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Section 634 (Engine - 3.0L Power Stroke Diesel): Assembly: Engine

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Special Tool(s) / General Equipment 

GFD554425Courtesy of FORD MOTOR COMPANY
 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge
GFD555958Courtesy of FORD MOTOR COMPANY
 303-1670 Pins, Camshaft Locking
GFD555999Courtesy of FORD MOTOR COMPANY
 303-1671 Pin, Locking Crankshaft
GFD556000Courtesy of FORD MOTOR COMPANY
 303-1672 Installer, Crankshaft Seal
GFD555959Courtesy of FORD MOTOR COMPANY
 303-1673 Installer, Camshaft Seal
GFD555960Courtesy of FORD MOTOR COMPANY
 303-1674 Tool, Holding Camshaft Sprocket
GFD556009Courtesy of FORD MOTOR COMPANY
 303-1676 Installer, Crankshaft Position Sensor Ring
GFD556001Courtesy of FORD MOTOR COMPANY
 303-1677 Locking Tool, Flywheel
GFD556204Courtesy of FORD MOTOR COMPANY
 303-1678 Remover, Fuel Pump Pulley Holding Tool
GFD556497Courtesy of FORD MOTOR COMPANY
 303-1679 Timing Tool, Fuel Pump Rear Access
GFD556020Courtesy of FORD MOTOR COMPANY
 303-1681 Spreader Bar
Floor Crane
Mounting Stand
Hose Clamp Remover/Installer
Piston Ring Compressor

Materials 

Name Specification
Motorcraft® Thread Sealant with PTFETA-24-B WSK-M2G350-A2
Motorcraft® High Performance Engine RTV SiliconeTA-357 WSE-M4G323-A6
Flange SealantCU7Z-19B508-A WSS-M2G348-A11
Motorcraft® SAE 5W-30 F-150 Diesel Motor OilXO-5W30-QFA WSS-M2C214-B1
NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.
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 in this information.
NOTE: Assembly of the engine requires various inspections/measurements of the engine components. These inspections/measurements will aid in determining if the engine components will require replacement. Refer to ENGINE SYSTEM - GENERAL INFORMATION .
NOTE: Refer to the exploded view under the Engine Component View in the Description and Operation.
  1. If equipped, install the block heater.

    Torque: 41 lb.ft (55 Nm)

    GFD556454Courtesy of FORD MOTOR COMPANY
  2. If removed. Install the cylinder block to flywheel housing dowels.
    GFD556498Courtesy of FORD MOTOR COMPANY
  3. Install the engine oil filter.
    GFD556499Courtesy of FORD MOTOR COMPANY
  4. Install the crankcase vent gaskets.
    GFD556500Courtesy of FORD MOTOR COMPANY
  5. Install the piston cooling jets and bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556450Courtesy of FORD MOTOR COMPANY
  6. Measure the length or distance in two directions.

    • Record the smallest measurement for each crankshaft main bearing journal.

    GFD556501Courtesy of FORD MOTOR COMPANY
  7. NOTE: Only tighten the bolts finger tight at this stage.

    Install the main bearing caps and the bolts.

    GFD556502Courtesy of FORD MOTOR COMPANY
  8. NOTE: Only tighten the bolts finger tight at this stage.
    NOTE: RH side shown, LH side similar.

    Install the main bearing cap side bolts.

    GFD556503Courtesy of FORD MOTOR COMPANY
  9. Tighten the main bearing bolts.

    Torque: Stage 1: Tighten bolts 1 thru 16 to : 30 lb.ft (40 Nm)

    Stage 2: Tighten bolts 1 thru 16 to : 66 lb.ft (90 Nm)

    Stage 3: Tighten bolts 1 thru 16, an additional : 45°

    Stage 4: Tighten bolts 1 thru 16, a second time, an additional : 45°

    Stage 5: Tighten bolts 17 thru 24 to : 124 lb.in (14 Nm)

    Stage 6: Tighten bolts 17 thru 24, an additional : 45°

    GFD556504Courtesy of FORD MOTOR COMPANY
  10. Measure each crankshaft block main bearing bore diameter.
    GFD556505Courtesy of FORD MOTOR COMPANY
  11. NOTE: This chart is continued in the next step.

    Using the chart, select the crankshaft main bearings.

    GFD556506Courtesy of FORD MOTOR COMPANY
  12. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.

    Using the original connecting rod cap bolts, install the connecting rod caps and bolts.

    Torque: Stage 1: 177 lb.in (20 Nm)

    Stage 2: 22 lb.ft (30 Nm)

    Stage 3: 90°

    GFD556507Courtesy of FORD MOTOR COMPANY
  13. Measure the connecting rod large end bore in 2 directions.
    GFD556508Courtesy of FORD MOTOR COMPANY
  14. Remove the bolts and the connecting rod caps. Discard the bolts.
    GFD556509Courtesy of FORD MOTOR COMPANY
  15. Measure the length or distance in two directions.

    • Record the smallest measurement for each crankshaft main bearing journal.

    GFD556510Courtesy of FORD MOTOR COMPANY
  16. Using the chart, select the correct connecting rod bearings for each crankshaft connecting rod journal.
    GFD556511Courtesy of FORD MOTOR COMPANY
  17. NOTE: RH side shown, LH side similar.

    Remove and discard the main bearing cap side bolts.

    GFD556512Courtesy of FORD MOTOR COMPANY
  18. Remove the bolts and the main bearing caps.

    • Discard the bolts.

    GFD556513Courtesy of FORD MOTOR COMPANY
  19. NOTE: Before assembling the cylinder block, all sealing surfaces must be free of chips, dirt, paint and foreign material. Also, make sure the coolant and oil passages are clear.
    NOTE: If reusing the crankshaft main bearings, install them in their original positions and orientation as noted during disassembly.

    Install the upper crankshaft bearings and lubricate.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    GFD556514Courtesy of FORD MOTOR COMPANY
  20. Lubricate with clean engine oil and install the crankshaft.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    GFD556515Courtesy of FORD MOTOR COMPANY
  21. Lubricate the crankshaft lower main bearings with clean engine oil and install them into the main bearing caps. Check seating and squareness of the bearings to make sure of proper seating in caps.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    GFD556516Courtesy of FORD MOTOR COMPANY
  22. NOTE: Only tighten the bolts finger tight at this stage.

    Install the main bearing caps and the bolts.

    GFD556517Courtesy of FORD MOTOR COMPANY
  23. NOTE: Only tighten the bolts finger tight at this stage.
    NOTE: RH side shown, LH side similar.

    Install the main bearing cap side bolts.

    GFD556445Courtesy of FORD MOTOR COMPANY
  24. Tighten the main bearing bolts.

    Torque: Stage 1: Tighten bolts 1 thru 6 and 9 thru 14 to : 30 lb.ft (40 Nm)

    Stage 2: Tighten bolts 1 thru 6 and 9 thru 14 to : 66 lb.ft (90 Nm)

    Stage 3: Tighten bolts 1 thru 6 and 9 thru 14, an additional : 45°

    Stage 4: Tighten bolts 1 thru 6 and 9 thru 14, a second time, an additional : 45°

    GFD556518Courtesy of FORD MOTOR COMPANY
  25. Push the crankshaft forward to the front of the engine to align the thrust bearings to the cylinder block.
    GFD556519Courtesy of FORD MOTOR COMPANY
  26. Tighten the main bearing bolts.

    Torque: Stage 1: Tighten bolts 15-16 and 7-8 to : 30 lb.ft (40 Nm)

    Stage 2: Tighten bolts 15-16 and 7-8 to : 66 lb.ft (90 Nm)

    Stage 3: Tighten bolts 15-16 and 7-8, an additional : 45°

    Stage 4: Tighten bolts 15-16 and 7-8, a second time, an additional : 45°

    Stage 5: Tighten bolts 17 thru 24 to : 124 lb.in (14 Nm)

    Stage 6: Tighten bolts 17 thru 24, an additional : 45°

    Fig 1: Main Bearing Tightening Sequence
    GFD556518Courtesy of FORD MOTOR COMPANY
    • Position the crankshaft to the rear of the cylinder block. Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.

    • Zero the Dial Indicator Gauge.

    • Move the crankshaft to the front of the cylinder block. Measure and record the crankshaft end play. Refer to: Specifications .

    GFD556520Courtesy of FORD MOTOR COMPANY
  28. NOTE: If reusing the connecting rod bearings, install them in their original positions and orientation as noted during disassembly.

    Install the connecting rod bearings and lubricate.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    GFD556521Courtesy of FORD MOTOR COMPANY
  29. NOTE: The arrow on the top of the piston indicates the front of the engine.

    1. Upper compression ring gap location
    2. Lower compression ring gap location.
    3. Piston oil control ring gap location.
    4. Piston oil control ring gap location.

    GFD556496Courtesy of FORD MOTOR COMPANY
  30. NOTE: Be sure not to scratch the cylinder wall or crankshaft journal with the connecting rod. Be sure not to damage or bend the piston oil cooling jets when seating the connecting rod on the crankshaft journal. Push the piston down until the connecting rod bearing seats on the crankshaft journal.
    NOTE: Lubricate the pistons, piston rings, connecting rod bearings and the entire cylinder bores with clean engine oil.
    NOTE: If the piston and or connecting rod are being installed new, the piston rod orientation marks and the arrow on the top of the dome of the piston should be facing toward the front of the engine block.
    NOTE: If the piston and connecting rod are to be reinstalled, they must be installed in the same orientation as disassembled.

    Using the Piston Ring Compressor, install the piston and connecting rod assemblies. Repeat until all 6 piston assemblies are installed. Use the General Equipment: Piston Ring Compressor

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    GFD556522Courtesy of FORD MOTOR COMPANY
  31. NOTE: The rod cap installation must keep the same orientation as marked during disassembly or engine damage may occur.
    NOTE: After installation of each piston, connecting rod, rod cap and bolts, rotate the crankshaft to verify smooth operation.

    Install the connecting rod cap and the new bolts.

    Torque: Stage 1: 177 lb.in (20 Nm)

    Stage 2: 22 lb.ft (30 Nm)

    Stage 3: 90°

    GFD556442Courtesy of FORD MOTOR COMPANY
  32. NOTE: Only rotate the oil pump in the clockwise direction when viewed from the front. Counter clockwise rotation will cause damage to the oil pump assembly.

    Prime the oil pump. Add 2 tablespoons of clean engine oil to the oil pump and rotate the oil pump by hand.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

  33. Install a new oil pump gasket.
    GFD556125Courtesy of FORD MOTOR COMPANY
  34. Install the oil pump and the bolts.

    Torque: Torque all bolts to: : 89 lb.in (10 Nm) Tighten bolts 1, 2 and 3 a second time to: : 89 lb.in (10 Nm)

    GFD556523Courtesy of FORD MOTOR COMPANY
  35. Install the oil pump body-to-cylinder block seals.
    GFD556121Courtesy of FORD MOTOR COMPANY
  36. NOTE: Rotate the seal as the seal is being installed on the crankshaft.

    Using the special tool, position the crankshaft front seal on the crankshaft. Use Special Service Tool: 303-1672 Installer, Crankshaft Seal.

    GFD556524Courtesy of FORD MOTOR COMPANY
  37. Using the special tool, install the crankshaft front seal. Use Special Service Tool: 303-1672 Installer, Crankshaft Seal.
    GFD556525Courtesy of FORD MOTOR COMPANY
  38. Install special tool.

    • NOTE: Only rotate the crankshaft clockwise.
      NOTE: The Locking Crankshaft Pin must be bottomed out against the cylinder block.

      Rotate the crankshaft clockwise so the crankshaft contacts the locking crankshaft pin. Use Special Service Tool: 303-1671 Pin, Locking Crankshaft.

    GFD556416Courtesy of FORD MOTOR COMPANY
  39. Verify that the crankshaft is correctly located against the locking crankshaft pin.
    GFD556526Courtesy of FORD MOTOR COMPANY
  40. NOTE: Align the crankshaft sprocket tab with the rib of the oil pump.
    NOTE: Final torque will be done after the engine is off the mounting stand.

    Install the crankshaft sprocket and the bolt.

    Torque: 74 lb.ft (100 Nm)

    GFD556527Courtesy of FORD MOTOR COMPANY
  41. Install the crankshaft rear seal retainer and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556528Courtesy of FORD MOTOR COMPANY
  42. NOTE: Make sure that the locating pin on the special tool is aligned with the crankshaft timing trigger wheel hole.

    Using the special tool, install the crankshaft timing trigger wheel. Use Special Service Tool: 303-1676 Installer, Crankshaft Position Sensor Ring.

    GFD556017Courtesy of FORD MOTOR COMPANY
  43. Install the CKP sensor and bolt.

    Torque: 44 lb.in (5 Nm)

    GFD556435Courtesy of FORD MOTOR COMPANY
  44. Install the CKP sensor cover.
    GFD556434Courtesy of FORD MOTOR COMPANY
  45. Install the engine block skirt stiffener alignment dowels.
    GFD556334Courtesy of FORD MOTOR COMPANY
  46. NOTE: The engine block skirt stiffener and the bolts must be installed with 4 minutes of sealant application. Final tightening of the engine block skirt stiffener bolts must be carried out within 60 minutes of sealant application.

    Apply a 8.0 mm bead of Motorcraft® High Performance Engine RTV Silicone to the engine block T-joints.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    GFD556529Courtesy of FORD MOTOR COMPANY
  47. Install a new engine block skirt stiffener gasket.
    GFD556530Courtesy of FORD MOTOR COMPANY
  48. Install the engine block skirt stiffener and the bolts.

    Torque: Stage 1: 18 lb.in (2 Nm)

    Stage 2: 89 lb.in (10 Nm)

    GFD556531Courtesy of FORD MOTOR COMPANY
  49. NOTE: Failure to use Motorcraft® High Performance Engine RTV Silicone may cause the engine oil to foam excessively and result in serious engine damage.

    Apply a 8 mm bead of Motorcraft® High Performance Engine RTV Silicone to the sealing surface of the oil pan.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    GFD556118Courtesy of FORD MOTOR COMPANY
    1. Install the oil pan and the 4 bolts. Tighten in the sequence shown.

      Torque: 89 lb.in (10 Nm)

    2. Install the remaining oil pan bolts.

      Torque: 89 lb.in (10 Nm)

    GFD556532Courtesy of FORD MOTOR COMPANY
  51. If removed, install the CCV (crankcase vent) separator to the fuel injection pump mounting bracket.
    GFD556431Courtesy of FORD MOTOR COMPANY
  52. Install the fuel injection pump mounting bracket and the bolts.

    Torque: 17 lb.ft (23 Nm)

    GFD556430Courtesy of FORD MOTOR COMPANY
  53. Install the fuel injection pump and the bolts.

    Torque: 17 lb.ft (23 Nm)

    GFD556429Courtesy of FORD MOTOR COMPANY
  54. Install the fuel injection pump bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556428Courtesy of FORD MOTOR COMPANY
  55. Install the oil cooler O-rings.
    GFD556112Courtesy of FORD MOTOR COMPANY
  56. 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.

    Install the oil cooler and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556427Courtesy of FORD MOTOR COMPANY
  57. NOTE: The largest measurement determines the choice of the cylinder head gasket.

    Check the piston protrusion. Refer to: Piston Protrusion Check .

  58. Install the LH cylinder head dowels and head gasket.
    GFD556533Courtesy of FORD MOTOR COMPANY
  59. NOTE: Using too much engine oil on the threads of the cylinder head bolts may cause damage to the threads and 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: The glow plugs protrude past the lower face of the cylinder head, any impact on the tip of the glow plug may result in glow plug damage.
    NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.

    Install the LH cylinder head and the new bolts.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    Torque: Stage 1: 177 lb.in (20 Nm)

    Stage 2: 30 lb.ft (40 Nm)

    Stage 3: 59 lb.ft (80 Nm)

    Stage 4: 180°

    GFD556534Courtesy of FORD MOTOR COMPANY
  60. NOTE: The largest measurement determines the choice of the cylinder head gasket.

    Check the piston protrusion. Refer to: Piston Protrusion Check .

  61. Install the RH cylinder head dowels and head gasket.
    GFD556535Courtesy of FORD MOTOR COMPANY
  62. NOTE: Using too much engine oil on the threads of the cylinder head bolts may cause damage to the threads and 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: The glow plugs protrude past the lower face of the cylinder head, any impact on the tip of the glow plug may result in glow plug damage.
    NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.

    Install the RH cylinder head and the new bolts.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    Torque: Stage 1: 177 lb.in (20 Nm)

    Stage 2: 30 lb.ft (40 Nm)

    Stage 3: 59 lb.ft (80 Nm)

    Stage 4: 180°

    GFD556536Courtesy of FORD MOTOR COMPANY
  63. NOTE: If the original hydraulic lash adjusters and roller followers are to be reinstalled, they must be installed in their original locations.

    1. Lubricate the RH hydraulic lash adjusters and roller followers with clean engine oil.

      Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    2. Install the hydraulic lash adjusters and roller followers.

    GFD555994Courtesy of FORD MOTOR COMPANY
  64. NOTE: Lubricate the camshafts with clean engine oil prior to installation.
    NOTE: Align the timing marks on the camshafts with the timing marks on the secondary timing chain.

    Install the RH camshafts, camshaft chain, secondary timing chain tensioner and the bolts.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    Torque: 89 lb.in (10 Nm)

    GFD556537Courtesy of FORD MOTOR COMPANY
  65. Apply sealer to the RH bearing caps.

    Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

    GFD555996Courtesy of FORD MOTOR COMPANY
  66. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
    NOTE: Tighten the camshaft bearing cap bolts one turn at a time.

    Apply clean engine oil to the camshaft bearing caps. Install camshaft bearing caps and the bolts.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    Torque: Stage 1: 9 lb.in (1 Nm)

    Stage 2: 44 lb.in (5 Nm)

    Stage 3: 89 lb.in (10 Nm)

    GFD556538Courtesy of FORD MOTOR COMPANY
  67. Remove the retaining pin.
    GFD555998Courtesy of FORD MOTOR COMPANY
  68. NOTE: If the original hydraulic lash adjusters and roller followers are to be reinstalled, they must be installed in their original locations.

    1. Lubricate the LH hydraulic lash adjusters and roller followers with clean engine oil.

      Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    2. Install the hydraulic lash adjusters and roller followers.

    GFD555981Courtesy of FORD MOTOR COMPANY
  69. NOTE: Coat the camshafts with clean engine oil prior to installation.
    NOTE: Align the timing marks on the camshafts with the timing marks on the secondary timing chain.

    Install the LH camshafts, camshaft chain, secondary timing chain tensioner and the bolts.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    Torque: 89 lb.in (10 Nm)

    GFD556539Courtesy of FORD MOTOR COMPANY
  70. Apply sealer to the LH bearing caps.

    Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

    GFD555983Courtesy of FORD MOTOR COMPANY
  71. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.
    NOTE: Tighten the camshaft bearing cap bolts one turn at a time.

    Apply clean engine oil to the camshaft bearing caps. Install camshaft bearing caps and the bolts.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    Torque: Stage 1: 9 lb.in (1 Nm)

    Stage 2: 44 lb.in (5 Nm)

    Stage 3: 89 lb.in (10 Nm)

    GFD556540Courtesy of FORD MOTOR COMPANY
  72. Remove the retaining pin.
    GFD555985Courtesy of FORD MOTOR COMPANY
  73. NOTE: Right side shown, left side front and rear similar.

    Using the special tool, install the camshaft seals. Use Special Service Tool: 303-1673 Installer, Camshaft Seal.

    GFD556541Courtesy of FORD MOTOR COMPANY
  74. NOTE: If the EOP sensor is to be reused, apply thread sealant.

    Install the EOP sensor.

    Material: Motorcraft® Thread Sealant with PTFE / TA-24-B (WSK-M2G350-A2)

    Torque: 159 lb.in (18 Nm)

    GFD556542Courtesy of FORD MOTOR COMPANY
  75. Install the dust shield. Install the timing belt idler pulleys and the bolts.

    Torque: Stage 1: 177 lb.in (20 Nm)

    Stage 2: 45°

    GFD556543Courtesy of FORD MOTOR COMPANY
  76. Install the coolant outlet connector gaskets.
    GFD556113Courtesy of FORD MOTOR COMPANY
  77. Install the oil cooler O-ring and lubricate with clean engine coolant. Refer to: Specifications .
    GFD556114Courtesy of FORD MOTOR COMPANY
  78. Install the coolant outlet connector and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556273Courtesy of FORD MOTOR COMPANY
  79. Install the coolant pump O-ring and lubricate with clean engine coolant. Refer to: Specifications .
    GFD556544Courtesy of FORD MOTOR COMPANY
  80. Install the coolant pump and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556423Courtesy of FORD MOTOR COMPANY
  81. NOTE: Only tighten the bolts finger tight at this stage.

    Install the timing belt tensioner and the bolt.

    GFD556140Courtesy of FORD MOTOR COMPANY
  82. NOTE: Use the original bolts for the special tool.

    Using the special tool, install the camshaft gear hubs and bolts. Use Special Service Tool: 303-1674 Tool, Holding Camshaft Sprocket.

    Torque: Stage 1: 59 lb.ft (80 Nm)

    Stage 2: 80°

    GFD556545Courtesy of FORD MOTOR COMPANY
  83. NOTE: Only tighten the bolts finger tight at this stage.

    Install the camshaft pulleys and the bolts.

    GFD556421Courtesy of FORD MOTOR COMPANY
  84. Install Special Service Tool: 303-1670 Pins, Camshaft Locking.
    GFD556546Courtesy of FORD MOTOR COMPANY
  85. NOTE: Make sure that a new component is installed.
    NOTE: It may be necessary to rotate the camshaft pulleys slightly to ensure the bolts are not at the end of the slots.

    1. Install the timing belt.
    2. Rotate the timing belt tensioner.
    3. Tighten the timing belt tensioner bolt.

      Torque: Stage 1: 177 lb.in (20 Nm)

      Stage 2: 45°

    GFD556547Courtesy of FORD MOTOR COMPANY
  86. If the timing belt tensioner pointer is not visible in the window, the timing belt tensioning step must be repeated.
    GFD556142Courtesy of FORD MOTOR COMPANY
  87. Tighten the camshaft pulley bolts.

    Torque: 17 lb.ft (23 Nm)

    GFD556269Courtesy of FORD MOTOR COMPANY
  88. Remove Special Service Tool: 303-1670 Pins, Camshaft Locking.
    GFD556420Courtesy of FORD MOTOR COMPANY
  89. Remove Special Service Tool: 303-1671 Pin, Locking Crankshaft.
    GFD556416Courtesy of FORD MOTOR COMPANY
  90. NOTE: Only rotate the crankshaft clockwise.

    This step is to verify that the timing is correct. Rotate the engine 1 7/8 revolutions.

  91. Install special tool.

    • NOTE: Only rotate the crankshaft clockwise.
      NOTE: The Locking Crankshaft Pin must be bottomed out against the cylinder block.

      Rotate the crankshaft clockwise so the crankshaft contacts the locking crankshaft pin. Use Special Service Tool: 303-1671 Pin, Locking Crankshaft.

    GFD556416Courtesy of FORD MOTOR COMPANY
  92. NOTE: The special tool can only be installed if the valve timing is correct.

    If the special tools do not install correctly, repeat the timing belt installation steps. Install Special Service Tool: 303-1670 Pins, Camshaft Locking.

    GFD556420Courtesy of FORD MOTOR COMPANY
  93. Install the fan drive and the bolts.

    Torque: 61 lb.ft (83 Nm)

    GFD556132Courtesy of FORD MOTOR COMPANY
  94. Install the rear engine cover lifting bracket.

    Torque: 17 lb.ft (23 Nm)

    GFD556419Courtesy of FORD MOTOR COMPANY
  95. NOTE: Only tighten the nut finger tight at this stage.

    Install the fuel injection pump pulley and nut.

    GFD556548Courtesy of FORD MOTOR COMPANY
  96. Using the special tool, tighten the fuel injection pump nut. Use Special Service Tool: 303-1678 Remover, Fuel Pump Pulley Holding Tool.

    Torque: 37 lb.ft (50 Nm)

    GFD556417Courtesy of FORD MOTOR COMPANY
  97. NOTE: Only tighten the bolts finger tight at this stage.

    Install the accessory drive cover.

    GFD555975Courtesy of FORD MOTOR COMPANY
  98. NOTE: Use the original bolts for the special tool.

    Using the special tool, install the camshaft gear hub and the bolt. Use Special Service Tool: 303-1674 Tool, Holding Camshaft Sprocket.

    Torque: Stage 1: 59 lb.ft (80 Nm)

    Stage 2: 80°

    GFD556549Courtesy of FORD MOTOR COMPANY
  99. Install the READ belt tensioner and the bolt.

    Torque: 17 lb.ft (23 Nm)

    GFD555974Courtesy of FORD MOTOR COMPANY
    1. NOTE: Make sure that the installation marks are aligned.
      NOTE: It may be necessary to rotate the camshaft pulley slightly to ensure the bolts are not at the end of the slots.
      NOTE: Install the camshaft pulley with the timing mark on the camshaft drive.
      NOTE: Only tighten the bolts finger tight at this stage.

      Install the READ belt, the camshaft pulley and the bolts.

    2. Remove the pin from the READ belt tensioner.
    3. Install Special Service Tool: 303-1679 Timing Tool, Fuel Pump Rear Access.
    4. Tighten the bolts for the camshaft pulley.

      Torque: 17 lb.ft (23 Nm)

    5. Tighten the bolts for the accessory drive cover.

      Torque: 89 lb.in (10 Nm)

    6. Remove Special Service Tool: 303-1679 Timing Tool, Fuel Pump Rear Access.
    GFD556550Courtesy of FORD MOTOR COMPANY
  101. Remove Special Service Tool: 303-1670 Pins, Camshaft Locking.
    GFD556420Courtesy of FORD MOTOR COMPANY
  102. Remove Special Service Tool: 303-1671 Pin, Locking Crankshaft.
    GFD556416Courtesy of FORD MOTOR COMPANY
  103. Install the timing pin bolt.

    Torque: 17 lb.ft (23 Nm)

    GFD556415Courtesy of FORD MOTOR COMPANY
  104. Install the RH valve cover gasket.
    GFD556200Courtesy of FORD MOTOR COMPANY
  105. NOTE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply an 6 mm dot of Motorcraft® High Performance Engine RTV Silicone to the locations shown.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    GFD556201Courtesy of FORD MOTOR COMPANY
  106. Install the RH valve cover and tighten the fasteners.

    Torque: Stage 1: Tighten bolt number 1 to : 9 lb.in (1 Nm)

    Stage 2: Tighten bolts 2 thru 14 to : 89 lb.in (10 Nm)

    GFD556551Courtesy of FORD MOTOR COMPANY
  107. Install the oil fill cap assembly.
    GFD556414Courtesy of FORD MOTOR COMPANY
  108. Connect the RH glow plug electrical connector.
    GFD556196Courtesy of FORD MOTOR COMPANY
  109. Install the turbocharger heat shield, the nut and the bolt.

    Torque: Nut : 53 lb.in (6 Nm) Bolt : 18 lb.ft (24 Nm)

    GFD556303Courtesy of FORD MOTOR COMPANY
  110. Install the LH valve cover gasket.
    GFD556181Courtesy of FORD MOTOR COMPANY
  111. NOTE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply an 6 mm dot of Motorcraft® High Performance Engine RTV Silicone to the locations shown.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    GFD556182Courtesy of FORD MOTOR COMPANY
  112. Install the LH valve cover and tighten the fasteners.

    Torque: Stage 1: Tighten bolt number 1 to : 9 lb.in (1 Nm)

    Stage 2: Tighten bolts 2 thru 14 to : 89 lb.in (10 Nm)

    GFD556552Courtesy of FORD MOTOR COMPANY
  113. Connect the LH glow plug electrical connector.
    GFD556177Courtesy of FORD MOTOR COMPANY
  114. Install the vacuum pump stud.

    Torque: 115 lb.in (13 Nm)

    GFD556413Courtesy of FORD MOTOR COMPANY
  115. Install the CMP sensor and the bolt.

    Torque: 89 lb.in (10 Nm)

    GFD556412Courtesy of FORD MOTOR COMPANY
  116. Install the RH fuel tube bracket and the nuts.

    Torque: 89 lb.in (10 Nm)

    GFD556194Courtesy of FORD MOTOR COMPANY
  117. Install the LH fuel tube bracket and the nuts.

    Torque: 89 lb.in (10 Nm)

    GFD556175Courtesy of FORD MOTOR COMPANY
  118. Install the RH fuel rail bracket and the bolts.

    Torque: 17 lb.ft (23 Nm)

    GFD556302Courtesy of FORD MOTOR COMPANY
  119. Install the LH fuel rail bracket and the bolts.

    Torque: 17 lb.ft (23 Nm)

    GFD556264Courtesy of FORD MOTOR COMPANY
  120. Install the sealing washer, the O-rings and the fuel injector hold down.
    GFD556553Courtesy of FORD MOTOR COMPANY
  121. NOTE: Only tighten the bolts finger tight at this stage.

    Install the RH fuel injectors and bolts.

    GFD556301Courtesy of FORD MOTOR COMPANY
  122. NOTE: Only tighten the bolts finger tight at this stage.

    Install the LH fuel injectors and bolts.

    GFD556261Courtesy of FORD MOTOR COMPANY
  123. Install the LH fuel injector noise insulator.
    GFD556260Courtesy of FORD MOTOR COMPANY
  124. Install the RH fuel injector noise insulator.
    GFD556300Courtesy of FORD MOTOR COMPANY
  125. Install the fuel injection pump noise insulator.
    GFD556411Courtesy of FORD MOTOR COMPANY
  126. NOTE: Only tighten the bolts finger tight at this stage.

    Install the LH fuel rail and the bolts.

    GFD556259Courtesy of FORD MOTOR COMPANY
  127. NOTE: Only tighten the bolts finger tight at this stage.

    Install the RH fuel rail and the bolts.

    GFD556299Courtesy of FORD MOTOR COMPANY
  128. NOTE: The component must be installed by hand before final tightening.

    Install the fuel injection pump balance tube.

    GFD556554Courtesy of FORD MOTOR COMPANY
  129. NOTE: The component must be installed by hand before final tightening.

    Install the LH fuel injector supply tubes.

    GFD556555Courtesy of FORD MOTOR COMPANY
  130. NOTE: The component must be installed by hand before final tightening.

    Install the LH fuel rail supply tube.

    GFD556556Courtesy of FORD MOTOR COMPANY
  131. NOTE: Only tighten the bolts finger tight at this stage.

    Install the LH fuel injector supply tube clamps.

    GFD556557Courtesy of FORD MOTOR COMPANY
  132. NOTE: Only tighten the bolts finger tight at this stage.

    Install the fuel tube clamps and the bolts.

    GFD556558Courtesy of FORD MOTOR COMPANY
  133. NOTE: The component must be installed by hand before final tightening.

    Install the RH fuel injector supply tubes.

    GFD556559Courtesy of FORD MOTOR COMPANY
  134. NOTE: The component must be installed by hand before final tightening.

    Install the RH fuel rail supply tube.

    GFD556560Courtesy of FORD MOTOR COMPANY
  135. NOTE: Only tighten the bolt finger tight at this stage.

    Install the RH fuel injector supply tube clamp.

    GFD556561Courtesy of FORD MOTOR COMPANY
  136. NOTE: Only tighten the bolt finger tight at this stage.

    Install the fuel tube bracket bolt.

    GFD556408Courtesy of FORD MOTOR COMPANY
    1. Tighten the fuel tube clamp bolts.

      Torque: 89 lb.in (10 Nm)

    2. NOTE: Tighten the fuel injector hold down bolts evenly.

      Tighten the fuel injector hold down bolts.

      Torque: 89 lb.in (10 Nm)

    3. Tighten the fuel rail bolts.

      Torque: 17 lb.ft (23 Nm)

    4. Tighten the fuel injector supply tubes.

      Torque: Stage 1: Tighten at the fuel rail: 89 lb.in (10 Nm)

      Stage 2: Tighten at the fuel injector: 89 lb.in (10 Nm)

      Stage 3: Tighten at the fuel rail: 142 lb.in (16 Nm)

      Stage 4: Tighten at the fuel injector: 142 lb.in (16 Nm)

      Stage 5: Tighten at the fuel rail: 50°

      Stage 6: Tighten at the fuel injector: 50°

    5. Tighten the fuel injection pump balance tube.

      Torque: Stage 1: 89 lb.in (10 Nm)

      Stage 2: 142 lb.in (16 Nm)

      Stage 3: 50°

    6. Tighten the fuel rail supply tubes.

      Torque: Stage 1: Tighten at the fuel rail: 89 lb.in (10 Nm)

      Stage 2: Tighten at the fuel injection pump: 89 lb.in (10 Nm)

      Stage 3: Tighten at the fuel rail: 142 lb.in (16 Nm)

      Stage 4: Tighten at the fuel injection pump: 142 lb.in (16 Nm)

      Stage 5: Tighten at the fuel rail: 50°

      Stage 6: Tighten at the fuel injection pump: 50°

    GFD556562Courtesy of FORD MOTOR COMPANY
  138. Install the fuel return hose assembly.
    GFD556563Courtesy of FORD MOTOR COMPANY
  139. Install the engine cover stud assemblies.

    Torque: 1 : 62 lb.in (7 Nm) 2 : 62 lb.in (7 Nm)

    GFD556564Courtesy of FORD MOTOR COMPANY
    • Install the RH exhaust manifold studs as needed.

      Torque: 115 lb.in (13 Nm)

    • Install the new RH exhaust manifold gasket.

    GFD556565Courtesy of FORD MOTOR COMPANY
  141. Install the RH exhaust manifold and the nuts.

    Torque: Tighten the nuts in the sequence shown to: : 21 lb.ft (28 Nm) Tighten the nuts in the following order 1, 2, 3, 5, 1, 2 to: : 21 lb.ft (28 Nm)

    GFD556566Courtesy of FORD MOTOR COMPANY
  142. Install the RH exhaust manifold heat shield and the bolts.

    Torque: 97 lb.in (11 Nm)

    GFD556567Courtesy of FORD MOTOR COMPANY
    • Install the LH exhaust manifold studs as needed.

      Torque: 115 lb.in (13 Nm)

    • Install the new LH exhaust manifold gasket.

    GFD556568Courtesy of FORD MOTOR COMPANY
  144. Install the LH exhaust manifold and the nuts.

    Torque: Tighten the nuts in the sequence shown to: : 21 lb.ft (28 Nm) Tighten the nuts in the following order 1, 2, 3, 5, 1, 2 to: : 21 lb.ft (28 Nm)

    GFD556569Courtesy of FORD MOTOR COMPANY
  145. Install the LH exhaust manifold heat shield and the bolts.

    Torque: 97 lb.in (11 Nm)

    GFD556570Courtesy of FORD MOTOR COMPANY
  146. Install the engine support bracket and the retainers.

    Torque: 62 lb.in (7 Nm)

    GFD556293Courtesy of FORD MOTOR COMPANY
  147. Install the heater hose support bracket and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556292Courtesy of FORD MOTOR COMPANY
  148. Install the wire harness bracket and the bolt.

    Torque: 89 lb.in (10 Nm)

    GFD556254Courtesy of FORD MOTOR COMPANY
  149. Install new gaskets on the intake manifold. Lubricate the gaskets with clean engine oil.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    GFD556101Courtesy of FORD MOTOR COMPANY
  150. NOTE: Install the intake manifold into the LH valve cover, then into the RH valve cover.

    Install the intake manifold, the stud bolt and the bolt.

    Torque: 89 lb.in (10 Nm)

    GFD556253Courtesy of FORD MOTOR COMPANY
  151. Install the front engine lifting eye and the bolts.

    Torque: 17 lb.ft (23 Nm)

    GFD556252Courtesy of FORD MOTOR COMPANY
  152. Install the fuel return tube assembly. Refer to: Quick Release Coupling .
    GFD556571Courtesy of FORD MOTOR COMPANY
  153. Install the fuel supply tube. Refer to: Quick Release Coupling .
    GFD556291Courtesy of FORD MOTOR COMPANY
  154. Install the fuel supply tube and the bolt. Refer to: Quick Release Coupling .

    Torque: 17 lb.ft (23 Nm)

    GFD556250Courtesy of FORD MOTOR COMPANY
  155. Install the accessory drive cover and the stud bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556249Courtesy of FORD MOTOR COMPANY
  156. Install the accessory drive cover.
    GFD556248Courtesy of FORD MOTOR COMPANY
  157. Install the wiring harness bracket, the nut and the bolt. Connect the retainers.

    Torque: 89 lb.in (10 Nm)

    GFD556247Courtesy of FORD MOTOR COMPANY
  158. Install the secondary fuel filter and the bolt. Connect the fuel line. Refer to: Quick Release Coupling .

    Torque: 89 lb.in (10 Nm)

    GFD556572Courtesy of FORD MOTOR COMPANY
  159. Install a new O-ring seal and lubricate with clean engine coolant. Refer to: Specifications .
    GFD556573Courtesy of FORD MOTOR COMPANY
  160. Install the coolant inlet connector and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556397Courtesy of FORD MOTOR COMPANY
  161. Install the EGR cooler brackets and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556396Courtesy of FORD MOTOR COMPANY
  162. NOTE: Only tighten the bolts finger tight at this stage.

    Install the EGR cooler and the bolts.

    GFD556574Courtesy of FORD MOTOR COMPANY
  163. Using new gaskets, install the EGR cooler-to-exhaust manifold pipe and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556082Courtesy of FORD MOTOR COMPANY
  164. Tighten the EGR cooler bolts.

    Torque: M6 bolt: 89 lb.in (10 Nm) M8 bolt: 17 lb.ft (23 Nm)

    GFD556575Courtesy of FORD MOTOR COMPANY
  165. Install the O-ring and the grommet on the EGR cooler coolant tube. Lubricate with clean engine coolant. Refer to: Specifications .
    GFD556083Courtesy of FORD MOTOR COMPANY
  166. Install the EGR cooler coolant tube and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556073Courtesy of FORD MOTOR COMPANY
  167. NOTE: Lubricate the O-ring seal prior to installing the oil level indicator tube.

    • Install the oil level indicator tube, the stud bolt and the bolt.

      Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

      Torque: M6 stud bolt: 89 lb.in (10 Nm) M8 bolt: 17 lb.ft (23 Nm)

    • Connect the wire retainers to the oil level indicator tube.

    GFD556071Courtesy of FORD MOTOR COMPANY
  168. Install the oil level indicator.
    GFD556070Courtesy of FORD MOTOR COMPANY
  169. Install the EP (exhaust pressure) sensor tube and hand start the tube nut. Install the stud bolt.

    Torque: M6 stud bolt: 89 lb.in (10 Nm) Tube nut : 177 lb.in (20 Nm)

    GFD556072Courtesy of FORD MOTOR COMPANY
  170. Install the LH exhaust manifold shield, the nut and the bolt.

    Torque: 89 lb.in (10 Nm)

    GFD556069Courtesy of FORD MOTOR COMPANY
  171. Install the front fuel tube support bracket and the nut.

    Torque: 89 lb.in (10 Nm)

    GFD556244Courtesy of FORD MOTOR COMPANY
  172. Install the fuel tube support bracket and the nuts.

    Torque: 89 lb.in (10 Nm)

    GFD556068Courtesy of FORD MOTOR COMPANY
  173. Install a new timing belt cover gasket.
    GFD556157Courtesy of FORD MOTOR COMPANY
  174. Install the timing belt cover, the stud bolts and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556155Courtesy of FORD MOTOR COMPANY
    • Using new gaskets, install the EGR outlet tube and the bolts.

      Torque: 89 lb.in (10 Nm)

    • Install the retainer in the timing belt cover.

      Torque: 31 lb.in (3.5 Nm)

    • Connect the wire retainers.

    GFD556576Courtesy of FORD MOTOR COMPANY
  176. Install the generator mounting bracket and the bolts.

    Torque: Install and tighten bolts 1 and 2 to: : 17 lb.ft (23 Nm) Install and tighten bolts 3 and 4 to: : 17 lb.ft (23 Nm)

    GFD556577Courtesy of FORD MOTOR COMPANY
  177. Install the A/C mounting bracket and the bolts.

    Torque: Install and tighten bolts 1 and 2 to: : 17 lb.ft (23 Nm) Install and tighten bolts 3 and 4 to: : 17 lb.ft (23 Nm) Install and tighten bolts 5 and 6 to: : 17 lb.ft (23 Nm)

    GFD556578Courtesy of FORD MOTOR COMPANY
  178. Install the coolant pump pulley and the bolts.

    Torque: 18 lb.ft (25 Nm)

    GFD556393Courtesy of FORD MOTOR COMPANY
  179. Install the crankshaft vibration damper and the bolts.

    Torque: 18 lb.ft (25 Nm)

    GFD556019Courtesy of FORD MOTOR COMPANY
  180. Install the accessory drive belt tensioner and the bolts.

    Torque: 18 lb.ft (25 Nm)

    GFD556242Courtesy of FORD MOTOR COMPANY
  181. Install the CAC bracket and the nuts.

    Torque: 53 lb.in (6 Nm)

    GFD556241Courtesy of FORD MOTOR COMPANY
  182. Install the fan pulley and the bolts.

    Torque: 18 lb.ft (25 Nm)

    GFD556152Courtesy of FORD MOTOR COMPANY
  183. Install the accessory drive belt tensioner and the bolt.

    Torque: 35 lb.ft (48 Nm)

    GFD556240Courtesy of FORD MOTOR COMPANY
  184. Install the coolant tube assembly O-rings and lubricate with clean engine coolant. Refer to: Specifications .
    GFD556579Courtesy of FORD MOTOR COMPANY
  185. Install the coolant tube assembly and the bolts.

    Torque: M6 bolt: 89 lb.in (10 Nm) M8 bolt: 18 lb.ft (25 Nm)

    GFD556391Courtesy of FORD MOTOR COMPANY
  186. Install the EGR cooler coolant hose and the clamps. Use the General Equipment: Hose Clamp Remover/Installer
    GFD556390Courtesy of FORD MOTOR COMPANY
  187. Install the coolant tube O-ring seal and lubricate with clean engine coolant. Refer to: Specifications .
    GFD556580Courtesy of FORD MOTOR COMPANY
  188. Install the coolant tube and the bolts.

    Torque: M6 bolt: 71 lb.in (8 Nm) M8 bolt: 18 lb.ft (25 Nm)

    GFD556388Courtesy of FORD MOTOR COMPANY
  189. Install the LH engine mount bracket and the bolts.

    Torque: 85 lb.ft (115 Nm)

    GFD556581Courtesy of FORD MOTOR COMPANY
  190. Install the RH engine mount bracket and the bolts.

    Torque: 76 lb.ft (103 Nm)

    GFD556386Courtesy of FORD MOTOR COMPANY
  191. Lubricate the O-ring seals with clean engine coolant. Install the new turbocharger coolant tube manifold and the bolt. Refer to: Specifications .

    Torque: 89 lb.in (10 Nm)

    GFD556582Courtesy of FORD MOTOR COMPANY
  192. Install the turbocharger studs and the gasket.

    Torque: 115 lb.in (13 Nm)

    GFD556583Courtesy of FORD MOTOR COMPANY
  193. Install the turbocharger and the nuts.

    Torque: Stage 1: 89 lb.in (10 Nm)

    Stage 2: 18 lb.ft (24 Nm)

    GFD556584Courtesy of FORD MOTOR COMPANY
  194. Position back the turbocharger coolant supply tube into the engine and install the bolt.

    Torque: 89 lb.in (10 Nm)

    GFD556287Courtesy of FORD MOTOR COMPANY
  195. NOTE: Fully seat the turbocharger oil return tube O-rings into the turbocharger and engine bore holes prior to fastener tightening.

    Lubricate the turbocharger oil return tube with clean engine oil. Install the turbocharger oil return tube and the bolts.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    Torque: 89 lb.in (10 Nm)

    GFD556585Courtesy of FORD MOTOR COMPANY
  196. NOTE: Fully seat the turbocharger oil supply tube O-rings into the turbocharger and engine bore holes prior to fastener tightening.

    Lubricate the turbocharger oil supply tube O-rings with clean engine oil. Install the turbocharger oil supply tube and the bolts.

    Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

    Torque: 89 lb.in (10 Nm)

    GFD556586Courtesy of FORD MOTOR COMPANY
  197. Install a new turbocharger coolant return tube O-ring seal. Lubricate the new O-ring seal and the tube sealing surface with clean engine coolant. Refer to: Specifications .
    GFD556587Courtesy of FORD MOTOR COMPANY
  198. Install the coolant return tube and the bolt.

    Torque: 89 lb.in (10 Nm)

    GFD556284Courtesy of FORD MOTOR COMPANY
  199. Install the exhaust crossover pipe bracket and the bolts.

    Torque: 17 lb.ft (23 Nm)

    GFD556385Courtesy of FORD MOTOR COMPANY
  200. Install the studs and the exhaust crossover pipe gaskets.

    Torque: 115 lb.in (13 Nm)

    GFD556588Courtesy of FORD MOTOR COMPANY
  201. NOTE: If any snaps become undone on the exhaust crossover pipe wrap. Install a new exhaust crossover pipe wrap.

    Install the exhaust crossover pipe, the nuts and the bolts.

    • Hand start the RH exhaust manifold nuts.

    • Hand start the LH exhaust manifold nuts.

    • Hand start the exhaust crossover pipe bracket bolts.

    • Tighten nuts 1 and 2 to:

      Torque: 89 lb.in (10 Nm)

    • Tighten nut 3 to:

      Torque: 18 lb.ft (24 Nm)

    • Tighten nuts 1 and 2 to:

      Torque: 18 lb.ft (24 Nm)

    • Tighten nuts 4 and 5 to:

      Torque: 89 lb.in (10 Nm)

    • Tighten nut 6 to:

      Torque: 18 lb.ft (24 Nm)

    • Tighten nuts 4 and 5 to:

      Torque: 18 lb.ft (24 Nm)

    • Tighten bolts 7 and 8 to:

      Torque: 18 lb.ft (24 Nm)

    GFD556589Courtesy of FORD MOTOR COMPANY
  202. Install the vacuum pump gasket.
    GFD556590Courtesy of FORD MOTOR COMPANY
  203. NOTE: If the vacuum pump is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

    Apply an 6 mm dot of Motorcraft® High Performance Engine RTV Silicone to the locations shown.

    Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

    GFD556164Courtesy of FORD MOTOR COMPANY
  204. NOTE: Manually align the brake vacuum pump drive key with the camshaft slot before installation.

    Align the brake vacuum pump drive key with the camshaft slot before installation.

    GFD556165Courtesy of FORD MOTOR COMPANY
  205. Install the vacuum pump and the retainers.

    Torque: Stage 1: Tighten bolt number 1 to: : 17 lb.ft (23 Nm)

    Stage 2: Tighten bolt number 2 to: : 17 lb.ft (23 Nm)

    Stage 3: Tighten bolt number 1 a second time to: : 17 lb.ft (23 Nm)

    Stage 4: Tighten the nut number 3 to: : 17 lb.ft (23 Nm)

    GFD556591Courtesy of FORD MOTOR COMPANY
  206. Install the lifting bracket and the bolts.

    Torque: 17 lb.ft (23 Nm)

    GFD556282Courtesy of FORD MOTOR COMPANY
  207. Install the valve bracket and the bolts.

    Torque: 89 lb.in (10 Nm)

    GFD556281Courtesy of FORD MOTOR COMPANY
  208. Install the vacuum hose assembly and the retainers. Connect the vacuum pump connector. Refer to: Quick Release Coupling .
    GFD556234Courtesy of FORD MOTOR COMPANY
  209. Install the ground strap and the nut.

    Torque: 106 lb.in (12 Nm)

    GFD556233Courtesy of FORD MOTOR COMPANY
  210. Position the engine wire harness on the engine and install the bolt. Connect the electrical wire retainers and the electrical connector.

    Torque: 89 lb.in (10 Nm)

    GFD556232Courtesy of FORD MOTOR COMPANY
  211. Connect the electrical connectors and the wire retainer.
    GFD556231Courtesy of FORD MOTOR COMPANY
  212. Connect the fuel injectors electrical connectors and the wire retainers.
    GFD556230Courtesy of FORD MOTOR COMPANY
  213. Connect the electrical connectors and the wire retainers.
    GFD556229Courtesy of FORD MOTOR COMPANY
  214. Connect the EGRT electrical connector and the wire retainers. Connect the turbocharger actuator electrical connector.
    GFD556592Courtesy of FORD MOTOR COMPANY
  215. Connect the electrical connectors and the wire retainer.
    GFD556227Courtesy of FORD MOTOR COMPANY
  216. Connect the fuel injectors electrical connectors and the wire retainers.
    GFD556226Courtesy of FORD MOTOR COMPANY
  217. Connect the electrical connectors and the wire retainers.
    GFD556225Courtesy of FORD MOTOR COMPANY
  218. Connect the EOP sensor electrical connector.
    GFD556224Courtesy of FORD MOTOR COMPANY
  219. Connect the EGR valve and the EP sensor electrical connectors. Disconnect the wire retainers.
    GFD556223Courtesy of FORD MOTOR COMPANY
  220. Connect the CKP electrical connector and the wire retainer.
    GFD556222Courtesy of FORD MOTOR COMPANY
  221. Connect the CMP electrical connector and the wire retainer.
    GFD556221Courtesy of FORD MOTOR COMPANY
  222. Connect the TB (throttle body) electrical connector and the wire retainer.
    GFD556220Courtesy of FORD MOTOR COMPANY
  223. Connect the oil pump electrical connector and the wire retainers.
    GFD556219Courtesy of FORD MOTOR COMPANY
  224. Remove the RH fuel injector noise insulator.
    GFD556218Courtesy of FORD MOTOR COMPANY
  225. Install the LH fuel injector noise insulator.
    GFD556217Courtesy of FORD MOTOR COMPANY
  226. Install the A/C compressor and the bolts.

    Torque: 18 lb.ft (25 Nm)

    GFD556384Courtesy of FORD MOTOR COMPANY
  227. Install the coolant hoses and connect the coolant hose connector.
    GFD556209Courtesy of FORD MOTOR COMPANY
  228. Install the battery cable harness and connect the wire harness retainer. Install the nuts.

    Torque: 106 lb.in (12 Nm)

    GFD556323Courtesy of FORD MOTOR COMPANY
  229. Connect the A/C electrical connectors and the wire retainer.
    GFD556322Courtesy of FORD MOTOR COMPANY
  230. Install the coolant tube and the nut.

    Torque: 106 lb.in (12 Nm)

    GFD556321Courtesy of FORD MOTOR COMPANY
  231. Position back and connect the coolant hose. Install the nut for the coolant hose bracket.

    Torque: 106 lb.in (12 Nm)

    GFD556320Courtesy of FORD MOTOR COMPANY
  232. Install the bolt for the coolant tube.

    Torque: 62 lb.in (7 Nm)

    GFD556319Courtesy of FORD MOTOR COMPANY
  233. Install the floor crane and special tool. Use Special Service Tool: 303-1681 Spreader Bar. Use the General Equipment: Floor Crane
    GFD556318Courtesy of FORD MOTOR COMPANY
  234. Using a floor crane, remove the engine from the mounting stand. Use the General Equipment: Floor Crane Use the General Equipment: Mounting Stand
    GFD556317Courtesy of FORD MOTOR COMPANY
  235. Install the flexplate and the bolts.
    GFD556593Courtesy of FORD MOTOR COMPANY
  236. NOTE: Only rotate the crankshaft clockwise.

    Install the special tool and the bolts. Use Special Service Tool: 303-1677 Locking Tool, Flywheel.

    GFD556003Courtesy of FORD MOTOR COMPANY
  237. Tighten the flexplate bolts. Use Special Service Tool: 303-1677 Locking Tool, Flywheel.

    Torque: Stage 1: 37 lb.ft (50 Nm)

    Stage 2: 45°

    Stage 3: 45°

    GFD556594Courtesy of FORD MOTOR COMPANY
  238. Final tighten the crankshaft bolt.

    Torque: Stage 1: 221 lb.ft (300 Nm)

    Stage 2: 90°

    GFD556595Courtesy of FORD MOTOR COMPANY
  239. Remove the bolts and the special tool. Use Special Service Tool: 303-1677 Locking Tool, Flywheel.
    GFD556003Courtesy of FORD MOTOR COMPANY
  240. Install the engine. Refer to: Engine - Body Off . Refer to: Engine - Body On .
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