Engine - Body On

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	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	307-346 (T97T-7902-A) Retainer, Torque Converter TKIT-1998-LM (NavigatoR) TKIT-1997-F/FLM/LT
Floor Crane
Transmission Jack
Hose Clamp Remover/Installer

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

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 can be removed, refer to Engine - Body Off .

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: 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: 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.

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 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 .
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.
- Position the engine in the vehicle. Allowing the engine to roll forward, install the engine. Use the General Equipment: Floor Crane
- Once the engine has cleared the crossmember. Install a ratchet strap.
- Using the ratchet strap, level the engine.
- Install the engine to the transmission.
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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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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)

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Install the oil level indicator tube.

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Refer to: Transmission Filler Tube - 6.7L Power Stroke Diesel .
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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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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Refer to: Starter Motor .
If equipped, connect the block heater electrical connector.

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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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Refer to: Exhaust Gas Recirculation (EGR) Cooler .
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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Install a new O-ring seal on the heater supply tube and lubricate.
Material: Motorcraft ® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

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Install the heater supply tube and the bolts.
Torque: 89 lb.in (10 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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Refer to: Exhaust Downpipe .
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 turbocharger inlet hose.

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Install the lower intake manifold and the bolts.
Torque: 18 lb.ft (24 Nm)

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

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

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Connect the EGRT sensor electrical connector and the wire retainers.

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Connect the TB (throttle body) electrical connector.

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Refer to: Crankcase Vent Oil Separator .
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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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 heater hose at the heater supply tube.

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Position back the heater hose and connect the retainers.

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Connect the heater hose.

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Install a new O-ring seal.

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Position the evaporator-to-compressor suction tube fitting and install the nut.
Torque: 159 lb.in (18 Nm)

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Install the PCM, the bracket and the nuts.
Torque: 80 lb.in (9 Nm)

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- Position back the wire harness and connect the retainers.
- Position back the ground wire and install the retainer.
  Torque: 106 lb.in (12 Nm)
- Connect the PCM electrical connectors and the electrical connector.
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- Connect the PCM electrical connector and the electrical connectors.
- Connect the retainer.
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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: Dual generator cable harness shown.
- Connect the retainers and electrical connectors.
- Install the cable nut.
  Torque: 80 lb.in (9 Nm)
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Position back the ground cable and install the ground bolt at the RH fender.
Torque: 106 lb.in (12 Nm)

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Connect the electrical connector at the RH fender.

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Connect the battery cable retainer.

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Position back the cable. Connect the retainer and install the nut.
Torque: 97 lb.in (11 Nm)

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Install the power distribution cover.

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Position back the ground strap and install the retainer.
Torque: 106 lb.in (12 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 lower radiator hose and install the clip.

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Connect the coolant hose and install the clip.

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Position back the lower radiator hose and install the bolts.
Torque: 53 lb.in (6 Nm)

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Connect the coolant hoses to the engine front cover tubes.

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Position back the power steering pump and bolts.
Torque: 18 lb.ft (25 Nm)

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

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If equipped with single generator, install the accessory drive belt.

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If equipped with dual generators, install the accessory drive belt.

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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)

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- Install the fan clutch electrical connector bolt.
  Torque: 18 lb.ft (25 Nm)
- Connect the fan clutch electrical connector.
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Install the cooling fan stator and nuts.
Torque: 159 lb.in (18 Nm)

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NOTE: Vehicle with brake booster shown, vehicles with Hydro-Boost ® similar.

Connect the vacuum hose and the retainers.

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Connect the coolant hoses and the retainer. Use the General Equipment: Hose Clamp Remover/Installer

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Fill the engine with the correct engine oil for the climate. Refer to: Specifications .
Install the following items:
1. Refer to: Cowl Panel Grille .
2. Refer to: Battery Tray .
3. Refer to: Air Cleaner Outlet Pipe .
4. Refer to: Air Cleaner .
5. Refer to: Charge Air Cooler (CAC) .
6. Refer to: Charge Air Cooler (CAC) Outlet Pipe .
7. Refer to: Charge Air Cooler (CAC) Intake Pipe .
8. Refer to: Cooling Module .
Bleed the fuel system. Refer to: Fuel System Bleeding .
Start the engine and check the exhaust for leaks.