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Section 713 (Engine - 6.0L Diesel -- F250-F550 Super Duty 6.0L (99P F450/550)): Assembly: Engine: Assembly

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying D-Ring Seals
G03899308Courtesy of FORD MOTOR CO.
    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.
  1. Install new D-ring seals on the crankcase-to-head tube assemblies.
    2. Fig 2: Installing Camshaft Bearings
    GF0005847Courtesy of FORD MOTOR CO.
    NOTE: Check alignment of the oil holes after installing the bearings.
  2. If removed, use the special tool to install the camshaft bearings.
    3. Fig 3: Identifying Piston Cooling Tube Bolt
    G03887603Courtesy of FORD MOTOR CO.
    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.
  3. Install the 8 piston cooling tubes and the 8 bolts.
    • Tighten to 13 Nm (10 lb-ft).
    4. Fig 4: Locating Thrust Plate Mounting Bolts
    G03887602Courtesy of FORD MOTOR CO.
    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.
  4. Install the camshaft and gear assembly and the thrust plate mounting bolts.
    • Tighten to 31 Nm (23 lb-ft).
    5. Fig 5: View Of Crankshaft Upper Bearing Seats
    G03887601Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine oil to each bearing prior to installation.
  5. Install the crankshaft upper bearings and the crankshaft upper thrust bearing.
    6. Fig 6: Aligning Camshaft Timing Mark
    GF0005848Courtesy of FORD MOTOR CO.
  6. Using the special tool, align the camshaft timing mark as shown.
    7. Fig 7: Installing Crankshaft (Camshaft Aligned)
    GF0005849Courtesy of FORD MOTOR CO.
  7. With the timing peg in the special tool over the camshaft timing mark, install the crankshaft.
    8. NOTE: Do not turn the crankshaft during the main bearing clearance check.
  8. Position commercially available plastigage in the center of each main bearing bolt cap.
    9. Fig 8: Lower Crankcase Bearings
    GF0005850Courtesy of FORD MOTOR CO.
  9. Install the lower bearings into the lower crankcase.
    10. Fig 9: Lower Crankcase Main Bearing Mounting Bolts Torque Sequence
    GF0005851Courtesy of FORD MOTOR CO.
    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.
  10. 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).
    11. Fig 10: Lower Crankcase Bolts
    GF0005835Courtesy of FORD MOTOR CO.
  11. Remove the 20 bolts and the lower crankcase.
    12. Fig 11: Measuring Main Bearing Clearance (With Specifications)
    GF0005852Courtesy of FORD MOTOR CO.
  12. Measure the clearances for the main bearings. Remove the plastigage.
    13. Fig 12: Locating Lower Crankcase Seals
    G03887599Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine oil to the lower main bearings.
  13. Install new lower crankcase seals.
    14. Fig 13: Lower Crankcase Main Bearing Mounting Bolts Torque Sequence
    GF0005851Courtesy of FORD MOTOR CO.
    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.
  14. 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).
    15. Fig 14: Special Tool & Bolt
    GF0005853Courtesy of FORD MOTOR CO.
  15. Remove the bolt and special tool.
    16. Fig 15: Checking Crankshaft End Play (With Specifications)
    GF0005854Courtesy of FORD MOTOR CO.
    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.
  16. Using the special tool, measure the crankshaft end play.
    17. Fig 16: Checking Camshaft End Play (With Specifications)
    GF0005833Courtesy of FORD MOTOR CO.
  17. Using the special tool, measure the camshaft end play.
    18. Fig 17: Checking Camshaft Gear Backlash (With Specifications)
    GF0005832Courtesy of FORD MOTOR CO.
  18. Using the special tool, measure the camshaft gear backlash.
    19. Fig 18: Identifying Block Heater
    G03887597Courtesy of FORD MOTOR CO.
  19. Install the block heater.
    • Tighten to 41 Nm (30 lb-ft).
    20. Fig 19: Identifying Camshaft Position (CMP) Sensor
    G03887596Courtesy of FORD MOTOR CO.
  20. Install the camshaft position (CMP) sensor and the bolt.
    • Tighten to 13 Nm (10 lb-ft).
    21. Fig 20: Identifying Crankshaft Position (CKP) Sensor
    G03887595Courtesy of FORD MOTOR CO.
  21. Install the crankshaft position (CKP) sensor and the bolt.
    • Tighten to 13 Nm (10 lb-ft).
    22. Fig 21: View Of Upper And Lower Connecting Rod Bearings
    G03887591Courtesy of FORD MOTOR CO.
    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.
  22. Install the connecting rod bearings.
    23. Fig 22: Piston Rings
    GF0005831Courtesy of FORD MOTOR CO.
    CAUTION: Make sure the ring openings are 120 degrees from each other, or engine damage can occur.
  23. 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.
    • Install the oil control ring.
    24. Fig 23: Installing Piston & Rod Assemblies
    GF0005855Courtesy of FORD MOTOR CO.
    NOTE: Cam V8 is toward the inside of the engine.
    NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.
  24. Install the piston and rod assemblies.
    • Coat the inside diameter of the ring compressor with clean engine oil.
    • 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.
    25. Fig 24: Positioning Piece Of Plastigage Across Bearing Surface
    GF0000201Courtesy of FORD MOTOR CO.
  25. Position a piece of plastigage across the bearing surface.
    26. Fig 25: Identifying Connecting Rod Cap Bolts
    G03887588Courtesy of FORD MOTOR CO.
    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.
  26. 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).
  27. Remove the bolts and the connecting rod cap.
    28. Fig 26: Measuring Plastigage (With Specifications)
    GF0005856Courtesy of FORD MOTOR CO.
  28. Measure the clearances for the connecting rod cap. Remove the plastigage.
    29. Fig 27: Identifying Connecting Rod Cap Bolts
    G03887588Courtesy of FORD MOTOR CO.
    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).
    30. Fig 28: Checking Connecting Rod Side Clearance (With Specifications)
    GF0005829Courtesy of FORD MOTOR CO.
  30. Using a feeler gauge, check for connecting rod side clearance.
    31. Fig 29: Oil Pan Gasket
    GF0005767Courtesy of FORD MOTOR CO.
  31. Install a new press-in-place gasket into the upper oil pan.
    32. Fig 30: Identifying Upper Oil Pan Bolts
    G03887278Courtesy of FORD MOTOR CO.
  32. Position the upper oil pan and install the bolts.
    • Tighten to 13 Nm (10 lb-ft).
    33. Fig 31: Locating Oil Pickup Tube O-Ring Seal
    G03887262Courtesy of FORD MOTOR CO.
  33. Install a new oil pickup tube O-ring seal.
    34. Fig 32: Locating Oil Pickup Tube Bolts
    G03887261Courtesy of FORD MOTOR CO.
  34. Install the oil pickup tube and screen and the 2 bolts.
    • Tighten to 13 Nm (10 lb-ft).
    35. Fig 33: Longer Oil Pan Bolts
    GF0005768Courtesy of FORD MOTOR CO.
  35. Install the oil pan and the 20 bolts.
    • Install the 5 longer oil pan bolts.
    • Install the remaining oil pan bolts.
    • Tighten to 13 Nm (10 lb-ft).
    36. Fig 34: Identifying Roller Follower Guide Bolt
    G03887584Courtesy of FORD MOTOR CO.
    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.
  36. 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).
    37. Fig 35: Identifying Rear Engine Tube Assembly
    G03887583Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  37. 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).
    38. Fig 36: Locating Cylinder Head Dowels
    G03887582Courtesy of FORD MOTOR CO.
  38. Install the 4 cylinder head dowels.
    39. Fig 37: Identifying Gasket Sealing Surfaces Area
    G03887503Courtesy of FORD MOTOR CO.
    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.
  39. Place the new cylinder head gasket over the dowel sleeves and onto the crankcase.
    40. Fig 38: Special Tool
    GF0005825Courtesy of FORD MOTOR CO.
  40. Using the special tool, install the cylinder heads.
    1. Install the lifting bracket.
    2. Install the bolts.
    41. Fig 39: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
  41. Install the 5 outer bolts for each cylinder head (finger tight).
    42. Fig 40: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
    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.
  42. Apply clean engine oil to each end of the push rods and insert them into their respective positions.
    43. Fig 41: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
    NOTE: Coat the end of each valve stem with clean engine oil.
  43. Install the 16 valve bridges.
    44. Fig 42: Identifying Rocker Arm Carrier Bolts
    GF0005824Courtesy of FORD MOTOR CO.
  44. Install the press-in-place gasket, the rocker arm carrier and the bolts.
    • Tighten to 62 Nm (46 lb-ft).
    45. Fig 43: Identifying Rocker Arm Assembly Bolts
    G03887497Courtesy of FORD MOTOR CO.
    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.
  45. Install the rocker arm assemblies and the 16 bolts.
    • Tighten to 31 Nm (23 lb-ft).
    46. Fig 44: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
    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.
  46. Install the 10 cylinder head retaining bolts for each cylinder head (finger tight).
    47. Fig 45: Cylinder Head Bolt Torque Sequence
    GF0005747Courtesy of FORD MOTOR CO.
  47. 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).
    48. Fig 46: Identifying O-Ring Seals, Copper Washer And Fuel Injector
    G03887397Courtesy of FORD MOTOR CO.
    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.
  48. Install new O-rings and a copper washer on the fuel injector.
    49. Fig 47: Identifying Fuel Injector Hold-Down Bolt
    G03887381Courtesy of FORD MOTOR CO.
    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.
  49. Install the fuel injector, the fuel injector hold-down and bolt.
    • Tighten to 35 Nm (26 lb-ft).
    50. Fig 48: Identifying Fuel Injector Electrical Connector
    G03887399Courtesy of FORD MOTOR CO.
    CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
  50. Install the fuel injector electrical connector into the rocker carrier.
    51. Fig 49: Identifying Top Fuel Injector O-Ring Seals
    G03888010Courtesy of FORD MOTOR CO.
  51. Apply clean engine oil to the top fuel injector O-ring seals.
    52. Fig 50: Locating High-Pressure Oil Rail On Injector Bolts
    G03887401Courtesy of FORD MOTOR CO.
    CAUTION: Using the bolts to push the high pressure oil rail into 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.
  52. 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.
    53. Fig 51: High-Pressure Oil Rail Torque Sequence
    GF0005748Courtesy of FORD MOTOR CO.
  53. 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).
    54. Fig 52: Locating D-Ring Seals
    G03887376Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine oil to the crankcase-to-head tube prior to installation.
  54. Install the crankcase-to-head tube assembly.
    • Tighten to 82 Nm (60 lb-ft).
    55. Fig 53: Applying Sealant To Upper And Lower Crankcase
    G03887338Courtesy of FORD MOTOR CO.
  55. Apply a bead of sealant at the back seam of the upper and lower crankcase.
    56. Fig 54: Locating Rear Engine Cover Bolts
    G03887334Courtesy of FORD MOTOR CO.
    CAUTION: To prevent engine damage, replace damaged or missing dowel pins before installing the engine rear cover.
    NOTE: Prior to installing the engine rear cover, check that the alignment dowels are centered so that 10 mm (0.39 in) of the dowel extends toward the engine and 10 mm (0.39 in) extends toward the transmission.
  56. Install a new press-in-place gasket, the engine rear cover and the bolts.
    • Tighten to 24 Nm (18 lb-ft).
    57. Fig 55: Installing Seal
    GF0005728Courtesy of FORD MOTOR CO.
    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.
  57. Using the special tools, install a new crankshaft rear oil seal.
    58. Fig 56: Identifying Flywheel Adapter
    G03887288Courtesy of FORD MOTOR CO.
  58. Install the flywheel adapter.
    59. Fig 57: Identifying Front Cover Crankcase Dowels
    G03887308Courtesy of FORD MOTOR CO.
  59. If removed, install the front cover crankcase dowels into the cylinder block.
    60. Fig 58: Applying Sealant To Upper And Lower Crankcase Front Seam
    GF0005857Courtesy of FORD MOTOR CO.
  60. Apply a bead of sealant at the front seam of the upper and lower crankcase.
    61. Fig 59: Guide Studs & Front Cover Gasket
    GF0005858Courtesy of FORD MOTOR CO.
    NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
  61. Install the guide studs and the front cover gasket.
    62. Fig 60: Locating Engine Front Cover Bolts
    G03887307Courtesy of FORD MOTOR CO.
  62. Install the engine front cover and the bolts.
    • Tighten to 24 Nm (18 lb-ft).
    63. Fig 61: Identifying Inner And Outer Oil Pump Drive Rotors With Alignment Marks
    G03887281Courtesy of FORD MOTOR CO.
    NOTE: Install oil pump drive rotors with marks pointing outward.
  63. 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.
    64. Fig 62: Locating Oil Pump Body Bolts
    G03887280Courtesy of FORD MOTOR CO.
    NOTE: Install a new O-ring seal.
  64. Install the gerotor cover and the 5 bolts.
    • Tighten to 13 Nm (10 lb-ft).
    65. Fig 63: Installing Oil Seal And Wear Sleeve Assembly
    GF0005711Courtesy of FORD MOTOR CO.
    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.
  65. Using the special tool, install a new oil seal and wear sleeve assembly.
    66. Fig 64: Crankshaft Vibration Damper Torque Sequence
    GF0005859Courtesy of FORD MOTOR CO.
    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.
  66. 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.
    67. Fig 65: Locating Dual Generator Pulley Bolts
    G03887210Courtesy of FORD MOTOR CO.
  67. If equipped, install the dual generator pulley and the 3 bolts.
    • Tighten to 47 Nm (35 lb-ft).
    68. Fig 66: Locating Coolant Pump Bolts
    G03887306Courtesy of FORD MOTOR CO.
    NOTE: Install a new O-ring seal on the coolant pump.
  68. Install the coolant pump and the 4 bolts.
    • Tighten to 23 Nm (17 lb-ft).
    69. Fig 67: Identifying Coolant Pump Pulley Bolts
    G04614086Courtesy of FORD MOTOR CO.
  69. Install the coolant pump pulley and the 4 bolts.
    • Tighten to 31 Nm (23 lb-ft).
    70. Fig 68: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    G03887197Courtesy of FORD MOTOR CO.
  70. Install the RH high-pressure oil rail-to-valve cover gasket.
    71. Fig 69: Identifying Valve Cover, Stud Bolts, And Bolts
    G03887372Courtesy of FORD MOTOR CO.
    CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.
    NOTE: RH shown, LH similar.
  71. 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).
    72. Fig 70: Locating Injection Control Pressure Sensor
    G03906932Courtesy of FORD MOTOR CO.
    NOTE: Clean and inspect the O-ring seal.
  72. Install the injection control pressure (ICP) sensor.
    • Tighten to 12 Nm (9 lb-ft).
    73. Fig 71: Identifying Glow Plug
    G03887484Courtesy of FORD MOTOR CO.
  73. Install the 8 glow plugs.
    • Tighten to 19 Nm (14 lb-ft).
    74. Fig 72: Identifying Glow Plug Harness Special Tool (303-1114)
    G04614327Courtesy of FORD MOTOR CO.
    NOTE: Clean and apply clean engine oil to the O-ring seals.
  74. Using the special tool, install the glow plug harness.
    75. Fig 73: Locating High-Pressure Oil Pump O-Ring Seal
    G03887542Courtesy of FORD MOTOR CO.
    CAUTION: To prevent engine damage, use only approved pump cover seal. Substitution can cause damage to the pump cover.
  75. Install a new O-ring seal on the high-pressure oil pump.
    76. Fig 74: Identifying High-Pressure Tube Assembly Bolts
    G03887702Courtesy of FORD MOTOR CO.
  76. Install the high-pressure tube assembly.
    77. Fig 75: Identifying Lower O-Ring Seals
    G03887540Courtesy of FORD MOTOR CO.
  77. Install new lower O-ring seals.
    78. Fig 76: Locating High-Pressure Oil Pump Bolts
    G03887539Courtesy of FORD MOTOR CO.
  78. Install the high-pressure pump and bolts.
    • Tighten to 31 Nm (23 lb-ft).
    79. Fig 77: Locating High-Pressure Tube Assembly Bolts
    G03887538Courtesy of FORD MOTOR CO.
  79. Install the high-pressure tube assembly bolts.
    • Tighten to 11 Nm (8 lb-ft).
    80. Fig 78: Checking Oil Pump Drive Gear Backlash
    GF0005821Courtesy of FORD MOTOR CO.
  80. Position the special tool and check the oil pump drive gear backlash.
    81. Fig 79: Identifying Press-In-Place High-Pressure Pump Cover Gasket
    G03887707Courtesy of FORD MOTOR CO.
  81. Install a new press-in-place gasket in the high-pressure pump cover.
    82. Fig 80: Applying Sealer At Seams
    G03887708Courtesy of FORD MOTOR CO.
  82. Clean the cover mounting surface and apply sealer at the seams.
    83. Fig 81: High-Pressure Oil Pump Cover Bolts
    GF0005819Courtesy of FORD MOTOR CO.
    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.
  83. Install the high-pressure oil pump cover and bolts.
    • Tighten to 11 Nm (8 lb-ft).
    84. Fig 82: Identifying Special Tool (303-1112)
    G04614381Courtesy of FORD MOTOR CO.
  84. Using the special tool, install the injection pressure regulator (IPR) valve.
    • Tighten to 50 Nm (37 lb-ft).
    85. Fig 83: Locating Heat Insulating Wrap
    G03887533Courtesy of FORD MOTOR CO.
  85. If equipped, install the heat insulating wrap and fasten the snap.
    86. Fig 84: Identifying Oil Pump Inlet Strainer
    G03887232Courtesy of FORD MOTOR CO.
  86. Install the oil pump inlet strainer.
    87. Fig 85: Identifying Oil Cooler Assembly Bolts
    G03887231Courtesy of FORD MOTOR CO.
    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.
  87. Install a new press-in-place gasket, the oil cooler assembly and the bolts.
    • Tighten to 22 Nm (16 lb-ft).
    88. Fig 86: Oil Cooler Cover Bolts (With Specifications)
    GF0005774Courtesy of FORD MOTOR CO.
    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.
  88. 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).
    89. Fig 87: Identifying EGR Cooler Coolant Supply Port Cover Bolts
    G03887229Courtesy of FORD MOTOR CO.
  89. 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).
    90. Fig 88: Identifying O-Ring Seals On Oil Filter Base
    G03887527Courtesy of FORD MOTOR CO.
  90. Install new O-ring seals in the oil filter base.
    91. Fig 89: Locating Accessory Drive Idler Pulley Bolt
    G03887524Courtesy of FORD MOTOR CO.
  91. Install the accessory drive idler pulley and bolts.
    • Tighten to 47 Nm (35 lb-ft).
    92. Fig 90: Identifying Accessory Drive Belt Tensioner Bolts
    G03887304Courtesy of FORD MOTOR CO.
  92. Install the belt tensioner and bolts.
    • Tighten to 25 Nm (18 lb-ft).
    93. Fig 91: Identifying Fuel Line Banjo Bolt
    G03887486Courtesy of FORD MOTOR CO.
    NOTE: Install new sealing washers.
  93. Install the LH cylinder head fuel tube.
    • Tighten to 38 Nm (28 lb-ft).
    94. Fig 92: Fuel Tube Bracket Bolt
    GF0005752Courtesy of FORD MOTOR CO.
  94. Install the fuel tubes and bracket bolt.
    • Tighten to 13 Nm (10 lb-ft).
    95. Fig 93: Thermostat Housing Bolts
    GF0005712Courtesy of FORD MOTOR CO.
    NOTE: Install a new O-ring seal on the thermostat.
  95. Install the thermostat housing and the bolts.
    • Tighten to 23 Nm (17 lb-ft).
    96. Fig 94: Locating Wire Harness Retainer
    G03907047Courtesy of FORD MOTOR CO.
    NOTE: Install a new O-ring seal on the oil indicator and tube. Apply clean engine oil to the O-ring seal.
  96. Position the oil level indicator tube and install the nut. Connect the wiring harness retainer to the stud bolt.
    97. Fig 95: Glow Plug Module Mounting Bracket Nuts
    GF0005701Courtesy of FORD MOTOR CO.
  97. Install the glow plug mounting bracket and the nuts.
    • Tighten to 9 Nm (80 lb-in).
    98. Fig 96: Motor Mount Bolts
    GF0005818Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  98. Install the LH and RH motor mounts and bolts.
    • Tighten to 62 Nm (46 lb-ft).
    99. Fig 97: Locating Cylinder Block Coolant Drain Plug
    G03887451Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
    NOTE: Lightly lubricate the O-ring seal with clean engine oil prior to installing.
  99. Install the cylinder block coolant drain plugs.
    • Tighten to 20 Nm (15 lb-ft).
    100. Fig 98: Starter & Bolt
    GF0005817Courtesy of FORD MOTOR CO.
  100. 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).
    101. Fig 99: Locating Engine Lift Adapters (303-D043-01)
    G04614140Courtesy of FORD MOTOR CO.
  101. Install the special tool.
    102. Fig 100: Special Tool
    GF0005860Courtesy of FORD MOTOR CO.
  102. Install the special tool.
  103. Install the lifting crane and remove the engine from the engine stand.
    104. Fig 101: Identifying Flexplate/Flywheel Bolt Tightening Sequence
    G04614191Courtesy of FORD MOTOR CO.
  104. 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).
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