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Section 60 (Engine - 6.0L Diesel -- F250-F550 Super Duty): Installation: Engine: Installation

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 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING .
  2. Raise the engine high enough to clear the No. 1 crossmember, then position the engine into the vehicle.
    Fig 1: Positioning Engine Into Vehicle
    G03907544Courtesy of FORD MOTOR CO.

    3. Vehicles with automatic transmission 

  3. Align the torque converter studs with the holes in the engine flywheel, then lower the engine onto the engine mount towers.

    4. Vehicles with manual transmission 

  4. Lower the engine onto the engine mount towers.

    5. All vehicles 

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

    6. Vehicles with automatic transmission 

  6. Remove the transmission jack.
  7. Install the transmission-to-engine mounting bolts.
    Fig 2: Installing Transmission-To-Engine Mounting Bolts
    G03907545Courtesy of FORD MOTOR CO.
  8. Install the new torque converter-to-flywheel retaining nuts.
    Fig 3: Installing Torque Converter-To-Flywheel Retaining Nuts
    G03907546Courtesy of FORD MOTOR CO.
  9. Install the flywheel housing cover.
    Fig 4: Installing Flywheel Housing Cover
    G03907267Courtesy of FORD MOTOR CO.

    10. All vehicles 

    NOTE: RH shown, LH similar.
    Fig 5: Installing LH And RH Side Engine Mount Retaining Nuts
    G03921734Courtesy of FORD MOTOR CO.
  10. Install the LH and RH side engine mount retaining nuts.
  11. Remove the engine lifting eye from the right side cylinder head.
    Fig 6: Removing Lifting Eye From Right Side Cylinder Head
    G03907279Courtesy of FORD MOTOR CO.
  12. Install the manufacturer's lifting bracket.
    Fig 7: Installing Manufacturer's Lifting Bracket
    G03907278Courtesy of FORD MOTOR CO.
  13. Remove the two engine lift adapters.
    Fig 8: Identifying Special Tool
    G03887258Courtesy of FORD MOTOR CO.
  14. Position the turbocharger outlet pipe.
    Fig 9: Positioning Turbocharger Outlet Pipe
    G03907586Courtesy of FORD MOTOR CO.
  15. Install the transmission cooler tube bracket and nut.
    Fig 10: Tightening Transmission Cooler Tube Bracket And Nut
    G03907110Courtesy of FORD MOTOR CO.
  16. Install the left rear valve cover stud.
    Fig 11: Tightening Left Rear Valve Cover Stud
    G03907553Courtesy of FORD MOTOR CO.
  17. Install the fuel injector control module bracket and nuts.
    Fig 12: Installing Fuel Injector Control Module Bracket And Tightening Nuts
    G03907048Courtesy of FORD MOTOR CO.

    18. Late build vehicles 

  18. Connect the exhaust pressure sensor tube fitting to the exhaust manifold and install the exhaust pressure sensor retaining nut.
    Fig 13: Connecting Exhaust Pressure Sensor Tube Fittings To Exhaust Manifold
    G03906833Courtesy of FORD MOTOR CO.
  19. Install the heat shield and bolts.
    Fig 14: Installing Heat Shield And Bolts
    G03907032Courtesy of FORD MOTOR CO.
  20. Position the turbocharger adapter pipes. Install the gasket and bolts.
    Fig 15: Installing Turbocharger Adapter Pipes Bolts
    G03907033Courtesy of FORD MOTOR CO.

    21. All vehicles 

    NOTE: To aid in installation, make sure the turbocharger Marmon clamp stud is positioned toward the drivers side.
    Fig 16: Identifying Turbocharger Adapter Pipe
    G03906944Courtesy of FORD MOTOR CO.
  21. Position the turbocharger adapter pipe.
    22. NOTE: Left side shown, right side similar.
    NOTE: Use a half-moon wrench to aid in accessing the fasteners.
    NOTE: Apply anti-seize lubricant to the threads prior to installing the bolts.
    Fig 17: Locating Turbocharger Adapter Plate Nuts
    G03899293Courtesy of FORD MOTOR CO.
  22. Loosely install the bolts for the turbocharger adapter pipe.
  23. Position back the block heater and starter wiring.
  24. Connect the block heater electrical connector.
    Fig 18: Identifying Block Heater Electrical Connector
    G03887446Courtesy of FORD MOTOR CO.
  25. Connect the starter wiring and install the solenoid cap.
    Fig 19: Connecting Starter Wiring
    G03907962Courtesy of FORD MOTOR CO.
  26. Connect the ground strap on the right head and install the bolt.
    Fig 20: Connecting Ground Strap
    G03907560Courtesy of FORD MOTOR CO.

    27. Vehicles with automatic transmission 

  27. Install the automatic transmission fluid indicator and tube.
    Fig 21: Identifying Nuts
    G03907561Courtesy of FORD MOTOR CO.

    28. All vehicles 

  28. Position back the wiring and connect the crankshaft position (CKP) sensor electrical connector.
    Fig 22: Locating CKP Sensor Electrical Connector
    G03888387Courtesy of FORD MOTOR CO.

    29. Vehicles with A/C 

  29. Install the A/C compressor and bolts.
    Fig 23: Tightening A/C Compressor And Bolts
    G03907563Courtesy of FORD MOTOR CO.
  30. Remove the cap or plug and install a new O-ring seal. Install the A/C hose and retaining nut.
    Fig 24: Identifying Suction Line Retainer At Accumulator
    G03905983Courtesy of FORD MOTOR CO.
  31. Connect the A/C high-pressure switch and the clutch electrical connectors.
    Fig 25: Connecting A/C High-Pressure Switch And Clutch Electrical Connectors
    G03907259Courtesy of FORD MOTOR CO.

    32. All vehicles 

  32. Connect the RH glow plug electrical connector and wire retainer.
    Fig 26: Connecting RH Glow Plug Electrical Connector And Wire Retainer
    G03907258Courtesy of FORD MOTOR CO.
  33. Connect the glow plug module electrical connectors. Connect the pushpin retainer and the injection control pressure (ICP) sensor electrical connector.
    Fig 27: Locating ICP And Glow Plug Electrical Connectors
    G03906822Courtesy of FORD MOTOR CO.
    34. NOTE: Only one retainer shown.
    Fig 28: Connecting Wire Retainers On Valve Cover Studs
    G03906931Courtesy of FORD MOTOR CO.
  34. Connect the wire retainers on the valve cover studs.
  35. Connect the ground cable and the ground stud.
    Fig 29: Connecting Ground Cable And Ground Stud
    G03907571Courtesy of FORD MOTOR CO.
  36. Install the battery cable bracket and the nut.
    Fig 30: Tightening Battery Cable Bracket And Nut
    G03906869Courtesy of FORD MOTOR CO.
  37. Position the power steering pump and install the lower bolt.
    Fig 31: Tightening Lower Bolt
    G03922157Courtesy of FORD MOTOR CO.
  38. Install the power steering pump upper bolts.
    Fig 32: Tightening Power Steering Pump Upper Bolts
    G03921472Courtesy of FORD MOTOR CO.
    39. NOTE: Only one standoff shown.
    Fig 33: Identifying Stator Standoffs
    G03907575Courtesy of FORD MOTOR CO.
  39. Install the stator standoffs.
  40. Connect the fuel lines and install the clips. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
    Fig 34: Connecting Fuel Lines
    G03907248Courtesy of FORD MOTOR CO.
  41. Install the lower radiator hose and clamp.
    Fig 35: Identifying Lower Radiator Hose And Clamp
    G03921454Courtesy of FORD MOTOR CO.
  42. Connect the heater hose at the front cover.
    Fig 36: Identifying Clamp And Heater Hose
    G03921453Courtesy of FORD MOTOR CO.
  43. Connect the camshaft position (CMP) sensor electrical connector.
    Fig 37: Locating Camshaft Position Sensor Electrical Connector
    G03888384Courtesy of FORD MOTOR CO.
  44. Connect the 12-pin and 8-pin electrical connectors.
    Fig 38: Connecting Electrical Connectors
    G03907243Courtesy of FORD MOTOR CO.
  45. Connect the powertrain control module (PCM) electrical connector.
    Fig 39: Connecting Powertrain Control Module (PCM) Electrical Connector
    G03907242Courtesy of FORD MOTOR CO.
  46. Connect the LH glow plug electrical connector.
    Fig 40: Connecting LH Glow Plug Electrical Connector
    G03907245Courtesy of FORD MOTOR CO.
  47. Install the battery tray and bolts.
    Fig 41: Installing Battery Tray And Bolts
    G03907583Courtesy of FORD MOTOR CO.
  48. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  49. Tighten the nuts at the turbocharger adapter pipe flange.
    Fig 42: Tightening Turbocharger Adapter Pipe Flange Nut
    G03907138Courtesy of FORD MOTOR CO.
  50. Install the upper radiator support and bolts.
    Fig 43: Installing Upper Radiator Support And Bolts
    G03907591Courtesy of FORD MOTOR CO.
    51. NOTE: Cover position back for clarity.
    Fig 44: Connecting Body Feed Cable
    G03907592Courtesy of FORD MOTOR CO.
  51. Connect the body feed cable and install the retaining nut.
  52. Install the transmission oil cooler.
    Fig 45: Installing Transmission Oil Cooler
    G03922171Courtesy of FORD MOTOR CO.
    53. NOTE: Remove the caps or plugs as needed.
    Fig 46: Connecting Transmission Cooler Hoses
    G03921834Courtesy of FORD MOTOR CO.
  53. Connect the transmission cooler hoses.
  54. Install the power steering cooler and bolts.
    Fig 47: Installing Power Steering Cooler And Bolts
    G03922173Courtesy of FORD MOTOR CO.
  55. Position back the power steering cooler tubes and install the tubes in the retaining clip.
    Fig 48: Installing Tubes In Retaining Clip
    G03921832Courtesy of FORD MOTOR CO.
    56. NOTE: Remove the caps or plugs as needed.
    Fig 49: connecting Power Steering Hoses And Clamps
    G03921831Courtesy of FORD MOTOR CO.
  56. Connect the power steering hoses and tighten the clamps.
  57. Install the front bumper.
  58. Install the radiator grille opening panel reinforcement. For additional information, refer to FRONT END BODY PANELS .

    59. Vehicles with A/C 

  59. Install the A/C condenser assembly. For additional information, refer to AIR CONDITIONING .

    60. All vehicles 

  60. Install the charge air cooler. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  61. Install the air cleaner assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  62. Install the cooling fan stator. For additional information, refer to ENGINE COOLING .

    63. Vehicles with manual transmission 

  63. Install the clutch disc and pressure plate. For additional information, refer to CLUTCH .
  64. Install the transmission. For additional information, refer to MANUAL TRANSAXLE/TRANSMISSION - ZF 6-SPEED .

    65. All vehicles 

  65. Fill the motor with clean engine oil.
  66. Connect the LH and RH battery cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  67. Fill the cooling system. For additional information, refer to ENGINE COOLING .
  68. Cycle the key three times prior to starting the vehicle to avoid the possibility of air lock in the fuel system.
  69. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM-GENERAL INFORMATION .
  70. Check and fill the transmission.
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