Engine - Body Off

WARNING: This page is about a different car, the 2018 Ford F-550 Super Duty, 2018 Ford F-450 Super Duty, 2018 Ford F-350 Super Duty, and 2018 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	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	307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1998-LM (NavigatoR) TKIT-1997-F/FLM/LT
Floor Crane
Transmission Jack

Materials

Name	Specification
Motorcraft ® Multi-Purpose Grease Spray XL-5-A	ESB-M1C93-B
Motorcraft ® SAE 10W-30 Super Duty Diesel Motor Oil XO-10W30-QSDF	WSS-M2C171-F1
Motorcraft ® Orange Concentrated Antifreeze/Coolant VC-3-B	WSS-M97B44-D
Motorcraft ® MERCON ® LV Automatic Transmission Fluid XT-10-QLVC	MERCON ® LVWSS-M2C938-A

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

NOTE: It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Engine - Body On .

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

NOTE: Failure to inspect the components for debris may result in repeat failures.

NOTE: It may be necessary to use a borescope to inspect the components.

When an engine or turbocharger is replaced due to a failure, inspect the following components for potential metal debris. If evidence of debris is found, clean or replace the components as needed.
- CAC and the CAC tubes
- Intake air system
- Exhaust manifolds
- EGR cooler and pipes
- Diesel Oxidation Catalyst (DOC)
- Turbocharger (on engine failure only)
Remove Special Service Tool: 307-346 (T97T-7902-A) Retainer, Torque Converter.

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NOTE: Prior to installation of the engine, lubricate the torque converter pilot hub or damage to the torque converter or the engine crankshaft can occur.

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

Material: Motorcraft ® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)

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NOTE: During installation of the engine, the engine oil cooler will pass very close to the frame crossmember. Install the engine slowly, continually checking to make sure the engine oil cooler does not hit the frame crossmember, or component damage may occur.

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

Using the floor crane and the ratchet strap, install the engine into the vehicle and join the engine to the transmission. Use the General Equipment: Floor Crane

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Install the RH bellhousing bolts.
Torque: 35 lb.ft (48 Nm)

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Install the LH bellhousing bolts.
Torque: 35 lb.ft (48 Nm)

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Remove the transmission jack. Use the General Equipment: Transmission Jack
Install the lower engine bellhousing bolts.
Torque: 35 lb.ft (48 Nm)

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- Lower the engine into position.
- Remove the ratchet strap.
- Remove the floor crane. Use the General Equipment: Floor Crane
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NOTE: Failure to replace the engine mount cross bolts may result in engine mount damage.

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

Install the LH engine mount cross bolt.

Torque: 258 lb.ft (350 Nm)

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NOTE: Failure to replace the engine mount cross bolts may result in engine mount damage.

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

Install the RH engine mount cross bolt.

Torque: 258 lb.ft (350 Nm)

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NOTE: Failure to replace the transmission support insulator nuts may result in transmission support insulator damage.

Remove and discard the transmission support insulator nuts.

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Tighten the transmission support insulator studs.
Torque: 66 lb.ft (90 Nm)

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NOTE: Failure to replace the transmission support insulator nuts may result in transmission support insulator damage.

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

Install new transmission support insulator nuts.

Torque: 85 lb.ft (115 Nm)

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Remove Special Service Tool: 303-050 (T70P-6000) Lifting Bracket, Engine.
Torque: 18 lb.ft (25 Nm)

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Remove Special Service Tool: 303-1518 Bracket, Engine Removal.

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Position the turbocharger inlet boot.

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Remove and discard the turbocharger oil supply filter.

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Install a new turbocharger oil supply filter.

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Install a new turbocharger mounting gasket.

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Install the turbocharger and the new bolts.
Torque:

Stage 1: 133 lb.in (15 Nm)

Stage 2: 41 lb.ft (55 Nm)

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Tighten the turbocharger inlet boot clamps.
Torque: 35 lb.in (4 Nm)

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Lubricate the O-ring. Position back the turbocharger coolant outlet tube and install the new bolt.
Material: Motorcraft ® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

Torque:

Stage 1: 106 lb.in (12 Nm)

Stage 2: 30 °

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NOTE: Clean all exhaust connections before assembly.

Install a new LH turbocharger inlet pipe gasket.

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NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.

Install the LH turbocharger inlet pipe and position the new turbocharger clamp. Install the new nuts.

Torque: 18 lb.ft (25 Nm)

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NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.

Tighten the LH turbocharger inlet pipe clamp.

Torque:

Stage 1: 150 lb.in (17 Nm)

Stage 2: Loosen : 3 turn(s)

Stage 3: 159 lb.in (18 Nm)

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NOTE: Do not tighten the clamp at this time.

Install the turbocharger outlet pipe and clamp.

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Install the turbocharger outlet pipe bolt hand tight.

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Tighten the turbocharger outlet pipe clamp.
Torque:

Stage 1: 150 lb.in (17 Nm)

Stage 2: Loosen : 3 turn(s)

Stage 3: 159 lb.in (18 Nm)

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Install the turbocharger outlet pipe bolt.
Torque: 18 lb.ft (25 Nm)

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NOTE: Clean all exhaust connections before assembly.

Install a new RH turbocharger inlet pipe gasket.

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NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.

Install the RH turbocharger inlet pipe and position the new turbocharger clamp. Install the new nuts.

Torque: 18 lb.ft (25 Nm)

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NOTE: Do not bend or twist the turbocharger inlet pipes or damage to the bellows on the turbocharger inlet pipes may occur.

Tighten the RH turbocharger inlet pipe clamp.

Torque:

Stage 1: 150 lb.in (17 Nm)

Stage 2: Loosen : 3 turn(s)

Stage 3: 159 lb.in (18 Nm)

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Install the turbocharger heat shield and bolts.
Torque: 89 lb.in (10 Nm)

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Install the CAC pipe and position back the clip.

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Install the new upper intake manifold gaskets.

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NOTE: Remove the covers or tape from the rocker covers and the lower intake.

Install the upper intake manifold and tighten the retainers.

Torque:

Stage 1: 89 lb.in (10 Nm)

Stage 2: 98 °

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Install the engine and transmission oil level indicator tube bolts and nut.
Torque:

Engine oil level indicator tube nut: 89 lb.in (10 Nm)

Engine oil level indicator tube bolt: 89 lb.in (10 Nm)

Transmission oil level indicator tube: 97 lb.in (11 Nm)

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Install the bolt for the transmission fluid level indicator tube.
Torque: 18 lb.ft (25 Nm)

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1. Install the EP (exhaust pressure) sensor tube assembly and nut. Tighten the EP sensor tube assembly.
  Torque: 133 lb.in (15 Nm)
2. Tighten the nut.
  Torque: 89 lb.in (10 Nm)
3. Tighten the EP sensor tube assembly.
  Torque: 177 lb.in (20 Nm)
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- Connect the MAP sensor, EP sensor, EGRT sensor and the turbocharger actuator electrical connectors.
- Connect the wiring harness retainers.
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Connect the coolant hose retainer to the upper intake manifold.

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Connect the coolant hoses to the engine front cover tubes.

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Install a new power steering tube O-ring seal.

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Position back the power steering hose and install the bolt.
Torque: 18 lb.ft (25 Nm)

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Install the retainer to the power steering line bracket.
Torque: 44 lb.in (5 Nm)

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NOTE: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. To prevent fuel system damage, it is essential that absolute cleanliness is observed when working with these components.

Position back the fuel tubes and connect the tubes. Refer to: Quick Release Coupling .

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Install the fuel tube bracket bolts to the transmission bellhousing.
Torque: 35 lb.ft (48 Nm)

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Install the fuel tube bracket bolt.
Torque: 85 lb.ft (115 Nm)

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Connect the heater hose retainer to the frame. Connect the heater hose to the retainers.

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Position the transmission cooler tubes to the RH side of the engine and install the bracket nut.
Torque: 106 lb.in (12 Nm)

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If necessary, remove the backing rings and band seals from the transmission.

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- Inspect the backing rings and the band seals, replace if necessary.
- Lubricate the backing rings and the band seals.
  Material: Motorcraft ® MERCON ® LV Automatic Transmission Fluid / XT-10-QLVC (MERCON ® LV) (WSS-M2C938-A)
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Position back the transmission cooler tubes and install the bolt.
Torque: 18 lb.ft (25 Nm)

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Install the cooling fan stator and nuts.
Torque: 159 lb.in (18 Nm)

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Connect the coolant hose retainer to the cooling fan stator.

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Position back the wire harness and install the bracket bolt and the ground wire bolt.
Torque: 22 lb.ft (30 Nm)

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NOTE: Using the crankshaft pulley bolts, turn the engine clockwise.

Install the new torque converter nuts.

Torque: 41 lb.ft (55 Nm)

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Install the access cover and the retainers.

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Install the starter motor and the bolts.
Torque: 18 lb.ft (25 Nm)

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Position back the starter cables and install the nuts.
Torque:

Large nut: 106 lb.in (12 Nm)

Small nut: 53 lb.in (6 Nm)

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Install the starter cable cover.

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If equipped, connect the block heater electrical connector.

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Install the exhaust downpipe and the new nuts.
Torque: 22 lb.ft (30 Nm)

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Tighten the clamp for the exhaust downpipe.
Torque: 41 lb.ft (55 Nm)

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Install the new exhaust downpipe bolts.
Torque: 26 lb.ft (35 Nm)

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Install a new oil filter.
Material: Motorcraft ® SAE 10W-30 Super Duty Diesel Motor Oil / XO-10W30-QSDF (WSS-M2C171-F1)

Torque:

Stage 1: 44 lb.in (5 Nm)

Stage 2: 230 °

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Fill the engine with the correct engine oil for the climate. Refer to: Specifications .
NOTE: Carry out the following 4 steps if installing a new engine, long block or short block to remove any contaminants from the radiator and heater core.
Remove the primary cooling system radiator. Refer to: Radiator .
NOTE: Radiator internal pressure must not exceed 138 kPa (20 psi). Damage to the radiator can result.

NOTE: Dispose of old coolant and flushing water contaminated with antifreeze and cleaning chemicals in accordance with local, state or federal laws.
- Backflush the radiator using a garden hose with the radiator rotated so the lower radiator hose location is at the top.
- Use a garden hose in the lower hose location and backflush.
NOTE: Heater core internal pressure must not exceed 138 kPa (20 psi). Damage to the heater core can result.

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

Backflush the heater core using a garden hose in the heater core outlet hose.
Install the primary cooling system radiator. Refer to: Radiator .
Install the body. Refer to: Body - 6.7L Power Stroke Diesel .
Bleed the fuel system. Refer to: Fuel System Bleeding .
Start the engine and check the exhaust for leaks.
Check the transmission fluid level. Refer to: Transmission Fluid Level Check .