Engine - Enhanced Long Block

WARNING: This page is about a different car, the 2019 Ford F-550 Super Duty, 2019 Ford F-450 Super Duty, 2019 Ford F-350 Super Duty, and 2019 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

For information on Ford Color Coded Illustrations refer to OEM Color Coding

Special Tool(s) / General Equipment

Courtesy of FORD MOTOR COMPANY	100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
Courtesy of FORD MOTOR COMPANY	205-036 (T70P-4067-A) Wrench
Courtesy of FORD MOTOR COMPANY	303-050 (T70P-6000) Lifting Bracket, Engine
Courtesy of FORD MOTOR COMPANY	303-1518 Bracket, Engine Removal TKIT-2009C-F TKIT-2009C-ROW
Courtesy of FORD MOTOR COMPANY	303-214 (T83T-6312-B) Wrench, Fan Clutch Nut
Courtesy of FORD MOTOR COMPANY	308-021 (T75L-4201-A) Gauge, Clutch Housing
Strap Wrench
Floor Crane
Hose Clamp Remover/Installer

Materials

Name	Specification
Motorcraft® SAE 10W-30 Super Duty Diesel Motor Oil XO-10W30-QSDF	WSS-M2C171-F1

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. 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".

NOTE: Refer to the exploded view under the Engine Component View in the Description and Operation.

Install Special Service Tool: 303-1518 Bracket, Engine Removal.
Torque: 41 lb.ft (55 Nm)

Courtesy of FORD MOTOR COMPANY
- Using a Floor Crane, remove the engine from the shipping crate. Position the engine on wood blocks as needed. Use the General Equipment: Floor Crane
- Verify that the engine is stable on the wooden blocks.
If equipped with a block heater, remove the block heater plug.

Courtesy of FORD MOTOR COMPANY
If equipped, install the block heater.
Torque: 30 lb.ft (40 Nm)

Courtesy of FORD MOTOR COMPANY
Install a new O-ring seal and lubricate.
Material: Motorcraft® SAE 10W-30 Super Duty Diesel Motor Oil / XO-10W30-QSDF (WSS-M2C171-F1)

Courtesy of FORD MOTOR COMPANY
Install the high-pressure fuel injection pump and the high-pressure fuel injection pump spacers.
Torque: 18 lb.ft (24 Nm)

Courtesy of FORD MOTOR COMPANY
Install the fuel rail supply tube bracket and the bolts.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
NOTE: The crankshaft gear contains a single timing mark. The camshaft gear contains a single timing mark and a double timing mark. The high-pressure fuel injection pump gear contains a double timing mark. The engine is timed correctly when the single mark on the crankshaft gear is aligned with the double mark on the camshaft gear, and the single mark on the camshaft gear is aligned with the double mark on the high-pressure fuel injection pump gear. Additionally, the keyway on the high-pressure fuel injection pump drive gear must be at 12 o'clock position.

NOTE: Engine front cover removed for clarity.
- Install the high pressure fuel injection pump drive gear and nut.
  Torque: 59 lb.ft (80 Nm)
- Verify the timing marks are aligned.
Courtesy of FORD MOTOR COMPANY
Using the special tool, check the high-pressure fuel injection pump drive gear backlash. Refer to: Specifications . Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge., 308-021 (T75L-4201-A) Gauge, Clutch Housing.

Courtesy of FORD MOTOR COMPANY
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 fuel injectors. Position the fuel injectors into the engine.

Courtesy of FORD MOTOR COMPANY
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.

NOTE: Only one fuel injector shown.

Install the fuel injector hold-down clamps and new fuel injector bolts.

Torque: Stage 1: 22 lb.ft (30 Nm) | Stage 2: 90 deg.

Courtesy of FORD MOTOR COMPANY
Final tighten the LH valve cover bolts in the sequence shown.
Torque: 106 lb.in (12 Nm)

Courtesy of FORD MOTOR COMPANY
Final tighten the RH valve cover bolts in the sequence shown.
Torque: 106 lb.in (12 Nm)

Courtesy of FORD MOTOR COMPANY
Install the glow plugs.
Torque: Stage 1: 35 lb.in (4 Nm) | Stage 2: 50 deg.

Courtesy of FORD MOTOR COMPANY
Install a new RH exhaust manifold gasket.

Courtesy of FORD MOTOR COMPANY
NOTE: Install the spacers as marked on removal.

Install the RH exhaust manifold, spacers and new nuts.

Torque: Stage 1: 159 lb.in (18 Nm) | Stage 2: 18 lb.ft (25 Nm) | Stage 3: Tighten a second time to : 18 lb.ft (25 Nm)

Courtesy of FORD MOTOR COMPANY
Install a new LH exhaust manifold gasket.

Courtesy of FORD MOTOR COMPANY
NOTE: Install the spacers as marked on removal.

Install the LH exhaust manifold, spacers and new nuts.

Torque: Stage 1: 159 lb.in (18 Nm) | Stage 2: 18 lb.ft (25 Nm) | Stage 3: Tighten a second time to : 18 lb.ft (25 Nm)

Courtesy of FORD MOTOR COMPANY
Apply oil to the threads and install the exhaust manifold studs.
Material: Motorcraft® SAE 10W-30 Super Duty Diesel Motor Oil / XO-10W30-QSDF (WSS-M2C171-F1)

Torque: 115 lb.in (13 Nm)

Courtesy of FORD MOTOR COMPANY
Install the RH exhaust manifold heat shield and bolts.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Install the LH exhaust manifold heat shield and bolts.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
NOTE: Do not use magnetic screwdrivers or other magnetic tools around the CKP sensor and the crankshaft sensor pulse ring or damage to the components may occur.

Install the crankshaft sensor pulse ring.

Courtesy of FORD MOTOR COMPANY
Install the flexplate and the new bolts.
Torque: Stage 1: 44 lb.in (5 Nm) | Stage 2: 74 lb.ft (100 Nm)

Courtesy of FORD MOTOR COMPANY
Install a new vacuum pump gasket.

Courtesy of FORD MOTOR COMPANY
Install the vacuum pump and the bolts.
Torque: Stage 1: 71 lb.in (8 Nm) | Stage 2: 30 deg.

Courtesy of FORD MOTOR COMPANY
NOTE: To prevent engine damage, always install 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 the new bolts. Use the General Equipment: Strap Wrench

Torque: Stage 1: 22 lb.ft (30 Nm) | Stage 2: 90 deg.

Courtesy of FORD MOTOR COMPANY
Install the new coolant crossover manifold gaskets.

Courtesy of FORD MOTOR COMPANY
Install the coolant crossover manifold and the bolts. Finger-tighten the bolts.

Courtesy of FORD MOTOR COMPANY
Install the new thermostat, thermostat housing and the bolts. Finger-tighten the bolts.

Courtesy of FORD MOTOR COMPANY
Tighten the coolant crossover manifold bolts and the thermostat housing bolts.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Position the RH fuel rail and loosely install the bolts.

Courtesy of FORD MOTOR COMPANY
Position the LH fuel rail and loosely install the bolts.

Courtesy of FORD MOTOR COMPANY
Position the fuel rail supply tube assembly. Hand start the fuel rail supply tube assembly connectors.

Courtesy of FORD MOTOR COMPANY
NOTE: Only 1 fuel injector supply tube shown.

NOTE: Only hand start the fuel injector supply tube.
- Install the fuel injector supply tubes.
- Start from front to rear of the engine.
Courtesy of FORD MOTOR COMPANY
NOTE: Only hand start the fuel rail supply tube assembly bolts.

Install the fuel rail supply tube assembly bolts.

Courtesy of FORD MOTOR COMPANY
Tighten the LH fuel rail bolts.
Torque: 18 lb.ft (24 Nm)

Courtesy of FORD MOTOR COMPANY
Tighten the RH fuel rail bolts.
Torque: 18 lb.ft (24 Nm)

Courtesy of FORD MOTOR COMPANY
Tighten the LH fuel injector supply tubes in the sequence shown.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Tighten the RH fuel injector supply tubes in the sequence shown.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Tighten the fuel rail supply tube assembly connectors in the sequence shown.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Tighten the LH fuel injector supply tubes in the sequence shown.
Torque: 65 deg.

Courtesy of FORD MOTOR COMPANY
Tighten the RH fuel injector supply tubes in the sequence shown.
Torque: 65 deg.

Courtesy of FORD MOTOR COMPANY
Tighten the fuel rail supply tube assembly connectors in the sequence shown.
Torque: 65 deg.

Courtesy of FORD MOTOR COMPANY
Tighten the fuel rail supply tube assembly bolts in the sequence shown.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
- Position the fuel injector return hose and vacuum hose assembly on the engine and connect the retaining clips.
- Connect the 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.
Courtesy of FORD MOTOR COMPANY
Install a new O-ring on the heater supply tube and lubricate. Refer to: Specifications .

Courtesy of FORD MOTOR COMPANY
Install the heater supply tube and bolts.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Install a new O-ring on the turbocharger coolant tube.

Courtesy of FORD MOTOR COMPANY
Install the turbocharger coolant tube. Use the General Equipment: Hose Clamp Remover/Installer

Courtesy of FORD MOTOR COMPANY
Install the secondary fuel filter bracket and bolts.
Torque: Stage 1: 71 lb.in (8 Nm) | Stage 2: 45 deg.

Courtesy of FORD MOTOR COMPANY
NOTE: Rotate the fuel filter clockwise to install.

Install the new secondary fuel filter.

Courtesy of FORD MOTOR COMPANY
If necessary, install the new crankcase vent oil separator gasket and O-ring seal.

Courtesy of FORD MOTOR COMPANY
NOTE: Do not lubricate the O-ring seal or gasket prior to installation.

Install the crankcase vent oil separator and bolts.

Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.

Courtesy of FORD MOTOR COMPANY
Install the new O-ring seals on the fuel injection pump supply tube assembly and lubricate.
Material: Motorcraft® SAE 10W-30 Super Duty Diesel Motor Oil / XO-10W30-QSDF (WSS-M2C171-F1)

Courtesy of FORD MOTOR COMPANY
Install the fuel injection pump supply tube assembly and hand start the bolt.

Courtesy of FORD MOTOR COMPANY
Hand start the fuel injection pump supply tube assembly bolt.

Courtesy of FORD MOTOR COMPANY
Hand start the fuel injection pump supply tube assembly bolts.

Courtesy of FORD MOTOR COMPANY
Tighten the fuel injection pump supply tube assembly bolt.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.

Courtesy of FORD MOTOR COMPANY
Tighten the fuel injection pump supply tube assembly bolts.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.

Courtesy of FORD MOTOR COMPANY
Tighten the fuel injection pump supply tube assembly bolt.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.

Courtesy of FORD MOTOR COMPANY
Connect the fuel injector return hose to the secondary fuel filter and connect the hose retainer. Install the fuel injection pump supply tube. Refer to: Quick Release Coupling .

Courtesy of FORD MOTOR COMPANY
Connect the fuel injection pump hose to the fuel rail. Refer to: Spring Lock Couplings .

Courtesy of FORD MOTOR COMPANY
Position the engine wire harness over the engine. Connect the retainers and install the bolt.
Torque: 106 lb.in (12 Nm)

Courtesy of FORD MOTOR COMPANY
Connect the RH valve cover wiring.

Courtesy of FORD MOTOR COMPANY
Connect the fuel volume control valve electrical connector.

Courtesy of FORD MOTOR COMPANY
Connect the CMP sensor electrical connector and the retainers.

Courtesy of FORD MOTOR COMPANY
Connect the ECT sensor electrical connector and the wire retainer.

Courtesy of FORD MOTOR COMPANY
Connect the fuel pressure and temperature sensor electrical connector and the wire retainer.

Courtesy of FORD MOTOR COMPANY
Connect the LH valve cover wiring.

Courtesy of FORD MOTOR COMPANY
- Connect the wire retainers.
- Install the ground strap and the bolt.
  Torque: 97 lb.in (11 Nm)
Courtesy of FORD MOTOR COMPANY
Connect the CKP sensor electrical connector and the wire retainer.

Courtesy of FORD MOTOR COMPANY
Install the CKP sensor cover.

Courtesy of FORD MOTOR COMPANY
Install the lower intake manifold and the bolts.
Torque: 18 lb.ft (24 Nm)

Courtesy of FORD MOTOR COMPANY
Install a new gasket for the TB (throttle body).

Courtesy of FORD MOTOR COMPANY
Install the TB and the bolts.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.

Courtesy of FORD MOTOR COMPANY
Connect the crankcase vent oil separator hose to the lower intake manifold.

Courtesy of FORD MOTOR COMPANY
Connect the TB electrical connector.

Courtesy of FORD MOTOR COMPANY
Install the new EGR cooler gaskets.

Courtesy of FORD MOTOR COMPANY
Install the EGR cooler assembly and the bolts.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Position the engine wire harness and install the bolts.
Torque: 80 lb.in (9 Nm)

Courtesy of FORD MOTOR COMPANY
Using new gaskets, install the EGR cooler outlet pipe and the bolts.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Connect the EGRT electrical connector and the wire retainers.

Courtesy of FORD MOTOR COMPANY
- Using new gaskets, install the EGR cooler inlet pipe and the bolts.
- Tighten the bolts at the exhaust manifold.
  Torque: 89 lb.in (10 Nm)
- Tighten the bolts at the EGR cooler.
  Torque: 89 lb.in (10 Nm)
Courtesy of FORD MOTOR COMPANY
1. Install the EGR cooler inlet pipe bracket and hand start the bolts.
2. Install the bolt.
  Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.
3. Tighten the bolt.
  Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.
4. Tighten the bolt.
  Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 45 deg.
Courtesy of FORD MOTOR COMPANY
Connect the electrical connector and the vacuum tubes to the EGR bypass valve solenoid. Attach the wire harness retainer.

Courtesy of FORD MOTOR COMPANY
Connect the EGR valve electrical connector and the wire harness retainer.

Courtesy of FORD MOTOR COMPANY
Connect the retainer for the PCM wire harness.

Courtesy of FORD MOTOR COMPANY
Install new O-rings on the oil level indicator tube and lubricate.
Material: Motorcraft® SAE 10W-30 Super Duty Diesel Motor Oil / XO-10W30-QSDF (WSS-M2C171-F1)

Courtesy of FORD MOTOR COMPANY
Install the oil level indicator tube.

Courtesy of FORD MOTOR COMPANY
Install a new O-ring seal on the oil fill pipe and lubricate.
Material: Motorcraft® SAE 10W-30 Super Duty Diesel Motor Oil / XO-10W30-QSDF (WSS-M2C171-F1)

Courtesy of FORD MOTOR COMPANY
Install the oil fill pipe and the bolt.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Install the LH sound shield and the push pins.

Courtesy of FORD MOTOR COMPANY
Install the RH sound shield and the push pins.

Courtesy of FORD MOTOR COMPANY
Install the stator standoffs.
Torque: 17 lb.ft (23 Nm)

Courtesy of FORD MOTOR COMPANY
NOTE: Only one tube shown.

Install the new transmission oil cooler coolant tube O-rings and lubricate. Refer to: Specifications .

Courtesy of FORD MOTOR COMPANY
Install the transmission oil cooler coolant tube and stud bolt.
Torque: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Install the transmission oil cooler coolant tube, bolt and nut.
Torque: Nut: 115 lb.in (13 Nm) Bolt: 89 lb.in (10 Nm)

Courtesy of FORD MOTOR COMPANY
Connect the engine vacuum hose at the tee.

Courtesy of FORD MOTOR COMPANY
1. Install the power steering pump mounting bracket and the 2 bolts.
  Torque: 18 lb.ft (25 Nm)
2. Install the remaining bolts.
  Torque: 18 lb.ft (25 Nm)
Courtesy of FORD MOTOR COMPANY
If equipped with dual generators, install the idler pulley.
Torque: 35 lb.ft (48 Nm)

Courtesy of FORD MOTOR COMPANY
Install the cooling fan drive assembly, lifting eye and the bolts. Use Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.
Torque: 18 lb.ft (25 Nm)

Courtesy of FORD MOTOR COMPANY
NOTE: Dual generator shown, single generator similar.

Install the secondary coolant pump assembly and the bolts.

Torque: 18 lb.ft (25 Nm)

Courtesy of FORD MOTOR COMPANY
If equipped with dual generators, connect the wire harness retainer.

Courtesy of FORD MOTOR COMPANY
Install the accessory drive belt tensioner and the bolt.
Torque: 35 lb.ft (48 Nm)

Courtesy of FORD MOTOR COMPANY
Install the A/C compressor and the bolts.
Torque: 18 lb.ft (25 Nm)

Courtesy of FORD MOTOR COMPANY
Install the battery wire harness and the nuts.
Torque: 106 lb.in (12 Nm)

Courtesy of FORD MOTOR COMPANY
Install the battery wire harness nut.
Torque: 106 lb.in (12 Nm)

Courtesy of FORD MOTOR COMPANY
Connect the A/C clutch electrical connector and the wire retainers.

Courtesy of FORD MOTOR COMPANY
Connect the A/C pressure switch electrical connector.

Courtesy of FORD MOTOR COMPANY
Position back the RH ground cable and install the bolt.
Torque: 18 lb.ft (25 Nm)

Courtesy of FORD MOTOR COMPANY
Install the nut for the battery wire harness.
Torque: 106 lb.in (12 Nm)

Courtesy of FORD MOTOR COMPANY
Connect the oil pressure switch and the oil temperature sensor electrical connectors.

Courtesy of FORD MOTOR COMPANY
Connect the heater hose and install the clip.

Courtesy of FORD MOTOR COMPANY
Position back the LH ground cable and install the bolt.
Torque: 18 lb.ft (25 Nm)

Courtesy of FORD MOTOR COMPANY
Install the bolts for the battery wire harness.
Torque: 106 lb.in (12 Nm)

Courtesy of FORD MOTOR COMPANY
Connect the battery wire harness retainer to the bracket.

Courtesy of FORD MOTOR COMPANY
- Position back the cable and install the nut. Position back the boot.
  Torque: 159 lb.in (18 Nm)
- Connect the generator electrical connector.
Courtesy of FORD MOTOR COMPANY
If equipped with single generator, install the accessory drive belt.

Courtesy of FORD MOTOR COMPANY
If equipped with dual generators, install the accessory drive belt.

Courtesy of FORD MOTOR COMPANY
Install the coolant engine fill hose. Use the General Equipment: Hose Clamp Remover/Installer

Courtesy of FORD MOTOR COMPANY
Install the lower radiator hose and install the clip.

Courtesy of FORD MOTOR COMPANY
Connect the coolant hose and install the clip.

Courtesy of FORD MOTOR COMPANY
Using the special tools, install the fan clutch. Use Special Service Tool: 205-036 (T70P-4067-A) Wrench., 303-214 (T83T-6312-B) Wrench, Fan Clutch Nut.
Torque: 98 lb.ft (133 Nm)

Courtesy of FORD MOTOR COMPANY
- Install the fan clutch electrical connector bolt.
  Torque: 18 lb.ft (25 Nm)
- Connect the fan clutch electrical connector.
Courtesy of FORD MOTOR COMPANY
Install the CAC pipe and the clip.

Courtesy of FORD MOTOR COMPANY
Install the air cleaner outlet pipe and tighten the clamp.
Torque: 35 lb.in (4 Nm)

Courtesy of FORD MOTOR COMPANY
- Position the coolant hose assembly. If equipped, connect the vacuum hose connector.
- Connect the coolant hose assembly. Use the General Equipment: Hose Clamp Remover/Installer
Courtesy of FORD MOTOR COMPANY
NOTE: Do not tighten the engine mount bracket bolts more than 90 degrees after initial torque or damage to the bolts may occur.

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

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

Install the RH engine mount bracket and the new bolts.

Torque: Stage 1: 41 lb.ft (55 Nm) | Stage 2: 60 deg.

Courtesy of FORD MOTOR COMPANY
NOTE: Do not tighten the engine mount bracket bolts more than 90 degrees after initial torque or damage to the bolts may occur.

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

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

Install the LH engine mount bracket and the new bolts.

Torque: Stage 1: 41 lb.ft (55 Nm) | Stage 2: 60 deg.

Courtesy of FORD MOTOR COMPANY
Using the Floor Crane and a ratchet strap, remove the engine from the wooden blocks. Use the General Equipment: Floor Crane
NOTE: The following steps are done on the body before the engine is installed.
Remove the CAC. Refer to: Charge Air Cooler (CAC) .
Flush the CAC and the CAC tubes with Simple Green® Pro HD. Refer to: Charge Air Cooler (CAC) Cleaning .
Install the CAC. Refer to: Charge Air Cooler (CAC) .
NOTE: Ensure the fuel is free of contaminants.

Replace the fuel filter. Refer to: Fuel Filter .
Install the engine. Refer to: Engine - Body Off . Refer to: Engine - Body On .