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Section 451 (Engine - 6.0L (99P F450/550) Diesel -- F250-F550 Super Duty): Assembly: Engine: Assembly

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Early build cylinder heads, head gaskets, cylinder block, rocker arm carriers and injector hold-down clamps are not interchangeable with late build engines. It is necessary to identify the head style prior to working on the cylinder heads. Early build heads are equipped with injector hold-down clamps with a square end and a T40 Torx® bolt. Late build heads have injector hold-down clamps with a tapered end and a T45 Torx® bolt.
    Fig 1: Identifying Injector Hold Down Clamps
    G04614222Courtesy of FORD MOTOR CO.
  1. Determine if the cylinder heads are early build (left frame of illustration) or late build (right frame of illustration).
    2. CAUTION: Install new D-ring seals on the crankcase-to-head tube. It requires several hours after installation for the D-ring seals to relax back to their original size. If the tube assembly is installed before the D-ring seals have relaxed, damage to the D-ring seals can occur.
    Fig 2: Identifying D-Ring Seals
    G03899308Courtesy of FORD MOTOR CO.
  2. Install new D-ring seals on the crankcase-to-head tube assemblies.
    3. NOTE: Check alignment of the oil holes after installing the bearings.
    Fig 3: Identifying Special Tool
    G04648982Courtesy of FORD MOTOR CO.
  3. If removed, use the special tool to install the camshaft bearings.
    4. CAUTION: The patch bolt is unique. Do not substitute the patch bolt or engine damage can occur.
    NOTE: Apply Threadlock 262 to the threads prior to installation.
  4. Install the 8 piston cooling tubes and the 8 bolts.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 4: Identifying Piston Cooling Tube Bolt
      G03887603Courtesy of FORD MOTOR CO.
    5. CAUTION: Do not nick or scratch the camshaft bearings with the camshaft lobes or engine damage can occur.
    NOTE: Apply clean engine oil to the camshaft prior to installing.
  5. Install the camshaft and gear assembly and the thrust plate mounting bolts.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 5: Locating Thrust Plate Mounting Bolts
      G03887602Courtesy of FORD MOTOR CO.
    6. NOTE: Apply clean engine oil to each bearing prior to installation.
    Fig 6: View Of Crankshaft Upper Bearing Seats
    G03887601Courtesy of FORD MOTOR CO.
  6. Install the crankshaft upper bearings and the crankshaft upper thrust bearing.
  7. Using the special tool, align the camshaft timing mark as shown.
    Fig 7: Locating Camshaft Timing Mark
    G04648986Courtesy of FORD MOTOR CO.
  8. With the timing peg in the special tool over the camshaft timing mark, install the crankshaft.
    Fig 8: Locating Camshaft Timing Mark
    G04648987Courtesy of FORD MOTOR CO.
    9. NOTE: Do not turn the crankshaft during the main bearing clearance check.
  9. Position commercially available plastigage in the center of each main bearing bolt cap.
  10. Install the lower bearings into the lower crankcase.
    Fig 9: Locating Lower Bearings
    G04648988Courtesy of FORD MOTOR CO.
    11. CAUTION: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.
  11. Position the lower crankcase and install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in 3 stages in the sequence shown.
    • Stage 1: Tighten to 122 Nm (90 lb-ft).
    • Stage 2: Tighten to 163 Nm (120 lb-ft).
    • Stage 3: Tighten to 231 Nm (170 lb-ft).
      Fig 10: Identifying Mounting Bolts Tightening Sequence
      G04648989Courtesy of FORD MOTOR CO.
  12. If equipped, install 8 M8 x 30 bolts around the outside of the lower crankcase.
    • Tighten bolts to 31 Nm (23 lb-ft) in the sequence shown.
      Fig 11: Identifying Lower Crankcase Bolts Tightening Sequence
      G04648990Courtesy of FORD MOTOR CO.
  13. Remove the 28 bolts and the lower crankcase.
    Fig 12: Locating Lower Crankcase Bolts
    G03887598Courtesy of FORD MOTOR CO.
  14. Measure the clearances for the main bearings. Remove the plastigage.
    Fig 13: Identifying Main Bearing Clearances
    G04648992Courtesy of FORD MOTOR CO.
    15. NOTE: Apply clean engine oil to the lower main bearings.
    Fig 14: Locating Lower Crankcase Seals
    G03887599Courtesy of FORD MOTOR CO.
  15. Install new lower crankcase seals.
    16. CAUTION: To prevent engine damage, make sure that the longer main cap bolts (M14 x 2 x 127) are installed inboard and the shorter bolts (M14 x 2 x 114) are installed outboard.
  16. Position the lower crankcase and install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in 3 stages in the sequence shown.
    • Stage 1: Tighten bolts to 122 Nm (90 lb-ft).
    • Stage 2: Tighten bolts to 163 Nm (120 lb-ft).
    • Stage 3: Tighten bolts to 231 Nm (170 lb-ft).
      Fig 15: Identifying Mounting Bolts Tightening Sequence
      G04648994Courtesy of FORD MOTOR CO.
  17. If equipped, install the 8 M8 x 30 bolts around the outside of the lower crankcase in the sequence shown.
    • Tighten bolts to 31 Nm (23 lb-ft).
      Fig 16: Identifying Lower Crankcase Bolts Tightening Sequence
      G04648995Courtesy of FORD MOTOR CO.
  18. Remove the bolt and special tool.
    Fig 17: Identifying Special Tool
    G04648996Courtesy of FORD MOTOR CO.
    19. CAUTION: To prevent engine damage, do not remove the rear primary crankshaft flange bolts under any circumstances. If the flange is removed and reinstalled, it will result in engine vibration and premature transmission component wear.
    Fig 18: Measuring Crankshaft End Play
    G04648997Courtesy of FORD MOTOR CO.
  19. Using the special tool, measure the crankshaft end play.
  20. Using the special tool, measure the camshaft end play.
    Fig 19: Measuring Camshaft End Play
    G04648998Courtesy of FORD MOTOR CO.
  21. Using the special tool, measure the camshaft gear backlash.
    Fig 20: Measuring Camshaft Gear Backlash
    G04648999Courtesy of FORD MOTOR CO.
  22. Install the block heater.
    • Tighten to 41 Nm (30 lb-ft).
      Fig 21: Identifying Block Heater
      G03887597Courtesy of FORD MOTOR CO.
  23. Install the camshaft position (CMP) sensor and the bolt.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 22: Identifying Camshaft Position (CMP) Sensor
      G03887596Courtesy of FORD MOTOR CO.
  24. Install the crankshaft position (CKP) sensor and the bolt.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 23: Identifying Crankshaft Position (CKP) Sensor
      G03887595Courtesy of FORD MOTOR CO.
    25. CAUTION: The connecting rods are powdered metal cracked rods. Make sure the connecting rod and cap are installed as a set or engine damage can occur.
    NOTE: Lubricate the connecting rod bearings with clean engine oil prior to installation.
    Fig 24: View Of Upper And Lower Connecting Rod Bearings
    G03887591Courtesy of FORD MOTOR CO.
  25. Install the connecting rod bearings.
    26. CAUTION: Make sure the ring openings are 120 degrees from each other, or engine damage can occur.
  26. Install new piston rings.
    1. The keystone ring is identified with one indentation mark and a 15-degree keystone profile.
    2. The intermediate compression ring is identified with 2 indentation marks and a square profile.
    3. Install the oil control ring.
      Fig 25: Identifying Oil Control Ring
      G04649004Courtesy of FORD MOTOR CO.
    27. NOTE: Cam V8 is toward the inside of the engine.
    NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.
  27. Install the piston and rod assemblies.
    1. Coat the inside diameter of the ring compressor with clean engine oil.
    2. Insert the piston into the special tool. Position the piston, connecting rod and special tool into the correct cylinder bore.
      • Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.
        Fig 26: Pushing Connecting Rod And Piston Assembly Down Into Cylinder Bore
        G04649005Courtesy of FORD MOTOR CO.
  28. Position a piece of plastigage across the bearing surface.
    Fig 27: Positioning Piece Of Plastigage Across Bearing Surface
    G03900006Courtesy of FORD MOTOR CO.
    29. CAUTION: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage can occur.
  29. Position the connecting rod cap and tighten the bolts in 2 stages.
    • Stage 1: Tighten to 45 Nm (33 lb-ft).
    • Stage 2: Tighten to 68 Nm (50 lb-ft).
      Fig 28: Identifying Connecting Rod Cap Bolts
      G03887588Courtesy of FORD MOTOR CO.
  30. Remove the bolts and the connecting rod cap.
  31. Measure the clearances for the connecting rod cap. Remove the plastigage.
    Fig 29: Identifying Connecting Rod Cap Clearance
    G04649008Courtesy of FORD MOTOR CO.
    32. CAUTION: The connecting rods are powdered metal cracked rods and care should be taken to make sure that the connecting rod caps are oriented correctly with the connecting rods or engine damage can occur.
  32. Position the connecting rod cap and tighten the bolts in 2 stages.
    • Stage 1: Tighten to 45 Nm (33 lb-ft).
    • Stage 2: Tighten to 68 Nm (50 lb-ft).
      Fig 30: Identifying Connecting Rod Cap Bolts
      G03887588Courtesy of FORD MOTOR CO.
  33. Using a feeler gauge, check for connecting rod side clearance.
    Fig 31: Identifying Connecting Rod Side Clearance
    G04649010Courtesy of FORD MOTOR CO.
  34. Install a new press-in-place gasket into the upper oil pan.
    Fig 32: Locating Upper Oil Pan Gasket
    G04649011Courtesy of FORD MOTOR CO.
  35. Position the upper oil pan and install the bolts.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 33: Identifying Upper Oil Pan Bolts
      G03887278Courtesy of FORD MOTOR CO.
  36. Install a new oil pickup tube O-ring seal.
    Fig 34: Locating Oil Pickup Tube O-Ring Seal
    G03887262Courtesy of FORD MOTOR CO.
  37. Install the oil pickup tube and screen and the 2 bolts.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 35: Locating Oil Pickup Tube Bolts
      G03887261Courtesy of FORD MOTOR CO.
  38. Install the oil pan and the 20 bolts.
    1. Install the 5 longer oil pan bolts.
    2. Install the remaining oil pan bolts.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 36: Locating Oil Pan Bolts
      G04649015Courtesy of FORD MOTOR CO.
    39. CAUTION: To prevent engine damage, keep the cam followers in the order in which they were removed. Install all cam followers back in their original positions.
    NOTE: Only the front guides use bolts.
  39. Apply clean engine oil to the hydraulic cam followers and install into the roller follower guide. Install the roller follower guide and the bolts.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 37: Identifying Roller Follower Guide Bolt
      G03887584Courtesy of FORD MOTOR CO.
    40. NOTE: RH shown, LH similar.
  40. Position the rear engine tube assembly and install the 2 bolts in 3 stages.
    • Stage 1: Tighten the RH bolt hand tight.
    • Stage 2: Tighten the LH bolt hand tight.
    • Stage 3: Tighten both rear engine tube assembly bolts to 13 Nm (10 lb-ft).
      Fig 38: Identifying Rear Engine Tube Assembly
      G03887583Courtesy of FORD MOTOR CO.
  41. Install the 4 cylinder head dowels.
    Fig 39: Locating Cylinder Head Dowels
    G03887582Courtesy of FORD MOTOR CO.
    42. NOTE: Install a new cylinder head gasket with the part number facing up. Verify the top 5 bolt holes and the head gasket push rod holes line up.
    NOTE: Use care to avoid scratching the blue compound on the cylinder head gaskets.
    Fig 40: Identifying Gasket Sealing Surfaces Area
    G03887503Courtesy of FORD MOTOR CO.
  42. Place the new cylinder head gasket over the dowel sleeves and onto the crankcase.
  43. Using the special tool, install the cylinder heads.
    1. Install the lifting bracket.
    2. Install the bolts.
      Fig 41: Identifying Special Tool
      G04649020Courtesy of FORD MOTOR CO.
  44. Install the 5 outer bolts for each cylinder head (finger tight).
    Fig 42: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
    45. CAUTION: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
    NOTE: On early build vehicles, higher mileage engines require push rods to be cleaned so the copper-colored end of the push rod can be identified and installed with the copper-colored end up. Push rods on late build vehicles and service push rods do not have a copper-colored end and can be installed with either end up.
    Fig 43: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
  45. Apply clean engine oil to each end of the push rods and insert them into their respective positions.
    46. NOTE: Coat the end of each valve stem with clean engine oil.
    Fig 44: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
  46. Install the 16 valve bridges.
    47. NOTE: Early build engines will have 4 rocker arm carrier-to-cylinder head bolts. Late build will have 2 rocker arm carrier-to-cylinder head bolts.
    NOTE: Early build shown, late build similar.
  47. Install the press-in-place gasket, the rocker arm carrier and the bolts.
    • Early build vehicles (M8 bolt), tighten to 31 Nm (23 lb-ft).
    • Late build vehicles (M10 bolt), tighten to 62 Nm (46 lb-ft).
      Fig 45: Locating Rocker Arm Carrier Bolts
      G04614344Courtesy of FORD MOTOR CO.
    48. NOTE: Rotate the crankshaft until the damper locating dowel notch is in the 6 o'clock position.
    NOTE: Apply clean engine oil to the top center of each valve bridge.
  48. Install the rocker arm assemblies and the 16 bolts.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 46: Identifying Rocker Arm Assembly Bolts
      G03887497Courtesy of FORD MOTOR CO.
    49. CAUTION: Using too much engine oil on the threads of the cylinder head bolts, can 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 can affect the true torque value of the bolts.
    NOTE: Left cylinder head shown, right cylinder head similar.
    NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
    Fig 47: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
  49. Install the 10 cylinder head retaining bolts for each cylinder head (finger tight).
  50. Tighten the head bolts in 7 stages in the sequence shown:
    • Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
    • Stage 2: Tighten bolts 1 through 10 to 115 Nm (85 lb-ft).
    • Stage 3: Tighten bolts in sequence 1 through 10, 90 degrees.
    • Stage 4: Tighten bolts in sequence 1 through 10, a second time, 90 degrees.
    • Stage 5: Tighten bolts in sequence 1 through 10, a third time, 90 degrees.
    • Stage 6: Tighten bolts 11 through 15 to 24 Nm (18 lb-ft).
    • Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
      Fig 48: Identifying Head Bolts Tightening Sequence
      G04649027Courtesy of FORD MOTOR CO.
    51. CAUTION: If the fuel injector oil inlet O-ring is damaged, a new fuel injector must be installed.
    NOTE: Lubricate the fuel injector and O-rings liberally with clean engine oil.
    Fig 49: Identifying O-Ring Seals, Copper Washer And Fuel Injector
    G03887397Courtesy of FORD MOTOR CO.
  51. Install new O-rings and a copper washer on the fuel injector.
    52. CAUTION: Failure to tighten the injector properly can lead to engine failure.
    CAUTION: To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
  52. Install the fuel injector, the fuel injector hold-down and bolt.
    • Early build vehicles (T40 Torx®), tighten to 33 Nm (24 lb-ft).
    • Late build vehicles (T45 Torx®), tighten to 35 Nm (26 lb-ft).
      Fig 50: Identifying Fuel Injector Hold-Down Bolt
      G03887381Courtesy of FORD MOTOR CO.
    53. CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
    Fig 51: Identifying Fuel Injector Electrical Connector
    G03887399Courtesy of FORD MOTOR CO.
  53. Install the fuel injector electrical connector into the rocker carrier.
  54. Apply clean engine oil to the top fuel injector O-ring seals.
    Fig 52: Identifying Top Fuel Injector O-Ring Seals
    G03888010Courtesy of FORD MOTOR CO.
    55. CAUTION: Using the bolts to push the high pressure oil rail in the fuel injectors can damage the fuel injectors and high pressure oil rail.
    NOTE: Apply clean engine oil to the top fuel injector O-ring seals before installing the high pressure oil rail.
  55. Position the high pressure oil rail on the injectors.
    • Place the high pressure oil rail on top of the carrier so that the 4 single ball tubes are engaging the fuel injector lead angle.
    • Insert 3 guide bolts, 2 on the ends of the straight side of the high pressure oil rail and 1 in the middle of the wavy side of the high pressure rail. Install the guide studs 6 to 7 turns.
    • Manually press the high pressure oil rail into the fuel injectors.
    • Inspect that the high pressure oil rail mounting feet are flat against the mounting surface.
    • Loosely install the 6 bolts.
      Fig 53: Locating High-Pressure Oil Rail On Injector Bolts
      G03887401Courtesy of FORD MOTOR CO.
  56. Remove the 3 guide bolts, install the remaining bolts and tighten the 9 bolts in the sequence shown.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 54: Identifying Bolts Tightening Sequence
      G04649033Courtesy of FORD MOTOR CO.
    57. NOTE: Apply clean engine oil to the crankcase-to-head tube prior to installation.
  57. Install the crankcase-to-head tube assembly.
    • Tighten to 82 Nm (60 lb-ft).
      Fig 55: Locating Crankcase-To-Head Tube Assembly Bolt
      G04649034Courtesy of FORD MOTOR CO.
  58. Apply a bead of sealant at the back seam of the upper and lower crankcase.
    Fig 56: Applying Sealant To Upper And Lower Crankcase
    G03887338Courtesy of FORD MOTOR CO.
  59. Install a new press-in-place gasket, the rear engine cover and the bolts.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 57: Locating Rear Engine Cover Bolts
      G03887334Courtesy of FORD MOTOR CO.
    60. NOTE: The crankshaft rear oil seal and wear sleeve are installed as an assembly.
    NOTE: Lubricate the outer diameter of the rubber seal with a solution of dish soap and water (approximately 50/50 mix) prior to assembly. Do not use any other type of lubricant.
    NOTE: Apply a bead of Threadlock 262 around the circumference of the outer rear edge of the secondary crankshaft flange.
    Fig 58: Identifying Special Tool
    G04649037Courtesy of FORD MOTOR CO.
  60. Using the special tools, install a new crankshaft rear oil seal.
  61. Install the flywheel adapter.
    Fig 59: Identifying Flywheel Adapter
    G03887288Courtesy of FORD MOTOR CO.
  62. If removed, install the front cover crankcase dowels into the cylinder block.
    Fig 60: Identifying Front Cover Crankcase Dowels
    G03887308Courtesy of FORD MOTOR CO.
  63. Apply a bead of sealant at the front seam of the upper and lower crankcase.
    Fig 61: Locating Sealant Areas
    G04649040Courtesy of FORD MOTOR CO.
    64. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
    Fig 62: Locating Guide Studs And Front Cover Gasket
    G04649041Courtesy of FORD MOTOR CO.
  64. Install the guide studs and the front cover gasket.
  65. Install the engine front cover and the bolts.
    • Tighten to 24 Nm (18 lb-ft).
      Fig 63: Locating Engine Front Cover Bolts
      G03887307Courtesy of FORD MOTOR CO.
    66. NOTE: Install oil pump drive rotors with marks pointing outward.
    Fig 64: Identifying Inner And Outer Oil Pump Drive Rotors With Alignment Marks
    G03887281Courtesy of FORD MOTOR CO.
  66. Lubricate inner drive rotor with a suitable lithium assembly grease and install onto crankshaft. Lubricate outer drive rotor with lithium assembly grease and mesh with inner drive rotor in oil pump housing. Wipe off excess assembly grease.
    67. NOTE: Install a new O-ring seal.
  67. Install the oil pump body and the 5 bolts.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 65: Locating Oil Pump Body Bolts
      G03887280Courtesy of FORD MOTOR CO.
    68. NOTE: Apply Threadlock 262 to the outer circumference of the leading edge of the crankshaft.
    NOTE: The seal and wear sleeve must not be separated.
    Fig 66: Identifying Special Tool
    G04649045Courtesy of FORD MOTOR CO.
  68. Using the special tool, install a new oil seal and wear sleeve assembly.
    69. CAUTION: To prevent engine damage, always install 4 new bolts when installing the vibration damper.
    NOTE: Do not use anti-seize compounds, grease or any lubricants. Lubricants have an adverse effect on the torque results.
  69. Install the crankshaft vibration damper and tighten the new bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 68 Nm (50 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
      Fig 67: Identifying Crankshaft Vibration Damper Bolts
      G04649046Courtesy of FORD MOTOR CO.
  70. If equipped, install the dual generator pulley and the 3 bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 68: Locating Dual Generator Pulley Bolts
      G03887210Courtesy of FORD MOTOR CO.
    71. NOTE: Install a new O-ring seal on the coolant pump.
  71. Install the coolant pump and the 4 bolts.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 69: Locating Coolant Pump Bolts
      G03887306Courtesy of FORD MOTOR CO.
  72. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 70: Identifying Coolant Pump Pulley Bolts
      G04614086Courtesy of FORD MOTOR CO.
  73. Install the RH high pressure oil rail-to-valve cover gasket.
    Fig 71: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    G03887197Courtesy of FORD MOTOR CO.
  74. CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.
    NOTE: RH shown, LH similar. Install the RH and LH valve covers.
    • Install new gaskets.
    • Install the valve covers.
    • Install the bolts and stud bolts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 72: Identifying Valve Cover, Stud Bolts, And Bolts
      G03887372Courtesy of FORD MOTOR CO.
    75. NOTE: Clean and inspect the O-ring seal.
  75. Install the injection control pressure (ICP) sensor.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 73: Locating Injection Control Pressure Sensor
      G03906932Courtesy of FORD MOTOR CO.
  76. Install the 8 glow plugs.
    • Tighten to 19 Nm (14 lb-ft).
      Fig 74: Identifying Glow Plug
      G03887484Courtesy of FORD MOTOR CO.
    77. NOTE: Clean and apply clean engine oil to the O-ring seals.
    Fig 75: Identifying Glow Plug Harness Special Tool (303-1114)
    G04614327Courtesy of FORD MOTOR CO.
  77. Using the special tool, install the glow plug harness.
    78. CAUTION: To prevent engine damage, use only approved pump cover seal. Substitution can cause damage to the pump cover.
    Fig 76: Locating High-Pressure Oil Pump O-Ring Seal
    G03887542Courtesy of FORD MOTOR CO.
  78. Install a new O-ring seal on the high pressure oil pump.
  79. Install the high pressure tube assembly.
    Fig 77: Identifying High-Pressure Tube Assembly Bolts
    G03887702Courtesy of FORD MOTOR CO.
  80. Install new lower O-ring seals.
    Fig 78: Identifying Lower O-Ring Seals
    G03887540Courtesy of FORD MOTOR CO.
  81. Install the high pressure pump and bolts.
    • Tighten to 31 Nm (23 lb-ft).
      Fig 79: Locating High-Pressure Oil Pump Bolts
      G03887539Courtesy of FORD MOTOR CO.
  82. Install the high pressure tube assembly bolts.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 80: Locating High-Pressure Tube Assembly Bolts
      G03887538Courtesy of FORD MOTOR CO.
  83. Position the special tool and check the oil pump drive gear backlash.
    Fig 81: Checking Oil Pump Drive Gear Backlash Using Special Tool (100-002)
    G04614384Courtesy of FORD MOTOR CO.
  84. Install a new press-in-place gasket in the high pressure pump cover.
    Fig 82: Identifying Press-In-Place High-Pressure Pump Cover Gasket
    G03887707Courtesy of FORD MOTOR CO.
  85. Clean the cover mounting surface and apply sealer at the seams.
    Fig 83: Applying Sealer At Seams
    G03887708Courtesy of FORD MOTOR CO.
    86. CAUTION: To prevent engine damage, the high pressure oil pump cover must be firmly seated on the O-ring seal to prevent cracking the cover plate.
    NOTE: Apply clean engine oil to the high pressure oil pump O-ring seal prior to installing the high pressure pump cover.
  86. Install the high pressure oil pump cover and bolts.
    • Tighten to 11 Nm (8 lb-ft).
      Fig 84: Locating High Pressure Oil Pump Cover Bolts
      G04649063Courtesy of FORD MOTOR CO.
  87. Using the special tool, install the injection pressure regulator (IPR) valve.
    • Tighten to 50 Nm (37 lb-ft).
      Fig 85: Identifying Special Tool (303-1112)
      G04614381Courtesy of FORD MOTOR CO.
  88. If equipped, install the heat insulating wrap and fasten the snap.
    Fig 86: Locating Heat Insulating Wrap
    G03887533Courtesy of FORD MOTOR CO.
  89. Install the oil pump inlet strainer.
    Fig 87: Identifying Oil Pump Inlet Strainer
    G03887232Courtesy of FORD MOTOR CO.
    90. CAUTION: In the event of a catastrophic engine failure, always install a new oil cooler cover assembly (with oil cooler). Foreign material cannot be removed from the oil cooler.
  90. Install a new press-in-place gasket, the oil cooler assembly and the bolts.
    • Tighten to 22 Nm (16 lb-ft).
      Fig 88: Identifying Oil Cooler Assembly Bolts
      G03887231Courtesy of FORD MOTOR CO.
    91. NOTE: The old oil cooler cover bolts or new self-tapping bolts must be used to cut the threads in the new oil cooler cover.
  91. Install the press-in-place gasket, the oil filter base and the bolts.
    1. Tighten to 22 Nm (16 lb-ft).
    2. Tighten to 10 Nm (89 lb-in).
      Fig 89: Locating Oil Filter Base Bolts
      G04649068Courtesy of FORD MOTOR CO.
  92. Install a new press-in-place gasket, the exhaust gas recirculation (EGR) cooler coolant supply port cover and the bolts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 90: Identifying EGR Cooler Coolant Supply Port Cover Bolts
      G03887229Courtesy of FORD MOTOR CO.
  93. Install new O-ring seals in the oil filter base.
    Fig 91: Identifying O-Ring Seals On Oil Filter Base
    G03887527Courtesy of FORD MOTOR CO.
  94. Install the serpentine belt idlers and bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 92: Locating Accessory Drive Idler Pulley Bolt
      G03887524Courtesy of FORD MOTOR CO.
  95. Install the belt tensioner and bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 93: Identifying Accessory Drive Belt Tensioner Bolts
      G03887304Courtesy of FORD MOTOR CO.
    96. NOTE: Install new sealing washers.
  96. Install the LH cylinder head fuel tube.
    • Tighten to 38 Nm (28 lb-ft).
      Fig 94: Identifying Fuel Line Banjo Bolt
      G03887486Courtesy of FORD MOTOR CO.
  97. Install the fuel tubes and bracket bolt.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 95: Locating Fuel Tube And Bracket Bolt
      G04649074Courtesy of FORD MOTOR CO.
    98. NOTE: Install a new O-ring seal on the thermostat.
  98. Install the thermostat housing and the bolts.
    • Tighten to 23 Nm (17 lb-ft).
      Fig 96: Locating Thermostat Housing Bolts
      G04649075Courtesy of FORD MOTOR CO.
    99. NOTE: Install a new O-ring seal on the oil indicator and tube. Apply clean engine oil to the O-ring seal.
    Fig 97: Locating Wire Harness Retainer
    G03907047Courtesy of FORD MOTOR CO.
  99. Position the oil level indicator tube and install the nut. Connect the wiring harness retainer to the stud bolt.
  100. Install the glow plug mounting bracket and the nuts.
    • Tighten to 9 Nm (80 lb-in).
      Fig 98: Locating Glow Plug Mounting Bracket Nuts
      G04649077Courtesy of FORD MOTOR CO.
    101. NOTE: LH shown, RH similar.
  101. Install the LH and RH motor mounts and bolts.
    • Tighten to 62 Nm (46 lb-ft).
      Fig 99: Locating LH And RH Motor Mount Bolts
      G04649078Courtesy of FORD MOTOR CO.
    102. NOTE: LH shown, RH similar.
    NOTE: Lightly lubricate the O-ring seal with clean engine oil prior to installing.
  102. Install the cylinder block coolant drain plugs.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 100: Locating Cylinder Block Coolant Drain Plug
      G03887451Courtesy of FORD MOTOR CO.
  103. Position the starter motor and install the 3 bolts in 3 stages.
    • Stage 1: Install the 3 bolts finger tight.
    • Stage 2: Tighten the upper bolt to 25 Nm (18 lb-ft).
    • Stage 3: Tighten the 2 lower bolts to 25 Nm (18 lb-ft).
      Fig 101: Locating Starter Motor Bolts
      G04649080Courtesy of FORD MOTOR CO.
  104. Install the special tool.
    Fig 102: Locating Engine Lift Adapters (303-D043-01)
    G04614140Courtesy of FORD MOTOR CO.
  105. Install the special tool.
    Fig 103: Identifying Special Tool
    G04649082Courtesy of FORD MOTOR CO.
  106. Install the lifting crane and remove the engine from the engine stand.
  107. Position the flexplate or flywheel and install the new bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 94 Nm (69 lb-ft).
      Fig 104: Identifying Flexplate/Flywheel Bolt Tightening Sequence
      G04614191Courtesy of FORD MOTOR CO.
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