Special Tool(s): Installation

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Change the engine oil any time the turbocharger is removed from the engine. The passages in the block, located underneath the turbocharger, are direct passages to the lubrication system. Debris and/or coolant may enter the lubrication system and engine damage may occur.

NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body can be removed, refer to ENGINE - BODY OFF .

NOTE: For EXPORT ONLY vehicles (outside US/Canada), an Export Supplement is provided and should be referenced to identify differences that can impact service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US EPA or CARB Regulations."

NOTE: Carry out the following 4 steps if installing a new engine, long block or short block to remove any contaminants from the radiator and heater core.

Remove the primary cooling system radiator. Refer to ENGINE COOLING - DIESEL ENGINES .
NOTE: Radiator internal pressure must not exceed 138 kPa (20 psi). Damage to the radiator can result.

NOTE: Dispose of old coolant and flushing water contaminated with antifreeze and cleaning chemicals in accordance with local, state or federal laws.

Backflush the radiator using a garden hose with the radiator rotated so the lower radiator hose location is at the top.
- Use a garden hose in the lower hose location and backflush.
NOTE: Heater core internal pressure must not exceed 138 kPa (20 psi). Damage to the heater core can result.

NOTE: Dispose of old coolant and flushing water contaminated with antifreeze and cleaning chemicals in accordance with local, state or federal laws.

Backflush the heater core using a garden hose in the heater core outlet hose.
Install the primary cooling system radiator. Refer to ENGINE COOLING - DIESEL ENGINES .
Clean the engine support insulator-to-frame mating surfaces of any dirt or foreign material prior to installation of the engine.
NOTE: Prior to installation of the engine, lubricate the torque converter pilot hub or damage to the torque converter or the engine crankshaft can occur.

Lubricate the torque converter pilot hub with multi-purpose grease and align the paint dot on the torque converter in the 12 o'clock position.

Fig 1: Locating Paint Dot Mark And Torque Converter Pilot Hub
Courtesy of FORD MOTOR CO.
NOTE: During installation of the engine, the engine oil cooler will pass very close to the frame crossmember. Install the engine slowly, continually checking to make sure the engine oil cooler does not hit the frame crossmember, or component damage may occur.

NOTE: Use caution to make sure the torque converter studs align with the holes in the flexplate while joining the engine to the transmission.

Using the Floor Crane, install the engine into the vehicle and join the engine to the transmission.
Install the 2 upper transmission bellhousing bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 2: Locating Upper Transmission Bellhousing Bolts
  Courtesy of FORD MOTOR CO.
Remove the transmission jack.
Remove the ratchet strap from the engine.
Remove the upper Front End Accessory Drive (FEAD) bracket mounting bolt and the Lifting Eye.

Fig 3: Locating Lifting Eye And Upper FEAD Bracket Mounting Bolt
Courtesy of FORD MOTOR CO.
Install the upper FEAD bracket mounting bolt.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 4: Locating Upper Front End Accessory Drive Bracket Mounting Bolt
  Courtesy of FORD MOTOR CO.
NOTE: Transmission not shown for clarity.

Using 2 new O-rings install the engine oil indicator tube to the engine.
Position the ground strap to the LH side of the cowl and install the ground strap bolt.
- Tighten to 10 Nm (89 lb-in).
Position the 3 ground straps to the RH side of the firewall and install the 3 ground strap bolts.
- Tighten to 10 Nm (89 lb-in).
Connect the 2 engine wiring harness electrical connectors at the rear of the RH battery tray.
If equipped, connect the secondary generator electrical connector at the front of the RH battery tray.
Connect the RH positive battery cable clamp.
- Tighten to 7 Nm (62 lb-in).
- Connect the 2 battery cable retainers.
  
  Fig 5: Locating RH Positive Battery Cable Clamp And Retainers
  Courtesy of FORD MOTOR CO.
Connect the 2 positive power distribution cables and install the 2 nuts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 6: Locating Positive Power Distribution Cables And Nuts
  Courtesy of FORD MOTOR CO.
Install the power distribution cover.

Fig 7: Locating Power Distribution Cover
Courtesy of FORD MOTOR CO.
Install the engine wiring harness bracket bolt and the ground wire bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 8: Locating Engine Wiring Harness Bracket Bolts
  Courtesy of FORD MOTOR CO.
Install the PCM, the bracket, and the 2 nuts.
- Tighten to 7 Nm (62 lb-in).
Connect the 3 PCM electrical connectors and wiring harness retainers.

Fig 9: Locating PCM Electrical Connectors
Courtesy of FORD MOTOR CO.
Install the crankcase vent oil separator. For additional information, refer to ENGINE EMISSION CONTROL .
Remove the caps or plugs as needed. Using a new O-ring seal and gasket, position the evaporator-to-compressor suction tube fitting and install the nut.
- Tighten to 15 Nm (133 lb-in).
  
  Fig 10: Locating Evaporator-To-Compressor Suction Tube Fitting Mounting Nuts
  Courtesy of FORD MOTOR CO.
Install the Exhaust Gas Recirculation (EGR) cooler. For additional information, refer to ENGINE EMISSION CONTROL .
On late build vehicles, apply a 3.4 mm (0.133 in) diameter bead of sealant 1.0 mm (0.039 in) outward of the chamfer on the lower oil pan sealing face.

Fig 11: Applying Sealant Bead On Lower Oil Pan Sealing Face
Courtesy of FORD MOTOR CO.
NOTE: On early build vehicles, install a new gasket.

Install the lower oil pan and the 15 bolts. Tighten in the sequence shown in the illustration.
- Tighten to 10 Nm (89 lb-in).
Install a new engine oil filter.
- Tighten to 5 Nm (44 lb-in).
- Tighten an additional 180 degrees.
Install the 9 transmission bellhousing bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 12: Locating Transmission Bellhousing Bolts
  Courtesy of FORD MOTOR CO.
If necessary, install 2 new engine support insulator studs.
- Tighten to 80 Nm (59 lb-ft).
NOTE: Failure to replace the engine support insulator nuts may result in engine support insulator damage.

NOTE: Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

Install the 4 new RH engine support insulator nuts.
- Tighten to 115 Nm (85 lb-ft).
NOTE: Failure to replace the engine support insulator nuts may result in engine support insulator damage.

NOTE: Only use hand tools when installing the engine support insulator nuts or damage to the engine support insulator may occur.

Install the 3 new LH engine support insulator nuts.
- Tighten to 200 Nm (148 lb-ft).
If necessary, install 2 new transmission support insulator studs.
- Tighten to 75 Nm (55 lb-ft).
NOTE: Failure to replace the transmission support insulator nuts may result in transmission support insulator damage.

NOTE: Only use hand tools when installing the transmission support insulator nuts or damage to the transmission support insulator may occur.

Install 2 new transmission support insulator nuts.
- Tighten to 115 Nm (85 lb-ft).
  
  Fig 13: Locating Transmission Support Insulator Nuts
  Courtesy of FORD MOTOR CO.
Position the transmission cooler lines to the RH side of the engine and install the bracket nut.
- Tighten to 12 Nm (106 lb-in).
  
  Fig 14: Locating Transmission Cooler Tube Bracket Nut
  Courtesy of FORD MOTOR CO.
Install the 6 new torque converter nuts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 15: Locating Torque Converter Nut
  Courtesy of FORD MOTOR CO.
Install the flexplate access cover and the 2 retainers.

Fig 16: Locating Flexplate Access Cover Retainers
Courtesy of FORD MOTOR CO.
Install the starter motor. For additional information, refer to STARTING SYSTEM - DIESEL ENGINES .
If equipped, connect the block heater cord.

Fig 17: Locating Block Heater Cord
Courtesy of FORD MOTOR CO.
NOTE: Position the turbocharger on the locating dowels before installation.

NOTE: The turbocharger is a tight fit between the cowl and the fuel rail supply tube. It is not necessary to remove the fuel rail supply tube.

NOTE: Clean and inspect the sealing surfaces of the engine block and the turbocharger.

Using a new gasket, install the turbocharger to the engine.
NOTE: The turbocharger mounting bolts are torque-to-yield design and cannot be reused.

NOTE: Turbocharger removed for clarity.

Install the 4 new turbocharger mounting bolts and tighten in 3 stages in the sequence shown in the illustration.
- Stage 1: Tighten finger tight.
- Stage 2: Tighten to 15 Nm (133 lb-in).
- Stage 3: Tighten to 55 Nm (41 lb-ft).
  
  Fig 18: Identifying Tightening Sequence Of Turbocharger Mounting Bolts
  Courtesy of FORD MOTOR CO.
Connect the turbocharger actuator electrical connector and position the wiring harness heat shield back over the electrical connector.
Using a new O-ring, install the heater core inlet tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
- Connect the heater core inlet tube fitting.
NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.

Using a new gasket, install the LH turbocharger inlet pipe and the 3 new nuts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 19: Locating Turbocharger Inlet Pipe Mounting Nuts
  Courtesy of FORD MOTOR CO.
NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.

Install a new LH turbocharger inlet pipe clamp.
- Tighten to 15 Nm (133 lb-in).
  
  Fig 20: Locating Turbocharger Inlet Pipe Clamps
  Courtesy of FORD MOTOR CO.
Install the turbocharger downpipe and loosely install the 2 bolts to the turbocharger downpipe flange.

Fig 21: Locating Turbocharger Downpipe Flange Bolts
Courtesy of FORD MOTOR CO.
Loosely install the turbocharger downpipe bracket bolt.

Fig 22: Locating Turbocharger Downpipe Bracket Bolt
Courtesy of FORD MOTOR CO.
Install a new turbocharger downpipe clamp.
- Tighten to 15 Nm (133 lb-in).
  
  Fig 23: Locating Turbocharger Downpipe Clamp
  Courtesy of FORD MOTOR CO.
Tighten the turbocharger downpipe bracket bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 24: Locating Turbocharger Downpipe Bracket Bolt
  Courtesy of FORD MOTOR CO.
Tighten the 2 turbocharger downpipe flange bolts.
- Tighten to 40 Nm (30 lb-ft).
  
  Fig 25: Locating Turbocharger Downpipe Flange Bolts
  Courtesy of FORD MOTOR CO.
Install the RH fender splash shield. For additional information, refer to FRONT END BODY PANELS .
NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.

Using a new gasket, install the RH turbocharger inlet pipe and the 3 new nuts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 26: Locating Turbocharger Inlet Pipe Mounting Nuts
  Courtesy of FORD MOTOR CO.
Connect the Exhaust Pressure (EP) sensor electrical connector.
- Position the EP sensor electrical connector heat shield over the electrical connector.
  
  Fig 27: Locating Exhaust Pressure Sensor Electrical Connector And Heat Shield
  Courtesy of FORD MOTOR CO.
NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.

Install a new RH turbocharger inlet pipe clamp.
- Tighten to 15 Nm (133 lb-in).
  
  Fig 28: Locating Turbocharger Inlet Pipe Clamps
  Courtesy of FORD MOTOR CO.
Connect the turbocharger coolant outlet tube to the turbocharger.
- Make sure the turbocharger coolant return tube is fully seated in the fitting and the retaining clip is in place.
  
  Fig 29: Locating Turbocharger Coolant Return Tube And Retaining Clip
  Courtesy of FORD MOTOR CO.
Install the lower intake manifold and the 3 bolts.
- Tighten to 24 Nm (18 lb-ft).
NOTE: It may be necessary to rotate the locking collar to connect the oil separator hose to lower intake manifold.

Connect the oil separator hose to the lower intake manifold. Connect the crankcase vent oil separator outlet hose sensor electrical connector.
Tighten the 4 turbocharger inlet boot clamps.
- Tighten to 4 Nm (36 lb-in).
  
  Fig 30: Locating Turbocharger Inlet Boot Clamps
  Courtesy of FORD MOTOR CO.
NOTE: The 2 upper bolts are shown, the 2 lower bolts are similar.

Using 2 new gaskets, install the EGR outlet pipe and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
Connect the Exhaust Gas Recirculation Temperature (EGRT) electrical connector and wiring harness retainer.
Connect the Throttle Body (TB) electrical connector.
NOTE: Remove the covers or tape from the rocker covers and the lower intake.

Using new gaskets, install the upper intake manifold and the 15 bolts in the sequence shown in the illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 31: Identifying Upper Intake Manifold Tightening Sequence
  Courtesy of FORD MOTOR CO.
Install the engine and transmission oil level indicator tube bolts.
- Tighten the transmission oil level indicator tube bolt to 11 Nm (97 lb-in).
- Tighten the engine oil level indicator tube bolt to 10 Nm (89 lb-in).
- Connect the wastegate vacuum line to the wastegate actuator.
  
  Fig 32: Locating Wastegate Vacuum Line And Transmission Oil Level Indicator Tube Bolts
  Courtesy of FORD MOTOR CO.
Connect the Manifold Absolute Pressure (MAP) sensor electrical connector.
- Connect the 2 wiring harness retainers.
Connect the lower radiator hose sections.

Fig 33: Locating Lower Radiator Hose Section Clip
Courtesy of FORD MOTOR CO.
Connect the lower radiator hose retainers to the lower radiator support.

Fig 34: Locating Lower Radiator Hose Support Retainers
Courtesy of FORD MOTOR CO.
NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components.

Connect the fuel supply tube quick connect coupling to the secondary fuel filter. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
- Connect the fuel return tube quick connect coupling to the fuel injection pump return tube. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  
  Fig 35: Locating Fuel Return Tube Quick Connect Coupling
  Courtesy of FORD MOTOR CO.
Install and connect the upper radiator hose.

Fig 36: Locating Upper Radiator Hose Clip
Courtesy of FORD MOTOR CO.
Install the LH battery tray assembly and the 4 bolts.
- Tighten to 18 Nm (159 lb-in).
Connect the 2 coolant hoses to the coolant reservoir.
Connect the wiring harness retainer to the LH battery tray.
Connect the power steering return hose to the power steering pump.
Using 2 new O-rings, connect the power steering pressure tube to the power steering pump and install the power steering pressure tube bolt.
- Tighten to 12 Nm (106 lb-in).
Fill the power steering system. For additional information, refer to STEERING SYSTEM .
Install the Charge Air Cooler (CAC) and the 2 mounting bolts.
- Tighten to 12 Nm (106 lb-in).
  
  Fig 37: Identifying CAC Cooler And Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the LH battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Connect the CAC outlet tube to the TB and connect the Charge Air Cooler Temperature (CACT) sensor.

Fig 38: Locating Charge Air Cooler Temperature Sensor And Outlet Tube
Courtesy of FORD MOTOR CO.
Connect the 2 coolant hoses to the CAC.

Fig 39: Locating CAC And Coolant Hoses
Courtesy of FORD MOTOR CO.
Connect the CAC inlet tube to the turbocharger.

Fig 40: Locating Charge Air Cooler Tube Clip
Courtesy of FORD MOTOR CO.
NOTE: Fan clutch has RH threads.

NOTE: Use torque conversion table quick link to determine torque wrench setting.

Using the Fan Clutch Nut Wrench and the Wrench, install the cooling fan and clutch.
- Calculate the correct torque wrench setting for the following torque. Refer to the chart below.
- Tighten to 133 Nm (98 lb-ft).
  
  Fig 41: Locating Fan Clutch Nut Wrench And Wrench
  Courtesy of FORD MOTOR CO.
NOTE: The wiring harness bracket bolt is hidden behind the serpentine belt.

Install the cooling fan clutch wiring harness bracket bolt and connect the cooling fan clutch electrical connector.
- Tighten to 25 Nm (18 lb-ft).
Install the cooling fan stator and the 4 nuts.
- Tighten to 17 Nm (150 lb-in).
  
  Fig 42: Locating Cooling Fan Stator Mounting Nuts
  Courtesy of FORD MOTOR CO.
Install the cooling module. For additional information, refer to ENGINE COOLING - DIESEL ENGINES .
Connect the negative battery cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Fill the engine with the correct motor oil for the climate. For additional information, refer to the Engine .