Section 1295 (Engine - 6.0L (99P E-Series) Diesel): Assembly: Engine: Assembly

All vehicles 

NOTE: 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.
1. Install new D-ring seals on each end of the crankcase-to-head tube assemblies.
Fig 1: Identifying D-Ring Seals
Courtesy of FORD MOTOR CO.
NOTE: Check alignment of the oil holes after installing the bearings.
2. If removed, using the Camshaft Service Set, install the new camshaft bearings.
Fig 2: Installing Camshaft Bearings
Courtesy of FORD MOTOR CO.
NOTE: The patch bolt is unique. Do not substitute or engine damage can occur.
NOTE: Apply threadlock to the threads prior to installation.
3. Install the 8 piston cooling tubes and 8 bolts.
   • Tighten to 13 Nm (115 lb-in).
Fig 3: Identifying Piston Cooling Tube Bolt
Courtesy of FORD MOTOR CO.
NOTE: 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.
4. Install the camshaft and gear assembly and the 2 thrust plate mounting bolts.
   • Tighten to 31 Nm (23 lb-ft).
Fig 4: Locating Thrust Plate Mounting Bolts
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to all the bearings.
5. Install the new crankshaft upper bearings and the new crankshaft upper thrust bearing.
Fig 5: View Of Crankshaft Upper Bearing Seats
Courtesy of FORD MOTOR CO.
6. Using the Camshaft Alignment Tool, align the camshaft timing mark as shown.
Fig 6: Installing Special Tool To Prevent Cam Gear From Turning
Courtesy of FORD MOTOR CO.
7. With the timing peg in the Camshaft Alignment Tool over the camshaft timing mark, install the crankshaft.
Fig 7: Installing Crankshaft (Camshaft Aligned)
Courtesy of FORD MOTOR CO.
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 new lower bearings into the lower crankcase.
Fig 8: Lower Crankcase Bearings
Courtesy of FORD MOTOR CO.
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.
10. Install the lower crankcase, all 20 lower crankcase main bearing mounting bolts and tighten the bolts in 3 stages, in the sequence shown.
    • Stage 1: Tighten to 122 Nm (90 lb-ft).
    • Stage 2: Tighten to 163 Nm (120 lb-ft).
    • Stage 3: Tighten to 231 Nm (170 lb-ft).
Fig 9: Lower Crankcase Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
11. Remove the 20 bolts and the lower crankcase.
Fig 10: Lower Crankcase Bolts
Courtesy of FORD MOTOR CO.
12. Measure the clearances for the main bearings.
    • Remove the Plastigage®.
Fig 11: Measuring Main Bearing Clearance With Specifications
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the lower main bearings.
13. Install new lower crankcase seals.
Fig 12: Locating Lower Crankcase Seals
Courtesy of FORD MOTOR CO.
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.
14. Install the lower crankcase, all 20 lower crankcase main bearing mounting bolts and tighten the bolts in 3 stages, in the sequence shown.
    • Stage 1: Tighten to 122 Nm (90 lb-ft).
    • Stage 2: Tighten to 163 Nm (120 lb-ft).
    • Stage 3: Tighten to 231 Nm (170 lb-ft).
Fig 13: Lower Crankcase Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
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.
15. Install the Dial Indicator Gauge with Holding Fixture and measure the crankshaft end play.
Fig 14: Checking Crankshaft End Play With Specifications
Courtesy of FORD MOTOR CO.
16. Install the Dial Indicator Gauge with Holding Fixture and measure the camshaft end play.
Fig 15: Checking Camshaft End Play With Specifications
Courtesy of FORD MOTOR CO.
17. Install the Dial Indicator Gauge with Holding Fixture and measure the camshaft gear backlash.
Fig 16: Checking Camshaft Gear Backlash With Specifications
Courtesy of FORD MOTOR CO.
18. Install the block heater.
    • Tighten to 41 Nm (30 lb-ft).
Fig 17: Identifying 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: Identifying Camshaft Position (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: Identifying Crankshaft Position (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 can occur.
NOTE: Lubricate with clean engine oil.
21. Install the new connecting rod bearings.
Fig 20: View Of Upper And Lower Connecting Rod Bearings
Courtesy of FORD MOTOR CO.
NOTE: Make sure the ring openings are 120 degrees from each other or engine damage can occur.
22. Install new piston rings.
    1. The keystone ring is identified with one indentation mark and a 15-degree keystone profile.
    2. The intermediate compression ring is identified with 2 indentation marks and a square profile.
    3. Install the oil control ring.
Fig 21: Piston Rings
Courtesy of FORD MOTOR CO.
NOTE: Cam V8 is toward the inside of the engine.
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 & Rod Assemblies
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 can occur.
NOTE: Only one connecting rod cap shown.
25. Install 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: Identifying Connecting Rod Cap 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 Connecting Rod Bearing Clearance With Specifications
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 can occur.
NOTE: Only one connecting rod cap shown.
28. Install 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: Identifying Connecting Rod Cap Bolts
Courtesy of FORD MOTOR CO.
29. Using a Feeler Gauge Set, check for the minimum connecting rod side clearance.
Fig 27: Checking For Minimum Connecting Rod Side Clearance Using A Feeler Gauge Set
Courtesy of FORD MOTOR CO.
30. Install new upper oil pan gasket, the upper oil pan and the 9 bolts.
    • Tighten to 13 Nm (115 lb-in).
Fig 28: Identifying Upper Oil Pan Bolts
Courtesy of FORD MOTOR CO.
NOTE: 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.
31. Apply clean engine oil to the hydraulic cam followers and install into the roller follower guide. Install the roller follower guides and the 2 bolts.
    • Tighten to 13 Nm (115 lb-in).
Fig 29: Identifying Roller Follower Guide Bolt
Courtesy of FORD MOTOR CO.
NOTE: Right side shown, left side similar.
32. Install the rear engine tube assembly and 2 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.
      • Tighten to 13 Nm (115 lb-in).
Fig 30: Identifying Rear Engine Tube Assembly
Courtesy of FORD MOTOR CO.
33. Install the 4 new cylinder head dowels.
Fig 31: Locating Cylinder Head Dowels
Courtesy of FORD MOTOR CO.
NOTE: Install a new cylinder head gasket with the part number facing upward. 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.
34. Place the new cylinder head gaskets over the dowel sleeves and onto the crankcase.
Fig 32: Identifying Gasket Sealing Surfaces Area
Courtesy of FORD MOTOR CO.
35. Using the Cylinder Head Lifting Bracket, install the cylinder heads.
Fig 33: Identifying Cylinder Head Lifting Bracket On Cylinder Head
Courtesy of FORD MOTOR CO.
36. Install the 10 outer head bolts finger-tight.
Fig 34: Identifying Outer Cylinder Head Bolts
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.
37. Apply clean engine oil to each end of the push rods and insert them into their respective positions.
Fig 35: Identifying Push Rods
Courtesy of FORD MOTOR CO.
NOTE: Coat the end of each valve stem with clean engine oil.
38. Install the 16 valve bridges.
Fig 36: Identifying Valve Bridges
Courtesy of FORD MOTOR CO.
NOTE: Left cylinder head shown, right cylinder head similar.
39. Install the new press-in-place gaskets, the rocker arm carriers and the 4 bolts.
    • Tighten to 62 Nm (46 lb-ft).
Fig 37: Rocker Arm Carrier Bolts
Courtesy of FORD MOTOR CO.
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.
40. Install the rocker arm assemblies and the 16 bolts.
    • Tighten to 31 Nm (23 lb-ft).
Fig 38: Identifying Rocker Arm Assembly Bolts
Courtesy of FORD MOTOR CO.
NOTE: 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.
NOTE: Left cylinder head shown, right cylinder head similar.
41. Install the 20 new cylinder head bolts finger-tight.
Fig 39: Identifying Cylinder Head Retaining Bolts
Courtesy of FORD MOTOR CO.
42. Tighten the head bolts in sequence in 7 stages:
    • Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
    • Stage 2: Tighten bolts 1 through 10 to 115 Nm (85 lb-ft).
    • Stage 3: Tighten bolts 1 through 10 an additional 90 degrees.
    • Stage 4: Tighten bolts 1 through 10, a second time, 90 degrees.
    • Stage 5: Tighten bolts 1 through 10, a third time, 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 40: Cylinder Head Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.
NOTE: Lubricate the fuel injector and O-ring seals liberally with clean engine oil.
43. Install new O-ring seals and a copper washer on the fuel injector.
Fig 41: Identifying O-Ring Seals, Copper Washer And Fuel Injector
Courtesy of FORD MOTOR CO.
NOTE: Failure to tighten the injector correctly can lead to engine failure.
NOTE: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.
44. Install the fuel injectors, the fuel injector hold-down and bolt.
    • Tighten to 35 Nm (26 lb-ft).
Fig 42: Identifying Fuel Injector Hold-Down Bolt
Courtesy of FORD MOTOR CO.
NOTE: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
45. Install the fuel injector electrical connector into the rocker carrier.
Fig 43: Identifying Fuel Injector Electrical Connector
Courtesy of FORD MOTOR CO.
46. Apply clean engine oil to the top fuel injector O-ring seals.
Fig 44: Identifying Top Fuel Injector O-Ring Seals
Courtesy of FORD MOTOR CO.
NOTE: Using the bolts to push the high-pressure oil rail into the fuel injectors can damage the fuel injectors and high-pressure oil rail.
NOTE: LH cylinder head shown, RH cylinder head similar.
NOTE: Apply clean engine oil to the top fuel injector O-ring seals before installing the high-pressure oil rail.
47. Position the high-pressure oil rail on the injectors.
    • Place the high-pressure oil rail on top of the carrier so that the 4 single ball tubes are engaging the fuel injector lead angle.
    • Insert 3 guide bolts, 2 on the ends of the straight side of the high-pressure oil rail and 1 in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 turns.
    • Manually 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 6 bolts.
Fig 45: Identifying Bolts And High-Pressure Oil Rail
Courtesy of FORD MOTOR CO.
48. Remove the 3 guide bolts, install the remaining bolts and tighten the 9 bolts in the sequence shown.
    • Tighten to 13 Nm (115 lb-in).
Fig 46: High-Pressure Oil Rail Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
49. Apply clean engine oil and reassemble the crankcase-to-head tube. Install the crankcase-to-head tubes.
    • Tighten to 82 Nm (60 lb-ft).
Fig 47: Locating D-Ring Seals
Courtesy of FORD MOTOR CO.
50. Connect the fuel injector electrical connectors.
Fig 48: Identifying Fuel Injector Electrical Connector & Retainer Clip
Courtesy of FORD MOTOR CO.
NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.
NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.
NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.
51. Install the LH exhaust manifold, 8 spacers and the 8 new bolts. Tighten in the sequence shown.
    • Tighten to 38 Nm (28 lb-ft).
Fig 49: Exhaust Manifold Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.
NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.
NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.
52. Install the RH exhaust manifold, 8 spacers and the 8 new bolts. Tighten in the sequence shown.
    • Tighten to 38 Nm (28 lb-ft).
Fig 50: Exhaust Manifold Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
53. Apply a bead of sealant at the back seam of the upper and lower crankcase.
Fig 51: Applying Sealant To Upper And Lower Crankcase
Courtesy of FORD MOTOR CO.
NOTE: To prevent engine 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.
54. Install the new press-in-place gasket, the engine rear cover and the 8 bolts.
    • Tighten to 24 Nm (18 lb-ft).
Fig 52: Locating Rear Engine Cover Bolts
Courtesy of FORD MOTOR CO.

Original seal 

NOTE: An original seal will have a flat wear sleeve and no pre-applied threadlock.
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 threadlock around the circumference of the outer rear edge of the secondary crankshaft flange.
55. Using the Crankshaft Rear Seal and Wear Ring Installer, install a new crankshaft rear oil seal.
Fig 53: Installing Seal
Courtesy of FORD MOTOR CO.

Redesigned seal 

NOTE: The crankshaft rear oil seal and wear sleeve are 1 piece and need to be installed as an assembly. Do not separate the wear sleeve from the seal or damage to the seal will occur. The metal face of the wear sleeve must be installed so it is on the outside of the engine (facing the transmission).
NOTE: The rear main seal face and the wear sleeve must be flush with the rear engine cover or damage to the rear main seal or wear sleeve may occur.
NOTE: A redesigned seal will have a flanged wear sleeve and pre-applied threadlock.
NOTE: Lubricate the outer diameter of the rubber seal with clean engine oil.
NOTE: Do not allow the engine to rotate during the installation of the rear main seal and wear sleeve.
56. Using the Crankshaft Rear Seal and Wear Ring Installer and the plastic step up tool packaged with the new seal, install the crankshaft rear seal.
Fig 54: Installing Seal
Courtesy of FORD MOTOR CO.

All vehicles 

57. Install the flywheel adapter.
Fig 55: Identifying Flywheel Adapter
Courtesy of FORD MOTOR CO.
58. If removed, install the front cover crankcase dowels into the cylinder block.
Fig 56: Identifying Front Cover Crankcase Dowels
Courtesy of FORD MOTOR CO.
59. Apply a bead of sealant at the front seam of the upper and lower crankcase.
Fig 57: Applying Sealant To Upper And Lower Crankcase Front Seam
Courtesy of FORD MOTOR CO.
NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
60. Install the guide studs and the new front cover gasket.
Fig 58: Guide Studs & Front Cover Gasket
Courtesy of FORD MOTOR CO.
61. Install the engine front cover and the 17 bolts.
    • Tighten to 24 Nm (18 lb-ft).
Fig 59: Locating Engine Front Cover Bolts
Courtesy of FORD MOTOR CO.
NOTE: Install oil pump drive rotors with marks pointing outward.
62. 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 in the oil pump housing.
Fig 60: Identifying Inner And Outer Oil Pump Drive Rotors With Alignment Marks
Courtesy of FORD MOTOR CO.
NOTE: Install a new O-ring seal.
63. Install the oil pump body and the 5 bolts.
    • Tighten to 13 Nm (115 lb-in).
Fig 61: Locating Oil Pump Body 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.
64. Using the Crankshaft Front Seal and Wear Ring Installer, install the new oil seal and wear sleeve assembly.
Fig 62: Installing Oil Seal And Wear Sleeve Assembly
Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, always install 4 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 tighten the 4 new bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 68 Nm (50 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
Fig 63: Crankshaft Vibration Damper Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
66. If equipped, install the dual generator pulley and the 3 bolts.
    • Tighten to 47 Nm (35 lb-ft).
Fig 64: Locating Dual Generator Pulley Bolts
Courtesy of FORD MOTOR CO.
NOTE: Install a new O-ring seal on the coolant pump.
67. Install the coolant pump and the 4 bolts.
    • Tighten to 23 Nm (17 lb-ft).
Fig 65: Locating Coolant Pump Bolts
Courtesy of FORD MOTOR CO.
68. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 31 Nm (23 lb-ft).
Fig 66: Identifying Coolant Pump Pulley Bolts
Courtesy 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
Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, do not use air-powered tools when installing the valve cover.
70. Install the gasket, the RH valve cover and the 5 bolts and 6 stud bolts.
    • Tighten to 9 Nm (80 lb-in).
Fig 68: Identifying RH Stud Bolts, Bolts & Valve Cover
Courtesy of FORD MOTOR CO.
71. Cover the LH cylinder head with an appropriate covering.
72. Install the 8 glow plugs.
    • Tighten to 19 Nm (168 lb-in).
Fig 69: Identifying Glow Plug
Courtesy of FORD MOTOR CO.
NOTE: Clean and apply clean engine oil to the O-ring seals.
73. Using the Glow Plug Connector Remover/Installer, install the glow plug harness.
Fig 70: Identifying Glow Plug Harness Special Tool (303-1114)
Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, use only an approved pump cover seal. Substitution can cause damage to the pump cover.
74. Install a new O-ring seal on the high-pressure oil pump.
Fig 71: Locating High-Pressure Oil Pump O-Ring Seal
Courtesy of FORD MOTOR CO.
75. Install new lower O-ring seals.
Fig 72: Identifying Lower O-Ring Seals
Courtesy of FORD MOTOR CO.
76. Install the high-pressure pump and the 3 bolts.
    • Tighten to 31 Nm (23 lb-ft).
Fig 73: Locating High-Pressure Oil Pump Bolts
Courtesy of FORD MOTOR CO.
77. Tighten the 2 bolts for the high-pressure tube assembly.
    • Tighten to 11 Nm (97 lb-in).
Fig 74: Locating High-Pressure Tube Assembly Bolts
Courtesy of FORD MOTOR CO.
78. Position the Dial Indicator Gauge with Holding Fixture and check the oil pump drive gear backlash.
Fig 75: Checking Oil Pump Drive Gear Backlash Using Special Tool (100-002)
Courtesy of FORD MOTOR CO.
79. Install a new press-in-place gasket in the high-pressure pump cover.
Fig 76: Identifying Press-In-Place High-Pressure Pump Cover Gasket
Courtesy of FORD MOTOR CO.
80. Clean the cover mounting surface and apply sealer at the seams.
Fig 77: Applying Sealer At Seams
Courtesy of FORD MOTOR CO.
NOTE: 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.
81. Install the high-pressure oil pump cover and the 8 bolts.
    • Tighten to 11 Nm (97 lb-in).
Fig 78: High-Pressure Oil Pump Cover Bolts
Courtesy of FORD MOTOR CO.
82. Using the Injection Pressure Regulator Socket, install the Injection Pressure Regulator (IPR) valve.
    • Tighten to 50 Nm (37 lb-ft).
Fig 79: Identifying Special Tool (303-1112)
Courtesy of FORD MOTOR CO.
83. Position the turbocharger heat shield and install the 3 bolts.
    1. Tighten to 49 Nm (36 lb-ft).
    2. Tighten to 11 Nm (97 lb-in).
Fig 80: Turbocharger Heat Shield Bolts
Courtesy of FORD MOTOR CO.
84. Install the oil pump inlet strainer.
Fig 81: Identifying Oil Pump Inlet Strainer
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.
85. Install the new press-in-place gasket, the oil cooler assembly and the 10 bolts.
    • Tighten to 22 Nm (16 lb-ft).
Fig 82: Identifying Oil Cooler Assembly Bolts
Courtesy of FORD MOTOR CO.
NOTE: The old oil cooler cover bolts or new self-tapping bolts must be used to cut the threads on the new oil cooler cover.
86. Install the new press-in-place gaskets, the oil cooler assembly and the 8 bolts.
    1. Tighten to 22 Nm (16 lb-ft).
    2. Tighten to 10 Nm (89 lb-in).
Fig 83: Oil Cooler Cover Bolts
Courtesy of FORD MOTOR CO.
87. Install the new press-in-place gasket, the EGR cooler coolant supply port cover and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
Fig 84: Identifying EGR Cooler Coolant Supply Port Cover Bolts
Courtesy of FORD MOTOR CO.
88. Install a new O-ring seal in the oil filter base.
Fig 85: Identifying O-Ring Seals On Oil Filter Base
Courtesy of FORD MOTOR CO.
89. Install the oil filter adapter and the 4 bolts.
    • Tighten to 15 Nm (133 lb-in).
Fig 86: Identifying Oil Filter Adapter Bolts
Courtesy of FORD MOTOR CO.
90. Install the accessory drive belt idler pulley and the bolt.
    • Tighten to 47 Nm (35 lb-ft).
Fig 87: Locating Accessory Drive Idler Pulley Bolt
Courtesy of FORD MOTOR CO.
91. If equipped, install the belt tensioner and 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 88: Identifying Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
NOTE: Install new sealing washers.
92. Install the LH cylinder head fuel tube.
    • Tighten to 38 Nm (28 lb-ft).
Fig 89: Identifying Fuel Line Banjo Bolt
Courtesy of FORD MOTOR CO.
NOTE: Install a new O-ring seal on the thermostat.
93. Install the thermostat housing and the 2 stud bolts.
    • Tighten to 23 Nm (17 lb-ft).
Fig 90: Identifying Thermostat Housing Stud Bolts
Courtesy of FORD MOTOR CO.
94. Position the fuel tube support bracket and install the nut.
Fig 91: Fuel Tube Support Bracket Nut
Courtesy of FORD MOTOR CO.
95. Install the RH motor mount plate and the 4 bolts.
    • Tighten to 80 Nm (59 lb-ft).
Fig 92: Right Motor Mount Plate Bolts
Courtesy of FORD MOTOR CO.
96. Install the Adapter for 303-D043.
Fig 93: Locating Engine Lift Adapters (303-D043-01)
Courtesy of FORD MOTOR CO.
97. Install the Adapter for 303-D043.
Fig 94: Identifying Special Tool (303-D043-02)
Courtesy of FORD MOTOR CO.
98. Remove the engine from the engine stand.
99. Install the flexplate and the 10 new bolts. Tighten in the sequence shown, in 2 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 94 Nm (69 lb-ft).
Fig 95: Identifying Flexplate/Flywheel Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.