Engine - Body Off: 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 cannot be removed, refer to ENGINE - BODY ON .

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: Use caution to ensure 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 5 upper transmission-to-engine mounting bolts.
- Tighten to 48 Nm (35 lb-ft).
- Remove the transmission jack.
  
  Fig 2: Locating Upper Transmission-To-Engine Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the 4 lower transmission-to-engine mounting bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 3: Locating Lower Transmission-To-Engine Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Failure to replace the engine support insulator cross bolts may result in engine support insulator damage.

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

NOTE: If it is necessary to loosen the engine support insulator nuts, new nuts must be installed. For additional information, refer to ENGINE SUPPORT INSULATORS .

Lower the engine onto the engine support insulators and install the 2 new engine support insulator cross bolts.
- Tighten to 350 Nm (258 lb-ft).
  
  Fig 4: Locating Engine Support Insulator Cross Bolts
  Courtesy of FORD MOTOR CO.
Remove the ratchet strap from the engine.
Remove the upper Front End Accessory Drive (FEAD) bracket mounting bolt and the Lifting Eye.

Fig 5: 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 6: Locating Upper Front End Accessory Drive Bracket Mounting Bolt
  Courtesy of FORD MOTOR CO.
NOTE: The turbocharger must be positioned forward, and then set down on the locating dowel pins.

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

Using a new gasket, install the turbocharger and the 2 turbocharger inlet boots.
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 7: Identifying Tightening Sequence Of Turbocharger Mounting Bolts
  Courtesy of FORD MOTOR CO.
Tighten the 4 turbocharger inlet boot clamps.
- Tighten to 4 Nm (36 lb-in).
  
  Fig 8: Locating Turbocharger Inlet Boot 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 9: Locating Turbocharger Coolant Return Tube And Retaining Clip
  Courtesy of FORD MOTOR CO.
Install and connect the Charge Air Cooler (CAC) tube to the turbocharger.

Fig 10: Locating Charge Air Cooler Tube Clip
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.

NOTE: Left side shown, right side similar.

Using 2 new gaskets and 2 new clamps, install the 2 turbocharger inlet pipes.
- Loosely position the 2 clamps.
  
  Fig 11: Locating Turbocharger Inlet Pipe Clamps
  Courtesy of FORD MOTOR CO.
NOTE: Left side shown, right side similar.

Install the 3 new nuts to each turbocharger inlet pipe.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 12: Locating Turbocharger Inlet Pipe Mounting Nuts
  Courtesy of FORD MOTOR CO.
NOTE: The Exhaust Pressure (EP) sensor and tube are attached to the RH turbocharger inlet pipe.

Connect the EP sensor electrical connector.
- Position the EP sensor electrical connector heat shield over the electrical connector.
  
  Fig 13: Locating Exhaust Pressure Sensor Electrical Connector And Heat Shield
  Courtesy of FORD MOTOR CO.
NOTE: Left side shown, right side similar.

Tighten the 2 turbocharger inlet pipe clamps.
- Tighten to 15 Nm (133 lb-in).
  
  Fig 14: Locating Turbocharger Inlet Pipe Clamps
  Courtesy of FORD MOTOR CO.
NOTE: Remove the covers or tape from the rocker covers and the lower intake.

Using new intake manifold 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 15: 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 16: Locating Wastegate Vacuum Line And Transmission Oil Level Indicator Tube Bolts
  Courtesy of FORD MOTOR CO.
Connect the Manifold Absolute Pressure (MAP) and the turbocharger actuator electrical connectors.
- Connect the 2 wiring harness retainers.
  
  Fig 17: Locating Manifold Absolute Pressure Sensor And Turbocharger Actuator Electrical Connectors
  Courtesy of FORD MOTOR CO.
NOTE: Only one retainer shown, 3 other retainers similar.

Connect the power steering pressure line to the 4 retainers.

Fig 18: Locating Power Steering Pressure Line To Engine Mounting Holder
Courtesy of FORD MOTOR CO.
Position the fuel line bracket to the left side of the transmission and install the 2 fuel line bracket bolts.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 19: Locating Fuel Line Bracket Bolts
  Courtesy of FORD MOTOR CO.
Install the 2 fuel line bracket bolts to the transmission bellhousing.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 20: Locating Fuel Line Bracket Bolts
  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 21: Locating Fuel Return Tube Quick Connect Coupling
  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 22: Locating Transmission Cooler Tube Bracket Nut
  Courtesy of FORD MOTOR CO.
Install the cooling fan stator and the 4 nuts.
- Tighten to 17 Nm (150 lb-in).
  
  Fig 23: Locating Cooling Fan Stator Mounting Nuts
  Courtesy of FORD MOTOR CO.
Install the engine wiring harness bracket bolt and the ground wire bolt.
- Tighten the 2 bolts to 25 Nm (18 lb-ft).
  
  Fig 24: Locating Engine Wiring Harness Bracket Bolts
  Courtesy of FORD MOTOR CO.
Install the 6 new torque converter nuts.
- Tighten nuts to 55 Nm (41 lb-ft).
  
  Fig 25: Locating Torque Converter Nut
  Courtesy of FORD MOTOR CO.
Install the flexplate access cover and the 2 retainers.

Fig 26: 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 27: Locating Block Heater Cord
Courtesy of FORD MOTOR CO.
Install the turbocharger downpipe and position a new clamp.

Fig 28: Locating Turbocharger Downpipe Clamp
Courtesy of FORD MOTOR CO.
Loosely install the turbocharger downpipe bracket bolt.

Fig 29: Locating Turbocharger Downpipe Bracket Bolt
Courtesy of FORD MOTOR CO.
Loosely install the 2 turbocharger downpipe flange bolts.

Fig 30: Locating Turbocharger Downpipe Flange Bolts
Courtesy of FORD MOTOR CO.
Tighten the turbocharger downpipe clamp.
- Tighten to 15 Nm (133 lb-in).
  
  Fig 31: Locating Turbocharger Downpipe Clamp
  Courtesy of FORD MOTOR CO.
Tighten the turbocharger downpipe bracket bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 32: 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 33: Locating Turbocharger Downpipe Flange Bolts
  Courtesy of FORD MOTOR CO.
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 the 2 new transmission support insulator nuts.
- Tighten to 115 Nm (85 lb-ft).
  
  Fig 34: Locating Transmission Support Insulator Nuts
  Courtesy of FORD MOTOR CO.
Install a new engine oil filter.
- Tighten to 5 Nm (44 lb-in).
- Tighten an additional 180 degrees.
Fill the engine with the correct motor oil for the climate. For additional information, refer to Engine .
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 .
Install the body. For additional information, refer to FULL FRAME & BODY MOUNTING .