may not have a copper-colored end and can be installed with either end up.
    Fig 39: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
  41. Apply clean engine oil to each end of the push rods. Insert them into their respective positions with the copper-colored end up.
    42. NOTE: Coat the end of each valve stem with clean engine oil.
    Fig 40: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
  42. Install the 16 valve bridges.
  43. Install the rocker arm carrier to the cylinder head.
    • Install the press-in-place gasket.
    • Install the rocker arm carrier.
    • Install the bolts.
      Fig 41: Installing Rocker Arm Carrier And Bolts - With Torque Specifications
      G03887669Courtesy of FORD MOTOR CO.
    44. NOTE: Rotate the crankshaft until the damper locating dowel notch is in the 6 o'clock position.
    NOTE: Apply clean engine oil to the top center of each valve bridge.
    Fig 42: Locating Rocker Arm Assembly Bolts - With Torque Specification
    G03887670Courtesy of FORD MOTOR CO.
  44. Install the rocker arm assemblies and the 16 bolts.
    45. CAUTION: Using too much engine oil on the threads of the cylinder head bolts, can 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 can affect the true torque value of the bolts.
    NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
    Fig 43: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
  45. Install the 10 cylinder head retaining bolts for each cylinder head (finger tight).
  46. Tighten the head bolts in the following sequence.
    1. Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
    2. Tighten bolts 1 through 10 to 115 Nm (85 lb-ft).
    3. Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
    4. Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees.
    5. Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees.
    6. Tighten bolts 11 through 15 to 24 Nm (18 lb-ft).
    7. Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
      Fig 44: Tightening Cylinder Head Retaining Bolts In Sequence
      G03887672Courtesy of FORD MOTOR CO.

    47. Early build vehicles 

    CAUTION: To prevent engine damage, check that the crankcase-to-head tube assemblies bottom out in the branch tube assembly. The oil rail, crankcase-to-head tube and the fuel injectors will not function correctly if these tubes are not bottomed out.
    Fig 45: Identifying Crankcase-To-Head Tube
    G03887400Courtesy of FORD MOTOR CO.
  47. Apply clean engine oil and install a crankcase-to-head tube assembly.

    48. All vehicles 

    CAUTION: If the fuel injector oil inlet O-ring is damaged, a new fuel injector must be installed.
    NOTE: Lubricate the fuel injector and O-rings liberally with clean engine oil.
    Fig 46: Identifying Fuel Injector O Rings And Electrical Connector
    G03887397Courtesy of FORD MOTOR CO.
  48. Install new O-rings and a copper washer on the fuel injector.
    49. CAUTION: Failure to tighten the injector properly can lead to engine failure.
    CAUTION: To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
    Fig 47: Installing Fuel Injector Hold-Down Clamp Bolt - With Torque Specification
    G03887398Courtesy of FORD MOTOR CO.
  49. Install the fuel injector, the fuel injector hold-down and bolt.
    50. CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
    Fig 48: Installing Fuel Injector Electrical Connector Into Rocker Carrier
    G03887399Courtesy of FORD MOTOR CO.
  50. Install the fuel injector electrical connector into the rocker carrier.
    51. NOTE: Apply clean engine oil to the top fuel injector O-ring seals before installing the high-pressure oil rail.
  51. Position the high-pressure oil rail on the injectors.
    • Place the high-pressure oil rail on top of the carrier so that the four single ball tubes are engaging the fuel injector lead angle.
    • Insert three guide bolts, two on the ends of the straight side of the high-pressure oil rail and one in the middle of the wavy side of the high-pressure rail. Install the guide studs six to seven turns.
    • Press the high-pressure oil rail into the fuel injectors.
    • Inspect that the high pressure oil rail mounting feet are flat against the mounting surface.
    • Loosely install the six bolts.
      Fig 49: Locating High-Pressure Oil Rail On Injectors
      G03887401Courtesy of FORD MOTOR CO.
  52. Install the remaining bolts and tighten.
    • Remove the three guide bolts.
    • Loosely install the three remaining bolts.
    • Tighten the nine bolts in the sequence shown.
      Fig 50: Installing Oil Rail Retaining Bolts In Sequence - With Torque Specifications
      G03887402Courtesy of FORD MOTOR CO.

    53. Late build vehicles 

    NOTE: Apply clean engine oil to the crankcase-to-head tube prior to installing.
    Fig 51: Crankcase-To-Head Tube - With Torque Specification
    G03887403Courtesy of FORD MOTOR CO.
  53. Install the crankcase-to-head tube assembly.

    54. All vehicles 

  54. Apply a bead of sealant at the back seam of the upper and lower crankcase.
    Fig 52: Installing Sealant
    G03887338Courtesy of FORD MOTOR CO.
  55. Install the rear engine cover.
    • Install the press-in-place gasket.
    • Install the rear engine cover.
    • Install the bolts.
      Fig 53: Installing Rear Engine Cover
      G03887340Courtesy of FORD MOTOR CO.
    56. NOTE: The crankshaft rear oil seal and wear sleeve are installed as an assembly.
    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.
    NOTE: Apply a bead of High Strength Threadlocker around the circumference of the outer rear edge of the secondary crankshaft flange.
    Fig 54: Installing Crankshaft Rear Oil Seal Using Special Tool
    G03887293Courtesy of FORD MOTOR CO.
  56. Using the special tools, install the crankshaft rear oil seal.
  57. Install the flywheel adapter.
    Fig 55: Identifying Flywheel Front Adapter
    G03887288Courtesy of FORD MOTOR CO.
  58. If removed, install the front cover crankcase dowels into the cylinder block.
    Fig 56: Installing Front Cover Crankcase Dowels Into Cylinder Block
    G03887308Courtesy of FORD MOTOR CO.
  59. Apply a bead of sealant at the front seam of the upper and lower crankcase.
    Fig 57: Installing Sealant At Front Seam Of Upper And Lower Crankcase
    G03887687Courtesy of FORD MOTOR CO.
    60. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
    Fig 58: Installing Guide Studs And Front Cover Gasket
    G03887688Courtesy of FORD MOTOR CO.
  60. Install the guide studs and the front cover gasket.
  61. Install the engine front cover and bolts.
    Fig 59: Installing Engine Front Cover And Bolts
    G03921466Courtesy of FORD MOTOR CO.
    62. NOTE: Install oil pump drive rotors with marks pointing outward.
    Fig 60: Identifying Inner And Outer Oil Pump Drive Rotors With Alignment Marks
    G03887281Courtesy of FORD MOTOR CO.
  62. Lubricate inner drive rotor with a suitable lithium assembly grease and install onto crankshaft. Lubricate outer drive rotor with lithium assembly grease and mesh with inner drive rotor in oil pump housing. Wipe off excess assembly grease.
    63. NOTE: Install a new O-ring seal.
    Fig 61: Installing Oil Pump Body And Bolts
    G03887283Courtesy of FORD MOTOR CO.
  63. Install the oil pump body and the bolts.
    64. NOTE: Apply High Strength Threadlocker to the outer circumference of the leading edge of the crankshaft.
    NOTE: The seal and wear sleeve must not be separated.
    Fig 62: Installing Oil Seal And Wear Sleeve Assembly Using Special Tool
    G03907068Courtesy of FORD MOTOR CO.
  64. Using the special tool, install the oil seal and wear sleeve assembly.
    65. CAUTION: To prevent engine damage, you must always install four new bolts when installing the vibration damper.
    NOTE: Do not use anti-seize compounds, grease, or any lubricants. Lubricants have an adverse effect on the torque results.
  65. Install the crankshaft vibration damper and bolts.
    • Tighten the bolts in the sequence shown.
    • Tighten the bolts to 68 Nm (50 lb-ft).
    • Tighten the bolts an additional 90 degrees.
      Fig 63: Installing Crankshaft Vibration Damper And Bolts
      G03887214Courtesy of FORD MOTOR CO.
  66. If equipped, install the dual generator pulley and bolts.
    Fig 64: Installing Dual Generator Pulley And Bolts
    G03887216Courtesy of FORD MOTOR CO.
    67. NOTE: Install a new O-ring seal on the coolant pump.
    Fig 65: Installing Coolant Pump And Bolts
    G03887313Courtesy of FORD MOTOR CO.
  67. Install the coolant pump and bolts.
  68. Install the coolant pump pulley and the bolts.
    Fig 66: Installing Coolant Pump Pulley And Bolts
    G03887314Courtesy of FORD MOTOR CO.
  69. Install the RH high-pressure oil rail-to-valve cover gasket.
    Fig 67: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    G03887197Courtesy of FORD MOTOR CO.
    70. CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.
    NOTE: RH side shown; LH side similar.
  70. Install the valve covers.
    • Install the gaskets.
    • Install the valve covers.
    • Install the bolts and stud bolts.
      Fig 68: RH Valve Cover - With Torque Specification
      G03887405Courtesy of FORD MOTOR CO.
    71. NOTE: Clean and inspect the O-ring seal.
    Fig 69: Installing Injection Control Pressure (ICP) Sensor
    G03907498Courtesy of FORD MOTOR CO.
  71. Install the injection control pressure (ICP) sensor.
  72. Install the eight glow plugs.
    Fig 70: Glow Plugs - With Torque Specification
    G03887699Courtesy of FORD MOTOR CO.
    73. NOTE: Clean and apply clean engine oil to the O-ring seals.
    Fig 71: Removing/Installing Glow Plug Harness Using Special Tool
    G03887483Courtesy of FORD MOTOR CO.
  73. Using the special tool, install the glow plug harness.
    74. CAUTION: To prevent engine damage, use only approved pump cover seal. Substitution can cause damage to the pump cover.
    Fig 72: Locating High-Pressure Oil Pump O-Ring Seal
    G03887542Courtesy of FORD MOTOR CO.
  74. Install a new O-ring seal on the high-pressure oil pump.
  75. Install the high-pressure tube assembly.
    Fig 73: Identifying High-Pressure Tube Bolts
    G03887702Courtesy of FORD MOTOR CO.
  76. Install new lower O-ring seals.
    Fig 74: Identifying O-Ring Seals
    G03887540Courtesy of FORD MOTOR CO.
  77. Install the high-pressure pump and bolts.
    Fig 75: Tightening High-Pressure Pump Bolts
    G03887704Courtesy of FORD MOTOR CO.
  78. Tighten the bolts for the high-pressure tube assembly.
    Fig 76: Tightening High-Pressure Tube Bolts
    G03907513Courtesy of FORD MOTOR CO.
  79. Position the dial indictor with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
    Fig 77: Checking Oil Pump Drive Gear Backlash
    G03887537Courtesy of FORD MOTOR CO.
  80. Install a new press-in-place gasket in the high-pressure pump cover.
    Fig 78: Placing Gasket In High-Pressure Pump Cover
    G03887707Courtesy of FORD MOTOR CO.
  81. Clean the cover mounting surface and apply sealer at the seams.
    Fig 79: Applying Sealer To Cover Mounting Surface
    G03887708Courtesy of FORD MOTOR CO.
    82. CAUTION: To prevent engine damage, the high-pressure oil pump cover must be firmly seated on the O-ring seal to prevent cracking the cover plate.
    NOTE: Apply clean engine oil to the high-pressure oil pump O-ring seal prior to installing the high-pressure pump cover.
    Fig 80: Installing High-Pressure Oil Pump Cover And Bolts
    G03887709Courtesy of FORD MOTOR CO.
  82. Install the high-pressure oil pump cover and bolts.

    83. Early build vehicles 

  83. Install the turbocharger heat shield and bolts.
    Fig 81: Turbocharger Heat Shield Bolts - With Torque Specification
    G03887341Courtesy of FORD MOTOR CO.

    84. All vehicles 

  84. Install the IPR valve.
    Fig 82: Installing Injection Pressure Regulator Valve
    G03887710Courtesy of FORD MOTOR CO.
  85. Install the heat insulating wrap and fasten the snap.
    Fig 83: Identifying Heat Insulating Wrap
    G03887533Courtesy of FORD MOTOR CO.
  86. Install the oil pump inlet strainer.
    Fig 84: Identifying Oil Pump Inlet Strainer
    G03887232Courtesy of FORD MOTOR CO.
    87. CAUTION: 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.
  87. Install the oil cooler assembly.
    • Install the press-in-place gasket.
    • Install the oil cooler assembly.
    • Install the bolts.
      Fig 85: Tightening Oil Cooler Assembly Bolts
      G03907057Courtesy of FORD MOTOR CO.
    88. NOTE: The old oil cooler cover bolts or new self-tapping bolts must be used to cut the threads in the new oil cooler cover.
  88. Install the oil filter base.
    • Install the press-in-place gasket.
    • Install the oil filter base.
    • Install the bolts.
      Fig 86: Installing Oil Filter Base
      G03907059Courtesy of FORD MOTOR CO.
  89. Install the exhaust gas recirculation (EGR) cooler coolant supply port cover.
    • Install the press-in-place gasket.
    • Install the EGR cooler coolant supply port cover.
    • Install the bolts.
      Fig 87: Tightening (EGR) Cooler Coolant Supply Port
      G03887239Courtesy of FORD MOTOR CO.
  90. Install new O-ring seals in the oil filter base.
    Fig 88: Identifying O-Ring Seals
    G03887527Courtesy of FORD MOTOR CO.
  91. Install the serpentine belt idlers and bolts.
    Fig 89: Tightening Serpentine Belt Idlers And Bolts
    G03887719Courtesy of FORD MOTOR CO.
  92. Install the belt tensioner and bolts.
    Fig 90: Accessory Drive Belt Tensioner Bolt - With Torque Specification
    G03887315Courtesy of FORD MOTOR CO.
    93. NOTE: Install new sealing washers.
    Fig 91: Installing Cylinder Head Fuel Line
    G03887721Courtesy of FORD MOTOR CO.
  93. Install the left cylinder head fuel line.
  94. Install the fuel lines and bracket bolt.
    Fig 92: Installing Fuel Lines And Bracket Bolt
    G03907030Courtesy of FORD MOTOR CO.
    95. NOTE: Install a new O-ring seal on the thermostat.
    Fig 93: Locating Stud Bolts And Thermostat Assembly - With Torque Specification
    G03887322Courtesy of FORD MOTOR CO.
  95. Install the thermostat housing and the stud bolts.

    96. Early build vehicles 

  96. Position the exhaust pressure bracket assembly and install the retaining nuts.
    Fig 94: Locating Retaining Nuts And Exhaust Backpressure Assembly - With Torque Specification
    G03906879Courtesy of FORD MOTOR CO.
  97. Tighten the exhaust pressure tube at the exhaust manifold.
    Fig 95: Exhaust Pressure Tube Fitting - With Torque Specification
    G03906880Courtesy of FORD MOTOR CO.

    98. All vehicles 

    NOTE: Install a new O-ring seal on the oil indicator and tube. Apply clean engine oil to the O-ring seal.
    Fig 96: Locating Wire Harness Retainer
    G03907047Courtesy of FORD MOTOR CO.
  98. Install the oil level indicator tube and nut. Connect the wiring retainer.
  99. Install the glow plug mounting bracket and the nuts.
    Fig 97: Installing Mounting Bracket And Nuts
    G03907568Courtesy of FORD MOTOR CO.
    100. NOTE: LH shown; RH similar.
    Fig 98: Installing LH And RH Motor Mounts And Bolts
    G03907227Courtesy of FORD MOTOR CO.
  100. Install the LH and RH motor mounts and bolts.
    101. NOTE: LH shown, RH similar.
    NOTE: Lightly lubricate the O-ring seal with clean engine oil prior to installing.
    Fig 99: Tightening Cylinder Block Drain Plugs
    G03907050Courtesy of FORD MOTOR CO.
  101. Install the cylinder block drain plugs.
  102. Install the starter and the three bolts.
    Fig 100: Installing Starter And Bolts
    G03907534Courtesy of FORD MOTOR CO.
  103. Install the special tool.
    Fig 101: Identifying Special Tool
    G03887258Courtesy of FORD MOTOR CO.
  104. Install the special tool.
    Fig 102: Installing Special Tool
    G03887726Courtesy of FORD MOTOR CO.
  105. Install the lifting crane and remove the engine from the engine stand.
  106. Install the flexplate or flywheel.
    • Install the new bolts.
    • Tighten the bolts in two stages in the sequence shown.
    • Stage 1: Tighten all bolts to 5 Nm (44 lb-in).
    • Stage 2: Tighten all bolts to 94 Nm (69 lb-ft).
      Fig 103: Tightening Flexplate Or Flywheel Bolts In Sequence
      G03907158Courtesy of FORD MOTOR CO.
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