Section 2100 (Engine - 5.4L (3V) -- F-250 & F350 Super Duty): Installation: Engine

Illustration	Tool Name	Tool Number
Courtesy of FORD MOTOR CO.	Modular Engine Lift Bracket	303-F047 (014-00073) or equivalent

All vehicles 

1. Using a suitable floor crane, position the engine assembly into the vehicle.
CAUTION: Only use hand tools when installing the RH engine through bolt or damage to the engine support insulator may occur.
2. Install the LH engine support insulator through bolt.
   • Tighten to 350 Nm (258 lb-ft).
Fig 1: Locating LH Engine Support Insulator Through Bolt
Courtesy of FORD MOTOR CO.
CAUTION: Only use hand tools when installing the LH engine through bolt or damage to the engine support insulator may occur.
3. Install the RH engine support insulator through bolt.
   • Tighten to 350 Nm (258 lb-ft).
Fig 2: Locating RH Engine Support Insulator Through Bolt
Courtesy of FORD MOTOR CO.

Manual transmission equipped vehicles 

4. Install the clutch and pressure plate. For additional information, refer to CLUTCH article.

All automatic transmission equipped vehicles 

NOTE: The upper 2 transmission-to-engine bolts will be installed later.
5. Install the lower 5 transmission-to-engine bolts.
   • Tighten to 48 Nm (35 lb-ft).
Fig 3: Lower Transmission-To-Engine Bolts
Courtesy of FORD MOTOR CO.
6. Install 4 new torque converter-to-flexplate nuts.
   • Tighten to 35 Nm (26 lb-ft).
Fig 4: Locating Torque Converter-To-Flexplate Nuts
Courtesy of FORD MOTOR CO.
7. Install the cylinder block opening cover.
Fig 5: Locating Cylinder Block Opening Cover
Courtesy of FORD MOTOR CO.
8. Install the 2 transmission rear mount nuts.
   • Tighten to 103 Nm (76 lb-ft).
Fig 6: Identifying Transmission Support Insulator Nuts
Courtesy of FORD MOTOR CO.
9. Install the starter. For additional information, refer to STARTING SYSTEM - GASOLINE ENGINES article.

Late build automatic transmission equipped vehicles 

10. Install the flexplate inspection cover and the 2 bolts.
    • Tighten to 34 Nm (25 lb-ft).
Fig 7: Locating Flexplate Inspection Cover Bolts
Courtesy of FORD MOTOR CO.

Early build automatic transmission equipped vehicles 

11. Position the transmission auxiliary fluid cooler assembly and install the 2 bolts.
    • Tighten to 35 Nm (26 lb-ft).
Fig 8: Locating Bolts & Transmission Auxiliary Fluid Cooler Assembly
Courtesy of FORD MOTOR CO.
12. Connect the 2 transmission auxiliary fluid cooler outlet tubes.
Fig 9: Locating Transmission Auxiliary Fluid Cooler Outlet Tubes
Courtesy of FORD MOTOR CO.
13. Connect the 2 transmission auxiliary fluid cooler inlet tubes.
Fig 10: Locating Transmission Auxiliary Fluid Cooler Inlet Tubes
Courtesy of FORD MOTOR CO.
14. Install the 2 transmission auxiliary fluid cooler outlet tube secondary latches.
Fig 11: Locating Transmission Auxiliary Fluid Cooler Outlet Tube Secondary Latches
Courtesy of FORD MOTOR CO.

All vehicles 

15. If equipped, connect the block heater electrical connector.
Fig 12: Locating Block Heater Electrical Connector
Courtesy of FORD MOTOR CO.
16. Position the transmission wiring harness support bracket and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 13: Locating Bolt & Transmission Wiring Harness Support Bracket
Courtesy of FORD MOTOR CO.
17. Connect the 2 engine wiring harness ground straps and install the nut.
    • Tighten to 10 Nm (89 lb-in).
Fig 14: Locating Nut & Engine Wiring Harness Ground Straps
Courtesy of FORD MOTOR CO.
18. Connect the RH heated oxygen sensor (HO2S) wiring harness retainers.
Fig 15: Locating RH Heated Oxygen Sensor (HO2S) Wiring Harness Retainers
Courtesy of FORD MOTOR CO.
19. Position the ground strap and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 16: Locating Bolt & Position Ground Strap Aside
Courtesy of FORD MOTOR CO.
20. Position the power steering pump and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 17: Locating Bolts & Position Power Steering Pump Aside
Courtesy of FORD MOTOR CO.
21. Position the A/C compressor and install the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 18: Locating Bolt Access Holes For A/C Compressor
Courtesy of FORD MOTOR CO.
22. Position the transmission auxiliary fluid cooler tube support bracket and the starter wiring harness support bracket on the engine front cover stud bolt and install the nut.
    • Tighten to 25 Nm (18 lb-ft).
Fig 19: Locating Nut & Transmission Auxiliary Fluid Cooler Tube Support Bracket
Courtesy of FORD MOTOR CO.
23. Install the 4 exhaust manifold flange nuts.
    • Tighten to 40 Nm (30 lb-ft).
Fig 20: Locating Exhaust Manifold-To-Catalytic Converter Nuts
Courtesy of FORD MOTOR CO.
24. Connect the 2 heated HO2S electrical connectors.
Fig 21: Connecting Heated Exhaust Gas Oxygen Sensor (HO2S) Electrical Connectors
Courtesy of FORD MOTOR CO.
25. Position the oil cooler and install the threaded shaft.
    • Tighten to 58 Nm (43 lb-ft).
Fig 22: Locating Engine Oil Cooler
Courtesy of FORD MOTOR CO.
26. Connect the oil cooler coolant hoses.
Fig 23: Locating Oil Cooler Coolant Hoses
Courtesy of FORD MOTOR CO.
27. Install a new engine oil filter.
    • Tighten to 16 Nm (12 lb-ft).
Fig 24: Locating Engine Oil Filter
Courtesy of FORD MOTOR CO.

Automatic transmission vehicles 

28. Install the upper 2 transmission-to-engine bolts.
    • Tighten to 48 Nm (35 lb-ft).
Fig 25: Locating Upper Transmission-To-Engine Bolts
Courtesy of FORD MOTOR CO.

All vehicles 

29. Using new O-ring seals, connect the 2 A/C compressor manifold tube assemblies to the A/C compressor and install the 2 nuts.
    • Tighten to 20 Nm (15 lb-ft).
Fig 26: Locating Compressor Manifold Tube Assemblies From A/C Compressor
Courtesy of FORD MOTOR CO.
30. Position the transmission fluid level indicator tube and install the bolt.
    • Tighten to 10 Nm (89 lb-in).
Fig 27: Locating Bolt & Transmission Fluid Level Indicator Tube
Courtesy of FORD MOTOR CO.
31. Position the generator wiring harness and connect the A/C compressor and crankshaft position (CKP) sensor electrical connectors.
Fig 28: Locating A/C Compressor & Crankshaft Position (CKP) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
32. Connect the generator wiring harness position retainers to the engine front cover studs.
Fig 29: Locating Generator Wiring Harness Position Retainers From Engine Front Cover Studs
Courtesy of FORD MOTOR CO.
33. Connect the engine wiring harness electrical connector located below the PCM.
Fig 30: Locating Engine Wiring Harness Located Below PCM
Courtesy of FORD MOTOR CO.
34. Connect the coolant hose to the coolant tube.
Fig 31: Locating Coolant Hose From Coolant Tube
Courtesy of FORD MOTOR CO.
35. Connect the lower radiator hose to the oil filter adapter.
Fig 32: Disconnecting/Connecting Lower Radiator Hose From Oil Filter Adapter
Courtesy of FORD MOTOR CO.
36. Connect the degas bottle coolant hose.
Fig 33: Locating Degas Bottle Coolant Hose
Courtesy of FORD MOTOR CO.
37. Position the accessory drive belt onto the accessory drive pulleys.
38. Install the intake manifold. For additional information, refer to Intake Manifold .
39. Install the PCM. For additional information, refer to ELECTRONIC ENGINE CONTROLS - GASOLINE ENGINES article.
40. Install the degas bottle. For additional information, refer to ENGINE COOLING article.
41. Fill the crankcase with clean engine oil.
42. Install the engine cooling module. For additional information, refer to ENGINE COOLING article.