Engine - Body On
For information on Ford Color Coded Illustrations refer to OEM COLOR CODING INFORMATION
Special Tool(s) / General Equipment
| 303-1681Spreader Bar | |
|---|---|
| 303-1684 Lifting Eye | |
| 307-625 Fixture, Bench Mounting, TKIT-2008ET-FLM, TKIT-2008ET-ROW | |
| Floor Crane | |
| Trolley Jack | |
| Hose Clamp Remover/Installer | |
| Wooden Block |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Multi-Purpose Grease Spray XL-5-A | ESB-M1C93-B |
| Motorcraft® Threadlock 262TA-26 | WSK-M2G351-A6 |
| Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil XO-5W30-QFA | WSS-M2C214-B1 |
4WD/LHD RWD
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- Inspect the engine mount-to-frame nut plate for thread damage.
- If the nut plate is damaged, remove and discard the engine mount-to-frame nut plate.
- Clean the engine mount-to-frame mating surfaces of any dirt or foreign material prior to installation.
- Remove Special Service Tool: 307-625 Fixture, Bench Mounting.
- Lubricate the torque converter pilot hub with multi-purpose grease.
Material: Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)
- The paint dot on the torque converter need to be at 12 o'clock and the stud needs to be assembled with the corresponding flexplate hole that is closest to 12 o'clock.
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NOTE: The use of a ratchet strap may be needed to level the engine.
Using the floor crane and the spreader bar, install the engine. Use the General Equipment: Floor Crane
- Using the floor crane and the spreader bar, position the engine to the transmission. Use the General Equipment: Floor Crane
- Align the engine to the transmission and draw together using the bolts.
Torque: 35 lb.ft (48 Nm)
- Install the RH engine mount.
- Install the LH engine mount.
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NOTE: Only use hand tools when loosening or tightening the engine mount through bolts or damage to the engine mount-to-cylinder block bracket can occur.NOTE: Only tighten the bolt finger tight at this stage.
Install the LH engine mount thought bolt.
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NOTE: Only use hand tools when loosening or tightening the engine mount through bolts or damage to the engine mount-to-cylinder block bracket can occur.NOTE: Only tighten the bolt finger tight at this stage.
Install the new RH engine mount through bolt.
- Using the floor crane, lower the engine. Use the General Equipment: Floor Crane
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NOTE: Only use hand tools when loosening or tightening the engine mount-to-frame bolts or damage to the engine mount-to-frame nut plate can occur.
Install the new LH engine mount bolts.
Torque: 129 lb.ft (175 Nm)
- Remove the floor jack and the block of wood. Use the General Equipment: Trolley Jack Use the General Equipment: Wooden Block
- Remove the floor crane and the special tools. Use Special Service Tool: 303-1681 Spreader Bar., 303-1684 Lifting Eye. Use the General Equipment: Floor Crane
- Remove the factory lifting eye with the special tool from the engine.
- Remove the bolts and the special tool. Use Special Service Tool: 303-1684 Lifting Eye.
- Install the upper lifting bracket and the bolts.
Torque: 17 lb.ft (23 Nm)
4WD
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NOTE: Install the top bolt first, it may be necessary to reposition the axle assembly to prevent interference with the steering components when installing the bolt.
If equipped, raise the front axle into position and hand start the bolts. Use the General Equipment: Trolley Jack
- Tighten the rear bolt to:
Torque: 136 lb.ft (185 Nm)
- Tighten the front bolts to:
Torque: 129 lb.ft (175 Nm)
- Remove the trolley jack. Use the General Equipment: Trolley Jack
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- Install the steering gear boot.
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- Position back the steering column shaft U-joint to the steering gear.
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WARNING: Install a new steering column shaft bolt. Reuse could result in bolt failure and loss of vehicle control. Failure to follow this instruction may result in serious injury to vehicle occupant(s).
Install a new steering column shaft bolt.
Torque: 22 lb.ft (30 Nm)
- Remove the holding device from the steering wheel.
4WD/LHD RWD
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NOTE: Only use hand tools when loosening or tightening the engine mount through bolts or damage to the engine mount-to-cylinder block bracket can occur.
Tighten the LH engine mount through bolt.
Torque: 258 lb.ft (350 Nm)
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NOTE: Only use hand tools when installing the engine mount nuts and studs or damage to the engine mount can occur.NOTE: Apply threadlock to the stud threads prior to installation.
Install the RH engine mount studs.
Material: Motorcraft® Threadlock 262 / TA-26 (WSK-M2G351-A6)
Torque: 22 lb.ft (30 Nm)
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NOTE: Only use hand tools when installing the engine mount nuts and studs or damage to the engine mount can occur.
Install the new RH engine mount nuts.
Torque: 111 lb.ft (150 Nm)
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NOTE: Only use hand tools when loosening or tightening the engine mount through bolts or damage to the engine mount-to-cylinder block bracket can occur.
Tighten the RH engine mount through bolt.
Torque: 258 lb.ft (350 Nm)
- Install the RH side bellhousing bolt.
Torque: 35 lb.ft (48 Nm)
- Install the LH side bellhousing bolts.
Torque: 35 lb.ft (48 Nm)
- Install the upper bellhousing bolts.
Torque: 35 lb.ft (48 Nm)
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NOTE: Only use hand tools when loosening or tightening the transmission mount-to-crossmember nuts or damage to the transmission mount can occur.
Remove and discard the transmission mount-to-crossmember nuts. Install new transmission mount-to-crossmember nuts.
Torque: 85 lb.ft (115 Nm)
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NOTE: Using the crankshaft pulley bolt, turn the engine clockwise.
Install new torque converter nuts.
Torque: 35 lb.ft (48 Nm)
- Install the access cover and the retainers.
- Install the following items:
- Install the starter motor. Refer to: Starter Motor .
- If equipped, install the front driveshaft. Refer to: Front Driveshaft .
- Install the secondary fuel filter and the bolt.
Torque: 89 lb.in (10 Nm)
- Connect the secondary fuel lines. Refer to: Quick Release Coupling
.
- Position back and connect the fuel tubes. Refer to: Quick Release Coupling
.
- Install the ground strap and the nut. Connect the ground strap retainers.
Torque: 106 lb.in (12 Nm)
- Position back the battery wire harness. Position back the power steering power cable and install the bolts.
Torque: 177 lb.in (20 Nm)
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- Position back the wire harness and connect the retainers.
- Install the bolt for the ground wire.
Torque: 80 lb.in (9 Nm)
- Position back the battery wire harness and install the nuts.
Torque: 97 lb.in (11 Nm)
- Install the power distribution box cover.
- Position back the wire bracket.
- Connect the electrical connectors.
- Position back and connect the retainers. Connect the PCM electrical connector and the electrical connector.
- Position back the wiring harness. Connect the transmission electrical connectors and the retainers.
- If equipped, connect the block heater electrical connector and the retainer.
- Install a new O-ring seal on the lower radiator coolant tube. Lubricate the O-ring seal with clean engine coolant. Refer to: Specifications
.
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NOTE: Apply coolant to the coolant connector opening before installing the tube.
Install the lower radiator coolant tube and the bolts. Refer to: Specifications .
Torque: M8 bolt : 18 lb.ft (25 Nm) M6 bolt : 71 lb.in (8 Nm)
- If equipped, connect the block heater cord retainers.
- Position back and connect the coolant hoses. Use the General Equipment: Hose Clamp Remover/Installer
- Install the following items:
- Install the generator. Refer to: Generator - 3.0L Power Stroke Diesel .
- Install the cowl panel. Refer to: Cowl Panel .
- Install the cowl panel grille. Refer to: Cowl Panel Grille .
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- Install the coolant pump and the bolts.
Torque: 177 lb.in (20 Nm)
- Connect the electrical connector and the coolant hose retainer.
- Install the coolant pump and the bolts.
- Connect the coolant hose connector and the retainers.
- Connect the heater hoses and the retainers. Use the General Equipment: Hose Clamp Remover/Installer
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- Connect the A/C pressure transducer electrical connector.
- Install a new O-ring seal.
- Connect the A/C compressor inlet line and install the nut.
Torque: 159 lb.in (18 Nm)
- Install the upper radiator hose. Use the General Equipment: Hose Clamp Remover/Installer
- Inspect the turbocharger or engine air intake system components and clean, if necessary.
- Install the LH CAC intake pipe and the clip. Tighten the clamp.
Torque: 44 lb.in (5 Nm)
- Connect the electrical connector and the wire retainer.
- Install the lower radiator hose. Connect the retainer. Use the General Equipment: Hose Clamp Remover/Installer
- Connect the electrical connector.
- Install the following items:
- Install the turbocharger. Refer to: Turbocharger .
- Install the LH and the RH fender splash shield. Refer to: Fender Splash Shield .
- Install the battery tray. Refer to: Battery Tray .
- Install the air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
- Install the cooling module. Refer to: Cooling Module .
- Install the degas bottle. Refer to: Degas Bottle .
- If equipped, install the skid plate and the bolts.
Torque: 30 lb.ft (40 Nm)
- If equipped, install the underbody shield and the bolts.
Torque: M8 bolt : 30 lb.ft (40 Nm) M6 bolt : 71 lb.in (8 Nm)
- Install the transmission housing cover and the bolts. Install the nut.
Torque: 71 lb.in (8 Nm)
- Remove the oil filter cap.
- Install a new oil filter.
- Install a new oil filter cap O-ring seal and lubricate.
Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)
- Install the oil filter cap.
Torque: 18 lb.ft (25 Nm)
- Install the engine appearance cover.
- Fill the engine with clean engine oil. Refer to: Specifications .
Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)
- Connect the battery ground cable. Refer to: Battery Disconnect and Connect .
- Start and check the exhaust system for leaks.
- Road test the vehicle.