Section 321 (Engine Mechanical - 6.7L Diesel): Assembly: Engine: Assembly

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: This procedure assumes the engine will be installed using the recommended body off engine installation procedure. If it will be necessary to install the engine using the alternate body on engine installation procedure, some of the components in this procedure should not be installed at this time. For additional information, refer to ENGINE - BODY ON .

NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel opening to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

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".

If removed, install a new cylinder block zero clearance patch on the engine.

Fig 1: Locating Engine Cylinder Block Zero Clearance Patch
Courtesy of FORD MOTOR CO.
If removed, install the turbocharger alignment dowels.
If removed, install the block heater.
- Tighten to 41 Nm (30 lb-ft).
NOTE: Only one pipe plug show.

If removed, install the pipe plugs.
- Refer to SPECIFICATIONS for the correct torque specification for each pipe plug.
  
  Fig 2: Locating Pipe Plug
  Courtesy of FORD MOTOR CO.
Install the high-pressure fuel injection pump mounting bolts and front cover roll pin.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 3: Locating High-Pressure Fuel Injection Pump Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Only one piston cooling tube shown.

NOTE: Apply clean engine oil to the outside of the piston cooling tubes prior to installation.

Install the 8 piston cooling tubes and 8 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 4: Locating Piston Cooling Tube Mounting Bolt
  Courtesy of FORD MOTOR CO.
NOTE: If the camshaft is being replaced, the camshaft bearings have to be replaced and machined by a machine shop. Failure to follow this may result in engine damage.

NOTE: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage may occur.

NOTE: Use the slide hammer as a handle for the camshaft. Using the slide hammer as intended may result in engine damage.

NOTE: Use care when installing the camshaft, the camshaft will slide out the other end of the cylinder block.

NOTE: Apply clean engine oil to the camshaft prior to installing.

Using the Camshaft Remover/Installer and the Slide Hammer, install the camshaft.

Courtesy of
NOTE: Apply clean engine oil to both sides of the camshaft thrust plate prior to installing.

Install the camshaft thrust plate and 2 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 5: Locating Camshaft Thrust Plate Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Use a suitable tool in the top camshaft gear hole to prevent the camshaft from turning. Make sure the suitable tool is secured against the cylinder block prior to tightening the camshaft bolt.

Install the camshaft gear and bolt. Tighten in 2 stages:
- Stage 1: Tighten to 70 Nm (52 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
  
  Fig 6: Locating Camshaft Gear Mounting Bolt
  Courtesy of FORD MOTOR CO.
NOTE: The crankshaft bearings are tangless and must be positioned in the center of the bearing cap or engine damage may occur.

NOTE: Verify there is no debris in the saddles in the cylinder block or main bearing caps.

NOTE: Apply clean engine oil to the upper crankshaft bearing prior to installing the crankshaft.

Install the 5 new upper crankshaft main bearings into the cylinder block.

Fig 7: Locating Upper Crankshaft Main Bearings
Courtesy of FORD MOTOR CO.
Position the camshaft with the 2 timing marks pointing up.

Fig 8: Locating Timing Marks Pointing On Camshaft
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the crankshaft bearing journals prior to installing.

Install the crankshaft into the cylinder block, aligning the with the 2 timing marks.

Fig 9: Locating Cylinder Block Crankshaft
Courtesy of FORD MOTOR CO.
Verify the timing marks are properly aligned.

Fig 10: Positioning Of Timing Marks
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the thrust faces of the crankshaft prior to installing the upper crankshaft main bearing thrust washers.

NOTE: Assemble the grooved side of the upper crankshaft main bearing thrust washer toward the crankshaft thrust surface.

Push the crankshaft rearward and install the upper crankshaft main bearing thrust washer to the rear of the number 5 bulkhead.

Courtesy of
NOTE: Apply clean engine oil to the thrust faces of the crankshaft prior to installing the upper crankshaft main bearing thrust washer.

NOTE: Assemble the grooved side of the thrust washer toward the crankshaft thrust surface.

Push the crankshaft forward and install the upper crankshaft main bearing thrust washer to the front of the number 5 bulkhead.

Courtesy of
NOTE: The crankshaft bearings are tangless and must be positioned in the center of the bearing cap or engine damage may occur.

NOTE: Assemble the grooved side of the lower crankshaft main bearing thrust washer toward the crankshaft thrust surface.

NOTE: The thrust washer tang will be positioned in a groove.

NOTE: Only one upper bearing shown.

Install the 5 new lower crankshaft main bearings into the crankshaft main bearing caps. Position the lower crankshaft main bearing thrust washer on the number 5 crankshaft main bearing cap.

Fig 11: Locating Lower Crankshaft Main Bearing Thrust Washer And Cap
Courtesy of FORD MOTOR CO.
Position commercially available plastigage in the center of each main bearing cap.
NOTE: Apply clean engine oil to the lower crankshaft main bearing thrust washer and to the rear face of number 5 crankshaft main bearing cap. Align the tab on the thrust washer with the slot in the number 5 main bearing cap.

NOTE: Apply clean engine oil to the lower crankshaft main bearings.

NOTE: Do not use the bolts to seat the crankshaft main bearing caps.

Install the 5 crankshaft main bearing caps into the cylinder block.

Courtesy of
NOTE: Lightly lubricate the main bearing cap bolt threads and flanges with clean engine oil.

Loosely install the 20 crankshaft main bearing cap bolts and 10 crankshaft main bearing cap side bolts. Tighten the crankshaft main bearing cap bolts in 7 stages, in the sequence shown in the illustration:
- Stage 1: Snug all the bolts.
- Stage 2: Tighten bolts 1 through 20 to 20 Nm (177 lb-in).
- Stage 3: Tighten bolts 1 through 10 to 80 Nm (59 lb-ft).
- Stage 4: Tighten bolts 11 through 20 to 160 Nm (118 lb-ft).
- Stage 5: Tighten bolts 1 through 20 an additional 90 degrees.
- Stage 6: Tighten bolts 21 through 30 to 40 Nm (30 lb-ft).
- Stage 7: Tighten bolts 21 through 30 an additional 90 degrees.
  
  Fig 12: Identifying Tightening Sequence Of Crankshaft Main Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
NOTE: RH side shown, LH side similar.

Remove the 10 crankshaft main bearing cap side bolts.

Fig 13: Locating Crankshaft Main Bearing Cap Side Bolts
Courtesy of FORD MOTOR CO.
Remove the 20 crankshaft main bearing cap bolts.

Fig 14: Locating Crankshaft Main Bearing Cap Bolts
Courtesy of FORD MOTOR CO.
Remove the 5 crankshaft main bearing caps from the cylinder block.

Fig 15: Locating Lower Crankshaft Main Bearing Caps
Courtesy of FORD MOTOR CO.
Measure the clearances for the crankshaft main bearing cap and compare to Specifications. For additional information, refer to SPECIFICATIONS .
- Remove and discard the plastigage.
  
  Fig 16: Measuring Crankshaft Main Bearing Cap Clearances Using Plastigage
  Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the lower crankshaft main bearing thrust washer and to the rear face of number 5 crankshaft main bearing cap. Align the tab on the thrust washer with the slot in the number 5 main bearing cap.

NOTE: Apply clean engine oil to the lower crankshaft main bearings.

NOTE: Do not use the bolts to seat the crankshaft main bearing caps.

Install the 5 crankshaft main bearing caps into the cylinder block.

Courtesy of
Loosely install the 20 crankshaft main bearing cap bolts and 10 crankshaft main bearing cap side bolts. Tighten the crankshaft main bearing cap bolts in 3 stages, in the sequence shown in the illustration:
- Stage 1: Snug all the bolts.
- Stage 2: Tighten bolts 1 through 20 to 20 Nm (177 lb-in).
- Stage 3: Back off the number 9 and 10 bolts.
  
  Fig 17: Identifying Tightening Sequence Of Crankshaft Main Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Push the crankshaft forward and the number 5 crankshaft main bearing cap rearward to align the crankshaft rear thrust washers.
- Continue to hold the crankshaft forward and the number 5 crankshaft main bearing cap rearward against the crankshaft thrust surface while tightening the outer bolts 9 and 10 on the crankshaft main bearing cap.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 18: Aligning Crankshaft Rear Thrust Washers
  Courtesy of FORD MOTOR CO.
Tighten the crankshaft main bearing cap bolts in 5 stages, in the sequence shown in the illustration:
- Stage 1: Tighten bolts 1 through 10 to 80 Nm (59 lb-ft).
- Stage 2: Tighten bolts 11 through 20 to 160 Nm (118 lb-ft).
- Stage 3: Tighten bolts 1 through 20 an additional 90 degrees.
- Stage 4: Tighten bolts 21 through 30 to 40 Nm (30 lb-ft).
- Stage 5: Tighten bolts 21 through 30 an additional 90 degrees.
  
  Fig 19: Identifying Tightening Sequence Of Crankshaft Main Bearing Cap Bolts
  Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture, measure the crankshaft end play. For additional information, refer to SPECIFICATIONS .

Fig 20: Checking Crankshaft End Play Using Dial Indicator Gauge
Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft end play. For additional information, refer to SPECIFICATIONS .

Fig 21: Measuring Camshaft End Play Using Dial Indicator Gauge
Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture, measure the camshaft gear backlash. For additional information, refer to SPECIFICATIONS .

Fig 22: Measuring Camshaft Gear Backlash Using Dial Indicator Gauge
Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the O-ring seal prior to installation.

Using a new O-ring seal, install the high-pressure fuel injection pump and the 3 high-pressure fuel injection pump spacers.
- Tighten to 24 Nm (18 lb-ft).
Install the fuel rail supply tube bracket and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
NOTE: The crankshaft gear contains a single timing mark. The camshaft contains a single timing mark. The high-pressure fuel injection pump drive gear contains a double timing mark. The engine is timed correctly when the single mark on the crankshaft drive gear is aligned with the double mark on the camshaft gear, and the single mark on the camshaft drive gear is aligned with the double mark on the high-pressure fuel injection pump drive gear. Additionally, the keyway on the high-pressure fuel injection pump drive gear must be at 12 o'clock position.

Install the high-pressure fuel injection pump drive gear and nut.
- Tighten to 80 Nm (59 lb-ft).
- Verify the timing marks are aligned.
  
  Fig 23: Aligning Timing Marks
  Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture, check the high-pressure fuel injection pump drive gear backlash.

Fig 24: Checking High-Pressure Fuel Injection Pump Drive Gear Backlash Using Dial Indicator Gauge
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 may occur.

NOTE: The connecting rod bearings are tangless and must be positioned in the center of the bearing cap or engine damage may occur.

NOTE: Only one piston assembly shown.

NOTE: The dark bearing is the upper connecting rod bearing. The bright aluminum bearing is the lower connecting rod bearing.

Install the new connecting rod bearings.

Fig 25: Locating Connecting Rod Bearings
Courtesy of FORD MOTOR CO.
NOTE: Make sure the piston ring openings are 120 degrees from each other or engine damage may occur.

Install the piston rings as follows:
1. The top compression ring is identified with a orange stripe on the running surface.
2. The intermediate ring is identified with yellow stripe on the running surface. Install the ring with the under cut to the bottom.
3. Install the oil control ring. Make sure the oil ring gap is 180 degrees from the spring wire latch.
  
  Fig 26: Identifying Top Compression Ring, Oil Control Ring And Intermediate Ring
  Courtesy of FORD MOTOR CO.

NOTE: Install the piston assembly with the arrow toward the front of the engine.

NOTE: Use care when installing the piston assembly to not damage the piston cooling tubes. If the tube is bent during installation of the piston assembly, install a new piston cooling tube.

NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.

Install the connecting rod and piston assemblies.

Coat the inside diameter of the Piston Ring Compressor with clean engine oil.

Insert the piston into the Piston Ring Compressor. Position the piston, connecting rod and Piston Ring Compressor into the cylinder bore.

Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.

Courtesy of

Position a piece of plastigage across the bearing surface.
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 may occur.

NOTE: Lubricate the connecting rod bearings with clean engine oil prior to installation.

NOTE: Only one connecting rod cap shown.

Position the connecting rod cap and install the 2 bolts. Tighten in 2 stages:
- Stage 1: Tighten to 45 Nm (33 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 27: Locating Connecting Rod Cap Mounting Bolts
  Courtesy of FORD MOTOR CO.
Remove the 2 bolts and the connecting rod cap.

Fig 28: Locating Connecting Rod Cap Mounting Bolts
Courtesy of FORD MOTOR CO.
Measure the clearances for the connecting rod cap and compare to Specifications. For additional information, refer to SPECIFICATIONS .
- Remove and discard the plastigage.
  
  Fig 29: Measuring Connecting Rod Cap Clearances Using Plastigage
  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 may occur.

NOTE: Lubricate the connecting rod bearings with clean engine oil prior to installation.

NOTE: Only one connecting rod cap shown.

Position connecting rod caps and install the 2 bolts. Tighten in 2 stages:
- Stage 1: Tighten to 45 Nm (33 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
  
  Fig 30: Locating Connecting Rod Cap Mounting Bolts
  Courtesy of FORD MOTOR CO.
Using a Feeler Gauge Set, check the connecting rod side clearance. For additional information, refer to SPECIFICATIONS .

Fig 31: Checking Connecting Rod Side Clearance Using Feeler Gauge Set
Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.

Using a new gasket, install the engine rear cover and the 10 bolts. Tighten in 2 stages, in the sequence shown in the illustration.
- Stage 1: Tighten bolts 1-9 to 10 Nm (89 lb-in).
- Stage 2: Tighten bolt 10 to 48 Nm (35 lb-ft).
  
  Fig 32: Identifying Tightening Sequence Of Engine Rear Cover Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Failure to install the rear crankshaft seal with the part numbers facing out may result in engine damage.

NOTE: Do not use grease or petroleum jelly instead of oil. Failure to follow this may result in rear crankshaft seal leakage.

NOTE: Do not discard the installation sleeve provided with the rear crankshaft seal. It is used for installation of the rear crankshaft seal.

NOTE: Check for correct orientation of the installation sleeve prior to sliding the seal on the crankshaft.

NOTE: Apply clean engine oil to the outer diameter of the crankshaft seal and crankshaft sealing surface.

Position the installation sleeve onto the crankshaft, slide the new rear crankshaft seal over the installation sleeve onto the crankshaft.
- Remove the installation sleeve.
  
  Fig 33: Locating Crankshaft Installation Sleeve
  Courtesy of FORD MOTOR CO.
Using the Rear Crank Seal Installer, install the new rear crankshaft seal.

Fig 34: Installing Rear Crankshaft Seal Using Rear Crank Seal Installer
Courtesy of FORD MOTOR CO.
Position the crankshaft drive flats level to aid in installing the engine front cover.

Fig 35: Positioning Crankshaft Drive Flats Level
Courtesy of FORD MOTOR CO.
NOTE: Failure to properly align the engine front cover to the oil pan rail may result in engine damage.

NOTE: Use care when installing the engine front cover not to scratch the crankshaft sealing surface.

NOTE: Use the Gauge Bar to align the bottom of the engine front cover to the oil pan rail prior to torquing the engine front cover.

Using new gaskets, install the new engine front cover and 14 bolts.
- Support the oil pump gerotor assembly in the engine front cover bore.
- Position the engine front cover assembly over the crankshaft without contacting the front sealing surface.
- Align the oil pump gerotor assembly with the crankshaft drive flats.
- Align the engine front cover assembly locating pin.
- Slide the front cover assembly over the crankshaft post to the cylinder block sealing surface.
- Hand start bolt numbers 1 and 2.
- Using the Gauge Bar, align the bottom of the engine front cover to the oil pan rail.
- Install the remaining engine front cover bolts. Tighten in the sequence shown in the illustration.
  - Tighten to 24 Nm (18 lb-ft).
    
    Fig 36: Identifying Tightening Sequence Of Engine Front Cover Bolts
    Courtesy of FORD MOTOR CO.
As a post-check, use the Gauge Bar and Feeler Gauge Set and verify the alignment of the engine front cover to the oil pan rail is within 0.25 mm (0.009 in).
- If the engine front cover is not within specifications, loosen the bolts and repeat step 48.
NOTE: Failure to install the front crankshaft seal with the part numbers facing out may result in engine damage.

NOTE: Do not discard the installation sleeve provided with the front crankshaft seal. It is used for installation of the front crankshaft seal.

NOTE: Check for correct orientation of the installation sleeve prior to sliding the seal on the crankshaft.

NOTE: Apply clean engine oil to the seal and crankshaft sealing surface.

Position the installation sleeve onto the crankshaft, slide the new front crankshaft seal over the installation sleeve onto the crankshaft.
- Remove the installation sleeve.
  
  Fig 37: Locating Crankshaft Sleeve
  Courtesy of FORD MOTOR CO.
Position the new front crankshaft slinger on the crankshaft.

Fig 38: Locating Crankshaft Front Crankshaft Slinger
Courtesy of FORD MOTOR CO.
Using the Front Crank Seal Installer, install a new front crankshaft seal and front crankshaft slinger.

Fig 39: Installing Front Crankshaft Seal And Front Crankshaft Slinger
Courtesy of FORD MOTOR CO.
Install a new upper oil pan gasket. Apply a dime-sized bead of sealant at the 4 cover joints.

Fig 40: Identifying Dime-Sized Bead Of Sealant Applying Area On Cover Joints
Courtesy of FORD MOTOR CO.
NOTE: Final torque must be reached within 30 minutes of sealant application.

Install the upper oil pan and 25 bolts. Tighten in 2 stages, in the sequence shown in the illustration.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 24 Nm (18 lb-ft).
  
  Fig 41: Identifying Tightening Sequence Of Upper Oil Pan Mounting Bolts
  Courtesy of FORD MOTOR CO.
Using a new gasket, install the oil filter adapter, 4 bolts and stud bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 42: Locating Oil Filter Adapter Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: In the event of catastrophic engine failure, always install a new oil cooler assembly. Foreign material cannot be removed from the oil cooler and engine damage may occur.

Using new gaskets, install the oil cooler assembly and 7 bolts.
- Tighten finger-tight.
NOTE: Failure to tighten the oil cooler nut first may result in oil cooler damage or leaks.

NOTE: On late build vehicles the internal nut is no longer on the oil cooler.

If equipped, install the oil cooler nut.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 43: Locating Oil Cooler Nut
  Courtesy of FORD MOTOR CO.
Tighten the 7 oil cooler bolts in the sequence shown in the illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 44: Identifying Tightening Sequence Of Oil Cooler Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Use care when installing the hose on the oil cooler, damage to the oil cooler may occur during installation.

Install the oil cooler outlet hose assembly and connect the hose retainer.

Fig 45: Locating Oil Cooler Outlet Hose Retainer
Courtesy of FORD MOTOR CO.
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 46: 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).
NOTE: To prevent engine damage, keep the valve tappets in the order in which they were removed. Install all valve tappets back in their original positions.

NOTE: Always keep the valve tappets in the upright position or the hydraulic lash adjuster may fall out.

NOTE: Apply clean engine oil to the valve tappet bores prior to installing the valve tappets.

NOTE: Only one cylinder shown.

Apply clean engine oil to the 16 valve tappets and install into the valve tappet bores.

Fig 47: Locating Valve Tappets
Courtesy of FORD MOTOR CO.
NOTE: Only one cylinder shown.

Install the 8 valve tappet guides.
- Verify that the retainer is fully seated.
  
  Fig 48: Locating Valve Tappet Guides
  Courtesy of FORD MOTOR CO.
NOTE: Only one cylinder head dowel shown.

Install the 4 new cylinder head dowels into the cylinder block.

Fig 49: Locating Cylinder Head Dowel
Courtesy of FORD MOTOR CO.
NOTE: LH side shown, RH side similar.

Position the 2 new cylinder head gaskets onto the cylinder block.

Fig 50: Locating Cylinder Head Gasket
Courtesy of FORD MOTOR CO.
NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface.

NOTE: Inspect the cylinder heads. Make sure the cylinder heads are free of corrosion, cracks, damage, foreign material and the coolant ports are open.

NOTE: RH cylinder head shown, LH cylinder head similar.

Install the cylinder heads.

Courtesy of
NOTE: Using too much engine oil on the threads of the cylinder head bolts may cause damage to the threads and result in poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads may affect the true torque value of the bolts.

NOTE: LH cylinder head shown, RH cylinder head similar.

NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.

Install 36 new M12 cylinder head bolts and 9 M8 cylinder head bolts.
- Tighten finger-tight.
  
  Fig 51: Locating Cylinder Head Bolts
  Courtesy of FORD MOTOR CO.
Tighten the LH cylinder head bolts in 8 stages, in the sequence shown in the illustration.
- Stage 1: Tighten bolts 1 through 18 to 20 Nm (177 lb-in).
- Stage 2: Tighten bolts 1 through 18 to 49 Nm (36 lb-ft).
- Stage 3: Tighten bolts 1 through 18, a second time to 49 Nm (36 lb-ft).
- Stage 4: Tighten bolts 1 through 18, a third time to 49 Nm (36 lb-ft).
- Stage 5: Tighten bolts 1 through 18, an additional 90 degrees.
- Stage 6: Tighten bolts 1 through 18, a second time, an additional 90 degrees.
- Stage 7: Tighten bolts 1 through 18, a third time, an additional 90 degrees.
- Stage 8: Tighten bolts 19 through 23 to 30 Nm (22 lb-ft).
  
  Fig 52: Identifying Tightening Sequence Of Left Hand Cylinder Head Bolts
  Courtesy of FORD MOTOR CO.
Tighten the RH cylinder head bolts in 8 stages, in the sequence shown in the illustration.
- Stage 1: Tighten bolts 1 through 18 to 20 Nm (177 lb-in).
- Stage 2: Tighten bolts 1 through 18 to 49 Nm (36 lb-ft).
- Stage 3: Tighten bolts 1 through 18, a second time to 49 Nm (36 lb-ft).
- Stage 4: Tighten bolts 1 through 18, a third time to 49 Nm (36 lb-ft).
- Stage 5: Tighten bolts 1 through 18, an additional 90 degrees.
- Stage 6: Tighten bolts 1 through 18, a second time, an additional 90 degrees.
- Stage 7: Tighten bolts 1 through 18, a third time, an additional 90 degrees.
- Stage 8: Tighten bolts 19 through 22 to 30 Nm (22 lb-ft).
  
  Fig 53: Identifying Tightening Sequence Of Right Hand 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.

NOTE: Only one cylinder shown.

Install the 32 push rods.
- Verify the push rod socket is engaged on the hydraulic lash adjuster.
  
  Fig 54: Locating Push Rods
  Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the push rod ball end prior to installing the rocker arm assembly.

NOTE: Apply clean engine oil to each rocker arm pivot ball prior to installing the rocker arm assembly.

NOTE: Verify the push rod socket is on the hydraulic lash adjuster prior to installing the rocker arm assembly.

Install the RH rocker arm assemblies in the following sequence.
1. Position the crankshaft with the cylinder number No. 1 approximately 155 degrees after Top Dead Center (TDC) by observing the crankshaft pulley dowel pin and clocking it to the 3:40 position (as viewed from the front of the engine).
2. Determine which cylinder is actually in the firing position by observing the push rods for the No. 1 exhaust push rods should be raised 1.0 mm (0.039 in) and No. 4 exhaust push rods should be raised 1.5 mm (0.059 in). If the push rods are not in the correct position, rotate the engine one revolution clockwise (360 degrees).
3. Install the rocker arm assemblies for the RH cylinder head (cylinder numbers 1, 2, 3 and 4). Tighten in 5 stages, in the sequence shown in the illustration.
  - Stage 1: Verify the top of the push rod engages the socket on each rocker arm.
  - Stage 2: Tighten to 4 Nm (35 lb-in).
  - Stage 3: Tighten to 8 Nm (71 lb-in).
  - Stage 4: Tighten to 13 Nm (115 lb-in).
  - Stage 5: Tighten a second time to 13 Nm (115 lb-in).
  - Repeat Stage 5, if any fastener moves more than 5 degrees in Stage 5.
    
    Fig 55: View Of RH Cylinder Head Rocker Arm Assembly Tightening Sequence
    Courtesy of FORD MOTOR CO.
NOTE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.

If necessary, install a new O-ring seal on the RH oil spray bar. Install the RH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown in the illustration until the RH oil spray bar nuts can be tightened.
- Tighten to 11 Nm (98 lb-in).
  
  Fig 56: Identifying RH Oil Spray Bar And Mounting Nuts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to each rocker arm pivot ball prior to installing the rocker arm assembly.

NOTE: Verify the push rod socket is on the hydraulic lash adjuster prior to installing the rocker arm assembly.

Install the LH rocker arm assemblies in the following sequence.
1. Rotate the crankshaft with the one revolution clockwise (360 degrees) to 155 degrees after TDC by observing the crankshaft pulley dowel pin and clocking it to the 3:40 position (as viewed from the front of the engine).
2. Install the rocker arm assemblies for the LH cylinder head (cylinder numbers 5, 6, 7 and 8). Tighten in 5 stages, in the sequence shown in the illustration.
  - Stage 1: Verify the top of the push rod engages the socket on each rocker arm.
  - Stage 2: Tighten to 4 Nm (35 lb-in).
  - Stage 3: Tighten to 8 Nm (71 lb-in).
  - Stage 4: Tighten to 13 Nm (115 lb-in).
  - Stage 5: Tighten a second time to 13 Nm (115 lb-in).
  - Repeat Stage 5, if any fastener moves more than 5 degrees in Stage 5.
    
    Fig 57: View Of LH Cylinder Head Rocker Arm Assembly Tightening Sequence
    Courtesy of FORD MOTOR CO.
NOTE: Failure to install the oil spray bar in steps may result in damage to the oil spray bar.

If necessary, install a new O-ring seal on the LH oil spray bar. Install the LH oil spray bar. Turn the nuts 2 revolutions at a time in the sequence shown in the illustration until the LH oil spray bar nuts can be tightened.
- Tighten to 11 Nm (98 lb-in).
  
  Fig 58: Identifying LH Oil Spray Bar And Mounting Nuts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: Failure to install the fuel injectors during the valve cover installation may result in engine failure.

NOTE: The valve cover will have to be tightened a second time after the fuel injectors are installed.

Using a new valve cover gasket, install the RH valve cover, 2 stud bolts and 16 bolts. Tighten in the sequence shown in the illustration.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 59: Identifying RH Valve Cover And Mounting Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: Failure to install the fuel injectors during the valve cover installation may result in engine failure.

NOTE: The valve cover will have to be tightened a second time after the fuel injectors are installed.

Using a new valve cover gasket, install the LH valve cover, 3 stud bolts and 15 bolts. Tighten in the sequence shown in the illustration.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 60: Identifying LH Valve Cover And Mounting Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: Do not apply engine oil to the fuel injectors.

NOTE: Only one fuel injector shown.

NOTE: If the fuel injector is being reused, make sure to install it in the original location.

Install a new copper combustion gasket, O-ring seal and fuel injector return fuel O-ring on the 8 fuel injectors.
- Position the 8 fuel injectors into the engine.
NOTE: Failure to tighten the fuel injector correctly can lead to engine failure.

NOTE: Apply clean engine oil to the concave surface of the fuel injector hold-down clamp.

Install the 8 fuel injector hold-down clamps and 8 new fuel injector bolts. Tighten in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
Final tighten the LH valve cover bolts in the sequence shown in the illustration.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 61: Identifying LH Valve Cover And Mounting Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Final tighten the RH valve cover bolts in the sequence shown in the illustration.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 62: Identifying RH Valve Cover And Mounting Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: Only one glow plug shown.

Install the 8 glow plugs.
- Tighten to 11 Nm (97 lb-in).
  
  Fig 63: Locating Glow Plugs
  Courtesy of FORD MOTOR CO.
Install the new exhaust manifold stud(s) as needed.
- Tighten to 13 Nm (115 lb-in).
Using a new gasket, install the RH exhaust manifold, 8 spacers and 8 new nuts. Tighten the nuts in 3 stages, in the sequence shown in the illustration.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 30 Nm (22 lb-ft).
- Stage 3: Tighten a second time to 30 Nm (22 lb-ft).
  
  Fig 64: Identifying Tightening Sequence Of RH Exhaust Manifold Mounting Nuts
  Courtesy of FORD MOTOR CO.
Using a new gasket, install the LH exhaust manifold, 8 spacers and 8 new nuts. Tighten the nuts in 3 stages, in the sequence shown in the illustration.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 30 Nm (22 lb-ft).
- Stage 3: Tighten a second time to 30 Nm (22 lb-ft).
  
  Fig 65: Identifying Tightening Sequence Of LH Exhaust Manifold Mounting Nuts
  Courtesy of FORD MOTOR CO.
Install the RH exhaust manifold heat shield and 5 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 66: Locating RH Exhaust Manifold Heat Shield Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the LH exhaust manifold heat shield and 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 67: Locating LH Exhaust Manifold Heat Shield Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Do not use magnetic screwdrivers or other magnetic tools around the Crankshaft Position (CKP) sensor and the crankshaft sensor pulse ring or damage to the components may occur.

Install the Crankshaft Position (CKP) sensor and bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 68: Locating Crankshaft Position Sensor Bolt
  Courtesy of FORD MOTOR CO.
Install the crankshaft sensor pulse ring.
Install the flexplate and 10 new bolts. Tighten the bolts in 2 stages, in the sequence shown in the illustration.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 100 Nm (74 lb-ft).
  
  Fig 69: Locating Tightening Sequence Of Flexplate Mounting Bolts
  Courtesy of FORD MOTOR CO.
Using a new gasket, install the vacuum pump and 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 70: Locating Vacuum Pump Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, always install 4 new bolts when installing the crankshaft pulley.

NOTE: Use the Strap Wrench to prevent the engine from turning while tightening the bolts.

Position the crankshaft pulley and install 4 new bolts. Tighten in 2 stages, in the sequence shown in the illustration.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
Using new gaskets, install the coolant crossover manifold assembly and 5 bolts.
- Finger-tighten the bolts.
  
  Fig 71: Locating Coolant Crossover Manifold Assembly Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Inspect the thermostat seal for tears, nicks or cuts. Replace if necessary.

Install the thermostat, thermostat housing and 3 bolts.
- Finger-tighten the bolts.
  
  Fig 72: Locating Thermostat Housing Mounting Bolts
  Courtesy of FORD MOTOR CO.
Tighten the 5 coolant crossover bolts and the 3 thermostat housing bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 73: Locating Coolant Crossover Bolts And Thermostat Housing Bolts
  Courtesy of FORD MOTOR CO.
Position the RH fuel rail and loosely install the 2 bolts.

Fig 74: Locating RH Fuel Rail Mounting Bolts
Courtesy of FORD MOTOR CO.
Position the LH fuel rail and loosely install the 2 bolts.

Fig 75: Locating LH Fuel Rail Mounting Bolts
Courtesy of FORD MOTOR CO.
NOTE: LH side shown, other connectors similar.

Position the fuel rail supply tube assembly. Hand start the 6 fuel rail supply tube assembly connectors.

Fig 76: Locating Fuel Rail Supply Tube Assembly
Courtesy of FORD MOTOR CO.
NOTE: Only 1 fuel injector supply tube shown.

Install the 8 fuel injector supply tubes.
- Start from front to rear of engine.
- Hand start only.
  
  Fig 77: Locating Fuel Injector Supply Tube Fittings
  Courtesy of FORD MOTOR CO.
Install the 5 fuel rail supply tube assembly bolts.
- Hand start only.
NOTE: LH side shown, RH side similar.

Tighten the 4 fuel rail bolts.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 78: Locating Fuel Rail Mounting Bolts
  Courtesy of FORD MOTOR CO.
Tighten the 4 LH fuel injector supply tubes in the sequence shown in the illustration.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 79: Identifying Tightening Sequence Of LH Fuel Injector Supply Tubes
  Courtesy of FORD MOTOR CO.
Tighten the 4 RH fuel injector supply tubes in the sequence shown in the illustration.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 80: Identifying Tightening Sequence Of RH Fuel Injector Supply Tubes
  Courtesy of FORD MOTOR CO.
Tighten the 6 fuel rail supply tube assembly connectors in the sequence shown in the illustration.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 81: Identifying Tightening Sequence Of Fuel Rail Supply Tube Assembly Connectors
  Courtesy of FORD MOTOR CO.
Tighten the 4 LH fuel injector supply tubes in the sequence shown in the illustration.
- Tighten to 35 Nm (26 lb-ft).
  
  Fig 82: Identifying Tightening Sequence Of LH Fuel Injector Supply Tubes
  Courtesy of FORD MOTOR CO.
Tighten the 4 RH fuel injector supply tubes in the sequence shown in the illustration.
- Tighten to 35 Nm (26 lb-ft).
  
  Fig 83: Identifying Tightening Sequence Of RH Fuel Injector Supply Tubes
  Courtesy of FORD MOTOR CO.
Tighten the 6 fuel rail supply tube assembly connectors in the sequence shown in the illustration.
- Tighten to 35 Nm (26 lb-ft).
  
  Fig 84: Identifying Tightening Sequence Of Fuel Rail Supply Tube Assembly Connectors
  Courtesy of FORD MOTOR CO.
Tighten the 2 fuel rail supply tube connectors at the high-pressure fuel injection pump.
- Tighten to 40 Nm (30 lb-ft).
Tighten the 5 fuel rail supply tube assembly bolts in the sequence shown in the illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 85: Identifying Tightening Sequence Of Fuel Rail Supply Tube Assembly Bolts
  Courtesy of FORD MOTOR CO.
NOTE: RH valve cover shown, other retaining clips similar.

Position the fuel injector return hose and vacuum hose assembly on the engine and connect the retaining clips.
Connect the 8 fuel injector return hose fittings to the fuel injectors.
- Push down on the center of the fuel injector return hose fitting to lock the fitting.
  
  Fig 86: Pushing Down Fuel Injector Return Hose Fitting
  Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with coolant prior to installing the heater supply tube.

Using a new O-ring seal, install the heater supply tube and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
Install the turbocharger coolant tube.
Install the secondary fuel filter assembly and 3 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 87: Locating Secondary Fuel Filter Assembly Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Only 2 bolts shown.

Using new gaskets, install the crankcase vent oil separator and 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 88: Locating Crankcase Vent Oil Separator Mounting Bolt
  Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the O-ring seal prior to installing the fuel injection pump supply tube.

Using a new O-ring seal, install the fuel injection pump supply tube and bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 89: Locating Fuel Injection Pump Supply Tube Assembly Mounting Bolt
  Courtesy of FORD MOTOR CO.
Install the fuel injection pump supply tube assembly stud bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 90: Locating Fuel Injection Pump Supply Tube Assembly Stud Bolt
  Courtesy of FORD MOTOR CO.
Install the 2 fuel injection pump supply tube assembly bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 91: Locating Fuel Injection Pump Supply Tube Assembly Bolts
  Courtesy of FORD MOTOR CO.
Connect the fuel injector return hose and retainer to the secondary fuel filter. Connect the secondary outlet hose to the fuel injection pump supply tube.
Connect the fuel injection pump hose to the fuel rail.
Install the power steering pump mounting bracket and the 4 bolts.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 92: Locating Power Steering Mounting Bracket Mounting Bolts
  Courtesy of FORD MOTOR CO.
Position the engine wire harness over the engine. Connect the 2 retainers and install the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 93: Locating Engine Wire Harness And Mounting Bolt
  Courtesy of FORD MOTOR CO.
NOTE: Only one retainer shown.

Connect the 6 retainers to the fuel supply manifolds.

Fig 94: Locating Fuel Supply Manifold Retainer
Courtesy of FORD MOTOR CO.
Position the engine wire harness on the LH valve cover and connect the 3 wire retainers.

Fig 95: Locating LH Valve Cover Wire Retainers
Courtesy of FORD MOTOR CO.
NOTE: Only one fuel injector and glow plug electrical connector shown.

Connect the 8 fuel injectors and the 8 glow plug electrical connectors.

Fig 96: Locating Fuel Injector And Glow Plug Electrical Connector
Courtesy of FORD MOTOR CO.
NOTE: Only one wire retainer shown.

Connect the CKP sensor electrical connector and the 3 wire retainers.

Fig 97: Locating Crankshaft Position Sensor Electrical Connector And Wire Retainer
Courtesy of FORD MOTOR CO.
Install the cylinder block opening cover.
Connect the fuel pressure control valve electrical connector.

Fig 98: Locating Fuel Pressure Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the Fuel Rail Pressure (FRP) sensor electrical connector and 2 retainers.

Fig 99: Locating Fuel Rail Pressure Sensor Electrical Connector And Wire Harness Retainer
Courtesy of FORD MOTOR CO.
Connect the fuel pressure switch and the fuel temperature sensor electrical connectors. Connect the wire retainer.
Connect the Engine Coolant Temperature (ECT) sensor electrical connector and wire retainer.

Fig 100: Locating ECT Sensor Electrical Connector And Wire Retainer
Courtesy of FORD MOTOR CO.
Connect the turbocharger wastegate control valve vacuum and electrical connector.

Fig 101: Locating Turbocharger Wastegate Control Vacuum And Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the vacuum hose retainer to the secondary fuel filter stud.
Connect the fuel volume control valve electrical connector.

Fig 102: Locating Fuel Volume Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the Camshaft Position (CMP) sensor electrical connector and the 3 pin type retainers.

Fig 103: Locating Camshaft Position Sensor Electrical Connector And Pin Type Retainers
Courtesy of FORD MOTOR CO.
Install the lower intake manifold and the 3 bolts.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 104: Locating Lower Intake Manifold Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: It may be necessary to rotate the locking collar to connect the oil separator hose to the lower intake.

Connect the crankcase vent oil separator hose to the lower intake manifold. Connect the crankcase vent oil separator outlet hose sensor electrical connector.
Connect the Throttle Body (TB) electrical connector.
Using new gaskets, install the EGR cooler assembly and the 7 bolts. Tighten the bolts in the sequence shown in the illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 105: Identifying Tightening Sequence Of EGR Cooler Assembly Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the 2 engine wire harness bolts to the EGR cooler.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 106: Locating EGR Cooler Engine Wire Harness Bolts
  Courtesy of FORD MOTOR CO.
Connect the wire retainer and the vacuum hose. Connect the EGR valve, bypass solenoid and EGR ECT sensor electrical connectors.
Connect the 2 wire harness retainers.

Fig 107: Locating Wire Harness Retainers
Courtesy of FORD MOTOR CO.
NOTE: LH side shown, RH side similar.

Install the 2 ground straps and 2 bolts to the back of the cylinder heads.
- Tighten to 10 Nm (89 lb-in).
Using new gaskets, install the EGR bypass outlet tube and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 108: Locating EGR Bypass Outlet Tube Mounting Bolts
  Courtesy of FORD MOTOR CO.
Connect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector and wire retainer.

Fig 109: Locating Exhaust Gas Recirculation Temperature Electrical Connector And Wire Retainer
Courtesy of FORD MOTOR CO.
NOTE: Exhaust side shown, EGR cooler side similar.

Using new gaskets, install the EGR valve inlet tube and the 4 bolts. Tighten the bolts in the following sequence.
- Tighten the bolts at the exhaust manifold to 10 Nm (89 lb-in).
- Tighten the bolts at the EGR cooler to 10 Nm (89 lb-in).
NOTE: Apply threadlock to the EGR cooler side bolt threads prior to installation.

Install the EGR valve inlet tube bracket and the 2 new bolts. Tighten in 4 stages:
- Stage 1: Tighten the EGR valve inlet tube bracket bolt at the EGR cooler to 10 Nm (89 lb-in).
- Stage 2: Tighten the EGR valve inlet tube bracket bolt at the EGR cooler an additional 45 degrees.
- Stage 3: Tighten the EGR valve inlet tube bracket bolt to 10 Nm (89 lb-in).
- Stage 4: Tighten the EGR valve inlet tube bracket bolt an additional 45 degrees.
  
  Fig 110: Locating EGR Valve Inlet Tube Bracket Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the O-ring seals prior to installing the oil level indicator tube.

NOTE: Verify that the oil level indicator tube is fully seated in the rear engine cover.

Using new O-ring seals, install the oil level indicator tube.
Using a new O-ring seal, install the oil fill pipe and bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 111: Locating Oil Fill Pipe Mounting Bolt
  Courtesy of FORD MOTOR CO.
Position the lower engine wire harness on the engine. Install the 2 front retaining nuts.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 112: Locating Front Retaining Nuts
  Courtesy of FORD MOTOR CO.
Install the lower engine wire harness nut.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 113: Locating Lower Engine Wire Harness Nut
  Courtesy of FORD MOTOR CO.
Install the lower engine wire harness nut at the oil filter adapter.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 114: Locating Oil Filter Adapter Lower Engine Wire Harness Nut
  Courtesy of FORD MOTOR CO.
Connect the Engine Oil Temperature (EOT) sensor and the Engine Oil Pressure (EOP) switch electrical connectors.

Fig 115: Locating Engine Oil Temperature Sensor And Engine Oil Pressure Switch Electrical Connectors
Courtesy of FORD MOTOR CO.
NOTE: Power steering pump mounting bracket removed for clarity.

Install the 2 lower engine wire harness bolts.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 116: Locating Lower Engine Wire Harness Bolts
  Courtesy of FORD MOTOR CO.
Connect the power steering tube into the retainer.

Fig 117: Locating Power Steering Tube Retainer
Courtesy of FORD MOTOR CO.
NOTE: RH side shown, LH side similar.

Install the 2 lower engine wire harness ground bolts.
- Tighten to 25 Nm (18 lb-ft).
Connect the lower engine wire harness retainer to the power steering bracket.

Fig 118: Locating Engine Wire Harness Retainer
Courtesy of FORD MOTOR CO.
NOTE: Boot positioned back for clarity.

Connect the generator electrical connector and the generator B+ terminal and install the terminal nut.
- Tighten to 12 Nm (108 lb-in).
NOTE: Use care when installing the hose to the oil cooler, damage to the oil cooler may occur during installation.

Install the oil cooler inlet hose.

Fig 119: Locating Oil Cooler Inlet Hose Retainers
Courtesy of FORD MOTOR CO.
Install the upper radiator hose and clip.

Fig 120: Locating Upper Radiator Hose Clip
Courtesy of FORD MOTOR CO.
Install engine fill hose to the engine front cover.

Fig 121: Locating Engine Fill Hose Clip
Courtesy of FORD MOTOR CO.
Install the lower radiator hose and clip.
NOTE: Hose retainer not shown.

Connect the oil cooler outlet hose to the lower radiator hose and the hose retainer.

Fig 122: Locating Lower Radiator Hose Retainer
Courtesy of FORD MOTOR CO.
Install the 2 stator standoffs.
- Tighten to 22 Nm (16 lb-ft).
  
  Fig 123: Locating Stator Standoffs
  Courtesy of FORD MOTOR CO.
Connect the engine vacuum hose at the tee. If equipped, install the brake booster vacuum hose.

Fig 124: Locating Engine Vacuum Hose Connector And Brake Booster Vacuum Hose
Courtesy of FORD MOTOR CO.
Install the cooling fan drive assembly and the 4 bolts. Tighten in the sequence shown in the illustration.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 125: Identifying Tightening Sequence Of Cooling Fan Drive Assembly Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the secondary coolant pump assembly and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 126: Locating Secondary Coolant Pump Assembly Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt tensioner and the bolt.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 127: Locating Accessory Drive Belt Tensioner And Mounting Bolt
  Courtesy of FORD MOTOR CO.
Install the A/C compressor and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 128: Locating A/C Compressor Mounting Bolts
  Courtesy of FORD MOTOR CO.
Connect the A/C compressor electrical connectors and the wire retainer.

Fig 129: Locating A/C Compressor Electrical Connectors And Wire Retainers
Courtesy of FORD MOTOR CO.
NOTE: Single generator shown, dual generator similar.

Install the accessory drive belt.

Courtesy of
Using the Fan Clutch Nut Wrench and Wrench, install the fan clutch.
- Calculate the correct torque wrench setting for the following torque. Refer to the chart below.
- Tighten the fan clutch to 133 Nm (98 lb-ft).
  
  Courtesy of
Install the fan clutch electrical connector bolt.
- Tighten to 25 Nm (18 lb-ft).
Connect the fan clutch electrical connector.
Position the EGR cooler hose and vent hose on the engine. Connect the EGR cooler hose and the vent hose.

Fig 130: Locating EGR Cooler Hose And Vent Hose Retainers
Courtesy of FORD MOTOR CO.
Connect the coolant hose to the vacuum hose retainer.

Fig 131: Locating Vacuum Hose Retainer
Courtesy of FORD MOTOR CO.
Install the EGR cooler hose on the EGR cooler.

Fig 132: Locating EGR Cooler Hose Clamp
Courtesy of FORD MOTOR CO.
Connect the EGR cooler hose retainer.

Fig 133: Locating EGR Cooler Hose Retainer
Courtesy of FORD MOTOR CO.
Install the Engine Removal Bracket and the 4 bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 134: Locating Engine Removal Bracket And Bolts
  Courtesy of FORD MOTOR CO.
Using a Floor Crane, remove the engine from the Engine Stand.
NOTE: Discard the engine support insulator bracket bolts and install new bolts or damage to the engine bolt may occur. They are torque-to-yield design and cannot be reused.

NOTE: Do not tighten the engine support insulator bracket bolts more than 90 degrees after initial torque or damage to the bolts may occur.

NOTE: Clean the engine support insulator mating surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine support insulator bracket or engine support insulator damage.

NOTE: Place a visible mark on the engine support insulator bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

NOTE: Left side shown, right side similar.

Install the LH and RH engine support insulator brackets and the 8 bolts. Tighten in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
  
  Fig 135: Locating Engine Support Insulator Brackets Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the engine. For additional information, refer to ENGINE - BODY OFF or ENGINE - BODY ON .