Section 14 (Engine - 3.2L DURATORQ-TDCI (148KW/200PS) - Puma): Assembly: Engine
For information on Ford Color Coded Illustrations refer to OEM Color Coding .
Special Tool(s) / General Equipment
| 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge |
|
|---|---|
| 205-036 (T70P-4067-A) Wrench |
|
| 303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F |
|
| 303-1310 Holding Wrench, Crankshaft |
|
| 303-1562 Timing Tool |
|
| 303-1587 Timing Tool, Crankshaft |
|
| 303-679A Remover/Installer, Engine Front Cover Inspection Plate |
|
| 303-682 Aligner, Engine Front Cover |
|
| 303-705 Aligner, Oil Pump |
|
| Feeler Gauge | |
| Floor Crane | |
| Mounting Stand | |
| Plastic Scraper | |
| Hose Clamp Remover/Installer | |
| Round-Ended Steel Rule | |
| 6 mm Drill Bit | |
| Piston Ring Compressor |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Thread Sealant with PTFE TA-24-B |
WSK-M2G350-A2 |
| Motorcraft® High Performance Engine RTV Silicone TA-357 |
WSE-M4G323-A6 |
| Motorcraft® Metal Surface Prep Wipes ZC-31-B |
- |
| Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil XO-5W40-5Q3SD |
WSS-M2C171-F1 |
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NOTE: The cylinder block oil filter must be installed flush to 0.04 inch (1 mm) underflush.
Install the cylinder block oil filter.
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NOTE: The piston cooling nozzles must be fully inserted before installing the bolt.
Install the piston cooling nozzles and new bolts.
Torque: 89 lb.in (10 Nm)
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NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.NOTE: Verify that the hole in the bearings aligns with the oil gallery in the cylinder block.
Install the crankshaft upper bearings. Lubricate with clean engine oil.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
- Lubricate with clean engine oil and install the crankshaft.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
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NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.
Install the crankshaft lower bearings. Lubricate with clean engine oil.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
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NOTE: Lightly lubricate the new crankshaft main bearing bolt threads and flanges with clean engine oil.
Install the crankshaft bearing caps and new bolts. Tighten in the sequence shown in 6 stages.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
Torque: Stage 1: 53 lb.in (6 Nm) Stage 2: 133 lb.in (15 Nm) Stage 3: 177 lb.in (20 Nm) Stage 4: 26 lb.ft (35 Nm) Stage 5: 59 lb.ft (80 Nm) Stage 6: 90 deg.
- Using the special tool, check the crankshaft end play. Refer to: Specifications .
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- If necessary, position the crankshaft sprocket washer.
- If necessary, install the crankshaft sprocket and bolt.
Torque: 27 lb.ft (36 Nm)
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NOTE: Care must be taken not to damage the piston cooling nozzles while doing the measuring.NOTE: Failure to have the crankshaft connecting rod journal at TDC may result in the incorrect selection of connecting rod.
Position the crankshaft connecting rod journal at TDC for the cylinder that is being measured. Using a commercially available Depth Gauge, measure the crankshaft connecting rod journal to cylinder block deck measurement on all cylinder bores. Record the measurements into table A below.
- Using the tables, calculate the connecting rod lengths.
- If any of the connecting rods need to be replaced. Refer to: Piston .
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NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.
Install the connecting rod bearings. Lubricate with clean engine oil.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
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NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Push the piston down until the connecting rod bearing seats on the crankshaft journal.NOTE: The upper and lower compression ring gaps are the be installed 180 degrees apart.NOTE: The oil control ring position is not controlled.NOTE: Mark sure the piston and connecting rod marks are pointing toward the front of engine block.NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
Using the Piston Ring Compressor, install the piston and connecting rod assemblies. Repeat until all 5 piston assemblies are installed. Use the General Equipment: Piston Ring Compressor
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
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NOTE: Lightly lubricate the new bolt threads and flanges with clean engine oil.
Install the connecting rod caps and new bolts. Tighten in 4 stages.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
Torque: Stage 1: 71 lb.in (8 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 44 lb.ft (60 Nm) Stage 4: 90 deg.
- Check for cap shift. If the fracture split line between the cap and rod can be felt or seen, the whole connecting rod should be replaced.
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- Check the piston protrusion. If not within specifications, repeat the connecting rod length calculation. Refer to: Piston Protrusion Check . Refer to: Specifications .
- Using new ladderframe gaskets, position the ladderframe and hand start the bolts.
- Using a straight edge, align the rear surface of the ladderframe flush with the rear surface of the engine block at the 2 places indicated. Use the General Equipment: Round-Ended Steel Rule
- Using a straight edge, align the side surface of the ladderframe flush with the side surface of the engine block. Use the General Equipment: Round-Ended Steel Rule
- Tighten the ladderframe bolts. Tighten in the sequence shown in 3 stages.
Torque: Stage 1: 53 lb.in (6 Nm) Stage 2: 18 lb.ft (25 Nm) Stage 3: 18 lb.ft (25 Nm)
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- Remove any deposits of sealer with a plastic scraper. Use the General Equipment: Plastic Scraper
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NOTE: Make sure that the mating faces are clean and free of foreign material.
Clean the crankshaft rear seal sealing surface.
- Prep the surface with Motorcraft® Metal Surface Prep Wipes.
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
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NOTE: Do not remove the alignment sleeve from the crankshaft rear seal prior to installation on the crankshaft.NOTE: Make sure that a new component is installed.NOTE: Make sure that the mating faces are clean and free of foreign material.
Clean the crankshaft rear seal sealing surface.
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NOTE: Make sure that the mating faces are clean and free of foreign material.
Clean and inspect the crankshaft sealing surface.
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NOTE: Install the new crankshaft rear seal within five minutes of applying the sealant.
Apply a 3 mm (0.12 in) bead of Silicone Sealant in the locations shown.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
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NOTE: The new crankshaft rear seal is supplied with an alignment sleeve which must be removed after installation.
Install the crankshaft rear seal and the bolts. Tighten in the sequence shown in 3 stages.
Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 89 lb.in (10 Nm) Stage 3: 89 lb.in (10 Nm)
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NOTE: Do this step only if the oil pump has been replaced.
- Fill the inlet with clean engine oil until it is brimmed.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
- With the oil pump still vertical, rotate the oil pump sprocket 10 times in either direction.
- Empty the excess oil from the oil pump.
- Fill the inlet with clean engine oil until it is brimmed.
- Install the oil pump guide stud.
Torque: 22 lb.ft (30 Nm)
NOTE: The next 7 steps are for Oil Pump Alignment for new short block replacement or when the ladderframe has been removed and installed. - Install the oil pump chain.
- Install the oil pump and the bolts finger tight.
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NOTE: The dial indicator will have to be moved to take additional checks once the dial indicator is set up.
Using a commercially available dial indicator with a magnetic base, set the magnetic base on the face of the engine block. Set the dial indicator up to take a reference measurement reading off the crankshaft oil pump chain sprocket.
- Carefully reposition the dial indicator to check the alignment of the oil pump sprocket. Position the oil pump so that the reference reading is the same between sprockets.
- Carefully reposition the dial indicator to check the alignment of the oil pump sprocket. Position the oil pump so that the reference reading is the same between sprockets.
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NOTE: Use care so that the oil pump does not move while the bolts are being tighten.
Tighten the oil pump bolts.
Torque: 89 lb.in (10 Nm)
- Install the oil pump drive tensioner and bolt.
Torque: 89 lb.in (10 Nm)
NOTE: The next 4 steps are for engines that the Oil Pump Aligner (303-705) installed on the ladderframe. -
NOTE: The Oil Pump Aligner is installed when the ladderframe is not removed or when reusing the original short block with the ladder frame installed.
Install the oil pump chain.
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NOTE: The profile of the special tool must be in contact with the oil pump sprocket.
Install the oil pump and the bolts.
Torque: 89 lb.in (10 Nm)
- Install the oil pump drive tensioner and bolt.
Torque: 89 lb.in (10 Nm)
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NOTE: The Oil Pump Aligner is installed when the ladderframe is not removed or when reusing the original short block with the ladder frame installed.
Remove Special Service Tool: 303-705 Aligner, Oil Pump.
- Lubricate the O-ring with clean engine oil.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
- Install the oil feedback pipe and the banjo bolt.
Torque: 115 lb.in (13 Nm)
- Lubricate the O-ring with clean engine oil.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
- Install the oil pickup tube and bolts.
Torque: 89 lb.in (10 Nm)
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NOTE: If the oil pan is not secured within 5 minutes of silicone sealant application, the silicone sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 3 mm bead of silicone sealant to the new oil pan.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- Install the oil pan, nuts and bolts. Tighten in the sequence shown in 2 stages.
Torque: Stage 1: 62 lb.in (7 Nm) Stage 2: 124 lb.in (14 Nm)
- Install the oil level sensor.
Torque: 20 lb.ft (27 Nm)
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NOTE: The largest measurement determines the choice of the cylinder head gasket.
Check the piston protrusion. Refer to: Piston Protrusion Check .
- Install the dowels and the cylinder head gasket.
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NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
Install the cylinder head and the new bolts. Tighten in the sequence shown in 12 stages.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
Torque: Stage 1: Bolts 1 - 12: 89 lb.in (10 Nm) Stage 2: Bolts 13 - 22: 44 lb.in (5 Nm) Stage 3: Bolts 1 - 12: 177 lb.in (20 Nm) Stage 4: Bolts 13 - 22: 89 lb.in (10 Nm) Stage 5: Bolts 1 - 12: 26 lb.ft (35 Nm) Stage 6: Bolts 13 - 22: 177 lb.in (20 Nm) Stage 7: Bolts 1 - 12: 33 lb.ft (45 Nm) Stage 8: Bolts 13 - 22: 19 lb.ft (26 Nm) Stage 9: Bolts 1 - 12: 90 deg. Stage 10: Bolts 13 - 22: 90 deg. Stage 11: Bolts 1 - 12: 90 deg. Stage 12: Bolts 13 - 22: 90 deg.
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NOTE: When the tool is properly installed, the locating pin will be approximately at the 10 o'clock position.
Using the special tool, set the crankshaft position. Install Special Service Tool: 303-1587 Timing Tool, Crankshaft.
- Remove Special Service Tool: 303-1587 Timing Tool, Crankshaft.
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NOTE: The camshafts need to be installed with the slots down aligning with the timing pin holes in the cylinder head.
Lubricate with clean engine oil and install the camshafts.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
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NOTE: If the upper cylinder head is not secured within 5 minutes of silicone sealant application, the silicone sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 2.5 mm (0.10 in) bead of silicone sealant.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
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NOTE: The component must be installed within 5 minutes of applying the sealant.
Install the upper cylinder head and the bolts. Tighten in the sequence shown in 6 stages.
Torque: Stage 1: 1 - 26 : 62 lb.in (7 Nm) Stage 2: 27 - 28 : 35 lb.in (4 Nm) Stage 3: 1 - 26 : 133 lb.in (15 Nm) Stage 4: 27 - 28 : 53 lb.in (6 Nm) Stage 5: 1 - 26 : 17 lb.ft (23 Nm) Stage 6: 27 - 28 : 89 lb.in (10 Nm)
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NOTE: Make sure that the rocker arms do not separate.NOTE: After the valve rocker arm assembly is installed, verify that the rocker arms are properly aligned with the camshafts and the valve stems.
Install the valve rocker arm housing and the bolts. Tighten in the sequence shown in 4 stages.
Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 71 lb.in (8 Nm) Stage 3: 89 lb.in (10 Nm) Stage 4: 45 deg.
- Install the thermostat bracket, nut and bolt.
Torque: M8 bolt : 17 lb.ft (23 Nm) M6 nut : 89 lb.in (10 Nm)
- Install the valve cover seals.
- Install the valve cover gasket.
- Install the valve cover and tighten the bolts. Tighten in the sequence shown in 3 stages.
Torque: Stage 1: 35 lb.in (4 Nm) Stage 2: 89 lb.in (10 Nm) Stage 3: 97 lb.in (11 Nm)
- Install the NVH padding.
- Apply clean engine oil and install the CMP sensor and bolt.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
Torque: 89 lb.in (10 Nm)
- If equipped, install the block heater.
Torque: 41 lb.ft (55 Nm)
- Using a new gasket, install the coolant manifold and bolts. Tighten in the sequence shown in 2 stages.
Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 89 lb.in (10 Nm)
- Install a new O-ring seal on the fuel injection pump and lubricate.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
- Install the fuel injection pump and the stud bolts.
Torque: 17 lb.ft (23 Nm)
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NOTE: This bolt has left hand threads.
Using the special tool, install the fuel injection pump sprocket and bolt. Use Special Service Tool: 205-036 (T70P-4067-A) Wrench.
Torque: Stage 1: : 55 lb.ft (75 Nm) Stage 2: Loosen : 90 deg. Stage 3: : 55 lb.ft (75 Nm)
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- Install the upper LH fuel injection pump bracket and the upper LH fuel injection pump bracket bolt finger tight.
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NOTE: Make sure that a new upper LH fuel injection pump bracket bolt is installed.
Install the upper LH fuel injection pump bracket bolt finger tight.
- Install the fuel injection pump bracket and the nut finger tight.
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- Install the lower RH fuel injection pump bracket and the lower RH fuel injection pump bracket bolts finger tight.
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NOTE: Make sure that a new lower RH fuel injection pump bracket bolt is installed.
Install the lower RH fuel injection pump bracket bolt finger tight.
- Tighten the fuel injection pump bracket nut and bolts. Tighten in the sequence shown.
Torque: 1: 89 lb.in (10 Nm) 2: 17 lb.ft (23 Nm) 3: 17 lb.ft (23 Nm) 4: 17 lb.ft (23 Nm)
- Install the fuel injection pump bracket, nut and the bolts finger tight.
- Tighten the fuel injection pump bracket nut and bolts. Tighten in the sequence shown.
Torque: 1: 16 lb.ft (22 Nm) 2: 89 lb.in (10 Nm) 3: 16 lb.ft (22 Nm)
- Install the new fuel injector sealing washers.
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NOTE: If a fuel injector is being reused, make sure to install the fuel injector in the original location.NOTE: Only tighten the bolts finger tight.
Install the fuel injectors, the fuel injector clamps and the fuel injector clamp bolts finger tight.
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NOTE: This uneven torque strategy is intentional as tightening bolt 2 cantilevers the fuel injector clamp about the fuel injector, increasing the clamp load imparted by bolt 1.
- Tighten bolt number 1 to:
Torque: 18 lb.in (2 Nm)
- Tighten bolt number 2 in the following stages:
Torque: Stage 1: 35 lb.in (4 Nm) Stage 2: 360 deg.
- Tighten both of the number 3 bolts in the following stages:
Torque: Stage 1: 53 lb.in (6 Nm) Stage 2: 360 deg.
- Tighten bolt number 1 to:
- Install the fuel rail, bracket and bolts.
Torque: 18 lb.in (2 Nm)
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NOTE: Do not tighten the fuel rail supply tube or bolts at this time.
Install the new fuel rail supply tube and bolts.
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NOTE: Do not tighten the fuel injector supply tubes at this time.
Install the fuel injector supply tubes.
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- Tighten the fuel rail supply tube and the fuel injector supply tubes at the fuel rail.
Torque: 133 lb.in (15 Nm)
- Tighten the fuel injector supply tubes at the fuel injectors.
Torque: 133 lb.in (15 Nm)
- Loosen the fuel rail bolts.
Torque: 720 deg.
- Tighten the fuel rail bolts.
Torque: 17 lb.ft (23 Nm)
- Tighten the fuel injector supply tubes at the fuel injectors.
Torque: 22 lb.ft (30 Nm)
- Tighten the fuel rail supply tube and the fuel injector supply tubes at the fuel rail.
Torque: 22 lb.ft (30 Nm)
- Tighten the fuel rail supply tube bolts.
Torque: 89 lb.in (10 Nm)
- Tighten the fuel rail supply tube and the fuel injector supply tubes at the fuel rail.
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NOTE: Make sure that the timing marks are aligned on the camshaft sprockets and the fuel injections pump drive sprocket.NOTE: Do not tighten the bolts at this time.
Install the timing chain, the camshaft sprockets and bolts.
- Install the timing chain guides and the bolts.
Torque: 1: 124 lb.in (14 Nm) 2: 23 lb.ft (31 Nm) 3: 30 lb.ft (40 Nm)
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- Install the timing chain tensioner and bolts.
Torque: 133 lb.in (15 Nm)
- Remove the pin.
- Install the timing chain tensioner and bolts.
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NOTE: When the tool is properly installed, the locating pin will be approximately at the 10 o'clock position.
Install Special Service Tool: 303-1587 Timing Tool, Crankshaft.
- Check the valve timing by inserting the end of 2 drill bits through the sprocket holes into the timing pin holes in the cylinder head. Use the General Equipment: 6 mm Drill Bit
Torque: Stage 1: 106 lb.in (12 Nm) Stage 2: 24 lb.ft (33 Nm)
- Remove Special Service Tool: 303-1587 Timing Tool, Crankshaft.
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NOTE: Only rotate the crankshaft clockwise.
Rotate the engine two revolutions.
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NOTE: When the tool is properly installed, the locating pin will be approximately at the 10 o'clock position.
Install Special Service Tool: 303-1587 Timing Tool, Crankshaft.
- Check the valve timing by inserting the end of 2 drill bits through the sprocket holes into the timing pin holes in the cylinder head. If the drill bit ends can not be inserted repeat the timing steps. Use the General Equipment: 6 mm Drill Bit
- Verify that the alignment dowel is installed in the crankshaft.
- If the alignment dowel is missing, install the alignment dowel in the crankshaft.
- Put a alignment mark from the crankshaft to the rear crankshaft seal cover.
- Remove Special Service Tool: 303-1587 Timing Tool, Crankshaft.
- Install the new engine front cover gasket.
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NOTE: If the engine front cover is not secured within 5 minutes of sealant application, the silicone sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 3 mm bead of silicone sealant to the new engine front cover.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
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NOTE: The component must be installed within 5 minutes of applying the sealant.
Apply a 5 mm (0.20 in) bead of silicone sealant at the T-joints.
Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)
- Using the special tool to align the engine front cover, install the engine front cover, nuts and bolts. Tighten in the sequence shown in 3 stages. Use Special Service Tool: 303-682 Aligner, Engine Front Cover.
Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 89 lb.in (10 Nm) Stage 3: 89 lb.in (10 Nm)
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NOTE: The new crankshaft front seal is supplied with an alignment sleeve which must be removed after installation.NOTE: Do not remove the alignment sleeve from the crankshaft front seal prior to installation on the crankshaft.
Position the crankshaft front seal on the crankshaft.
- Using the special tool, install the crankshaft front seal. Use Special Service Tool: 303-679A Remover/Installer, Engine Front Cover Inspection Plate.
Torque: 168 lb.in (19 Nm)
- Install the crankshaft pulley washer.
- Install the crankshaft pulley and the new bolts.
- Using the special tool, tighten the crankshaft pulley bolts. Tighten in 5 stages. Use Special Service Tool: 303-1310 Holding Wrench, Crankshaft.
Torque: Stage 1: 177 lb.in (20 Nm) Stage 2: 33 lb.ft (45 Nm) Stage 3: 66 lb.ft (90 Nm) Stage 4: 45 deg. Stage 5: 45 deg.
- Install the coolant connector, nut and bolts.
Torque: 17 lb.ft (23 Nm)
- Install the accessory drive belt idler assembly and bolts. Install the idler pulley assembly.
Torque: 35 lb.ft (48 Nm)
- Install a new gasket.
- Install the oil cooler, bolts and studs bolts. Tighten in the sequence shown in 3 stages.
Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 17 lb.ft (23 Nm) Stage 3: 17 lb.ft (23 Nm)
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NOTE: If the oil pressure switch is to be reused, apply thread sealant.
Install the oil pressure switch.
Material: Motorcraft® Thread Sealant with PTFE / TA-24-B (WSK-M2G350-A2)
Torque: 177 lb.in (20 Nm)
- Install the glow plugs.
Torque: 115 lb.in (13 Nm)
- Install the glow plug harness. Tighten in 2 stages.
Torque: Stage 1: 9 lb.in (1 Nm) Stage 2: 21 lb.in (2.4 Nm)
- Install the intake manifold and the bolts. Tighten in the sequence shown in 3 stages.
Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 115 lb.in (13 Nm) Stage 3: 142 lb.in (16 Nm)
- Install the new fuel injector fuel return line fitting retaining clips into the fuel injectors.
- Lubricate the new fuel injector return line fitting O-ring seals.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
- Install the fuel pump supply and return tubes assemblies. Refer to: Quick Release Coupling
.
- Install the fuel return tube bracket and bolt.
Torque: 62 lb.in (7 Nm)
- Install the coolant pump and bolts. Tighten in the sequence shown.
Torque: 17 lb.ft (23 Nm)
- Apply clean engine oil to the O-ring and install a new gasket.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
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NOTE: Do not tighten the bolts at this time.
Install the mixer tube and 2 bolts.
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NOTE: Do not tighten the nuts at this time.
Install the EGR valve and nuts.
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NOTE: Install the new seal by hand with no lubricant.
Install the vacuum pump seal.
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NOTE: Manually align the brake vacuum pump drive key with the camshaft slot before installation.
Install the vacuum pump and bolts.
Torque: 17 lb.ft (23 Nm)
- Position a new EGR cooler gasket on the EGR cooler.
- Install the EGR cooler and bolt.
Torque: 17 lb.ft (23 Nm)
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NOTE: Make sure that a new EGR cooler vee-clamp and a new nut is installed.
Install the EGR cooler vee-clamp and nut in the position as shown. Tighten the EGR cooler vee-clamp nut.
Torque: 80 lb.in (9 Nm)
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NOTE: After alignment of the EGR cooler the lower bolt will be removed.
Using a new gasket, install the EGR valve bolts.
Torque: 17 lb.ft (23 Nm)
- Tighten the mixer tube nuts.
Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 89 lb.in (10 Nm)
- Tighten the mixer tube bolts.
Torque: 89 lb.in (10 Nm)
- Remove the lower EGR valve bolt.
- Install the heat shield and bolts. Tighten in the sequence shown.
Torque: 89 lb.in (10 Nm)
- Install the oil level indicator tube assembly and bolt.
Torque: 17 lb.ft (23 Nm)
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NOTE: Make sure that the mating surfaces are clean and free of foreign material.
Replace the turbocharger mounting studs.
Torque: 124 lb.in (14 Nm)
- Install the turbocharger and the new upper turbocharger nut. Tighten in 2 stages.
Torque: Stage 1: 133 lb.in (15 Nm) Stage 2: 17 lb.ft (23 Nm)
- Install the new lower turbocharger nuts. Tighten in 2 stages.
Torque: Stage 1: 133 lb.in (15 Nm) Stage 2: 17 lb.ft (23 Nm)
- Install a new gasket and lubricate the O-ring with engine oil.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
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- Position the turbocharger drain tube in the cylinder block.
- Install the cylinder block bolt finger tight.
- Install the bolts at the turbocharger finger tight.
- Install the bolt for the turbocharger drain tube finger tight.
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- Tighten the cylinder block bolt.
Torque: 17 lb.ft (23 Nm)
- Tighten the bolts at the turbocharger.
Torque: 89 lb.in (10 Nm)
- Tighten the cylinder block bolt.
- Tighten the bolt for the turbocharger drain tube.
Torque: 17 lb.ft (23 Nm)
- Install the new turbocharger oil supply tube assembly, the new washers and the new banjo bolts.
Torque: 177 lb.in (20 Nm)
- Install the turbocharger heat shield and bolts.
Torque: 18 lb.ft (25 Nm)
- Install the turbocharger heat shield bolt.
Torque: 18 lb.ft (25 Nm)
- Install the bracket assembly and bolts.
Torque: 18 lb.ft (25 Nm)
- Connect the vacuum hose at the vacuum pump.
- Connect the vacuum hose and the retaining clip.
- Install the lifting eye, bracket and bolts. Tighten in the sequence shown in 3 stages.
Torque: M8 bolts: Stage 1: 133 lb.in (15 Nm) Stage 2: 17 lb.ft (23 Nm) Stage 3: 17 lb.ft (23 Nm) M10 bolts: Stage 4: 177 lb.in (20 Nm) Stage 5: 35 lb.ft (48 Nm) Stage 6: 35 lb.ft (48 Nm)
- Install the generator and bolts.
Torque: 35 lb.ft (48 Nm)
- Install the studs.
Torque: 62 lb.in (7 Nm)
- Install the accessory drive belt tensioner, nuts and bolts.
Torque: 22 lb.ft (30 Nm)
- Install the mounting bracket and bolt. Install the stud.
Torque: Bolt : 18 lb.ft (25 Nm) Stud : 62 lb.in (7 Nm)
- Position the engine wire harness and if equipped, the block heater cord.
- Connect the harness to the valve cover and connect the fuel injector electrical connectors. Install the ground wire and the nut. Connect the wire retainer.
Torque: 62 lb.in (7 Nm)
- Connect the electrical connectors and the wire retainer.
- Connect the TP electrical connector and wire retainer.
- Connect the oil pressure switch electrical connector and wire retainer.
- Connect the wire retainers and the electrical connector. If equipped, connect the block heater.
- Install the bolts. Connect the electrical connectors and the wire retainer.
Torque: Front bolt : 44 lb.in (5 Nm) Rear bolt : 89 lb.in (10 Nm)
- Connect the electrical connector and the wire retainer. Install the nut and the cover.
Torque: 89 lb.in (10 Nm)
- Connect the hose to the crankcase vent hose. Connect the electrical connectors and the wire harness retainers.
- Connect the electrical connectors and the wire harness retainers.
- Install the coolant tube and the bolts. Tighten the hose clamps.
Torque: Bolts : 17 lb.ft (23 Nm) Hose clamps : 35 lb.in (4 Nm)
- Install the coolant hose and tighten the clamps.
Torque: 35 lb.in (4 Nm)
- Install the coolant hose and tighten the clamps.
Torque: 35 lb.in (4 Nm)
- Install the coolant hose and tighten the clamps.
Torque: 35 lb.in (4 Nm)
- Install the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
- Install the lower radiator hose. Use the General Equipment: Hose Clamp Remover/Installer
- Position the coolant hose and connect the retainers. Install the bolt.
Torque: 35 lb.in (4 Nm)
- Connect the coolant hose.
- Install the RH engine mount bracket and the bolts.
Torque: 46 lb.ft (63 Nm)
- Install the LH engine mount bracket and the bolts.
Torque: 46 lb.ft (63 Nm)
- Install the floor crane. Use the General Equipment: Floor Crane
- Remove the engine from the mounting stand. Use the General Equipment: Mounting Stand
- Align the alignment marks on the crankshaft and the rear crankshaft seal cover,
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NOTE: Do not allow the crankshaft to turn during installation of the flywheel.
Install the flexplate and the bolts.
- Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Tighten the bolts in the sequence shown in 3 stages.
Torque: Stage 1: 18 lb.ft (25 Nm) Stage 2: 33 lb.ft (45 Nm) Stage 3: 45 deg.
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NOTE: Do not tighten the bolts.
Install the CKP sensor bracket and bolts.
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NOTE: Make sure the timing tool is seated in the opening for the trigger wheel.
Using the special tool, align the CKP sensor bracket. Tighten the bolts. Use Special Service Tool: 303-1562 Timing Tool.
Torque: 17 lb.ft (23 Nm)
- Rotate the crankshaft until the trigger tooth is visible through the CKP sensor housing.
- Using a 0.02 inch (0.5 mm) feeler gauge blade, install the CKP sensor and bolt. Use the General Equipment: Feeler Gauge
Torque: 71 lb.in (8 Nm)
- Connect the CKP electrical connector.
- Install the heat shield and the bolt.
Torque: 21 lb.ft (28 Nm)