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Engine - 6.0L Diesel: Assembly: Engine: Assembly

  1. If removed, install the camshaft bearings.
    NOTE: Check alignment of the oil holes after installing the bearings.
    Fig 1: Installing Camshaft Bearing
    G01549775Courtesy of FORD MOTOR CO.
  2. Install the eight piston cooling tubes and bolts.
    CAUTION: The patch bolt is unique - Do not  substitute or engine damage can occur.
    NOTE: Apply threadlock 262 to the threads prior to installation.
    Fig 2: Installing Piston Cooling Tubes & Bolts
    G01549776Courtesy of FORD MOTOR CO.
  3. Install the camshaft and gear assembly. Install the thrust plate mounting bolts.
    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.
    Fig 3: Installing Thrust Plate Mounting Bolts
    G01549777Courtesy of FORD MOTOR CO.
  4. Install the crankshaft upper bearings and the crankshaft upper thrust bearing.
    NOTE: Apply clean engine oil to all the bearings.
    Fig 4: Installing Crankshaft Upper Bearings & Crankshaft Upper Thrust Bearing
    G01549778Courtesy of FORD MOTOR CO.
  5. Using the special tool, align the camshaft timing mark as shown.
    Fig 5: Aligning Camshaft Timing Marks
    G01549779Courtesy of FORD MOTOR CO.
  6. With the timing peg in the special tool over the camshaft timing mark, install the crankshaft.
    Fig 6: Installing Crankshaft
    G01549780Courtesy of FORD MOTOR CO.
  7. Position plastigage in the center of each main bearing bolt cap.
    NOTE: Do not turn the crankshaft during the main bearing clearance check.
  8. Install the lower bearings into the lower crankcase.
    Fig 7: Installing Lower Bearings Into Lower Crankcase
    G01549781Courtesy of FORD MOTOR CO.
  9. Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in the following sequence.
    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.
    1. Torque bolts to 149 Nm (110 lb-ft) in numerical sequence.
    2. Torque bolts again to 176 Nm (130 lb-ft) in numerical sequence.
    3. Torque bolts to 231 Nm (170 lb-ft) in the numerical sequence.
    Fig 8: Lower Crankcase Torque Sequence
    G01549782Courtesy of FORD MOTOR CO.
  10. Install eight M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence shown.
    Fig 9: Lower Crankcase Outside Bolts Torque Sequence
    G01549783Courtesy of FORD MOTOR CO.
  11. Remove the 28 bolts and the lower crankcase.
    Fig 10: Identifying Lower Crankcase Bolts
    G01549784Courtesy of FORD MOTOR CO.
  12. Measure the clearances for the main bearings. Remove the plastigage.
    Fig 11: Measuring Plastigage
    G01549785Courtesy of FORD MOTOR CO.
  13. Install new lower crankcase seals.
    NOTE: Apply clean engine oil to the lower main bearings.
    Fig 12: Installing Lower Crankcase Seals
    G01549786Courtesy of FORD MOTOR CO.
  14. Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten mounting bolts in the following sequence.
    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.
    1. Tighten bolts to 149 Nm (110 lb-ft) in numerical sequence.
    2. Tighten bolts again to 176 Nm (130 lb-ft) in numerical sequence.
    3. Tighten bolts to 231 Nm (170 lb-ft) in the numerical sequence.
    Fig 13: Lower Crankcase Torque Sequence
    G01549787Courtesy of FORD MOTOR CO.
  15. Install eight M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence shown.
    Fig 14: Lower Crankcase Outside Bolts Torque Sequence
    G01549788Courtesy of FORD MOTOR CO.
  16. Install the special tool and measure the crankshaft end play.
    Fig 15: Measuring Crankshaft End Play
    G01549789Courtesy of FORD MOTOR CO.
  17. Install the special tool and measure the camshaft end play.
    Fig 16: Measuring Camshaft End Play
    G01549790Courtesy of FORD MOTOR CO.
  18. Install the special tool and measure the camshaft gear backlash.
    Fig 17: Measuring Camshaft Gear Backlash
    G01549791Courtesy of FORD MOTOR CO.
  19. Install the block heater.
    Fig 18: Installing Block Heater
    G01549792Courtesy of FORD MOTOR CO.
  20. Install the camshaft position (CMP) sensor and the bolt.
    Fig 19: Installing Camshaft Position Sensor
    G01549793Courtesy of FORD MOTOR CO.
  21. Install the crankshaft position (CKP) sensor and the bolt.
    Fig 20: Installing Crankshaft Position Sensor
    G01549794Courtesy of FORD MOTOR CO.
  22. Install the connecting rod bearings.
    NOTE: Lubricate with clean engine oil.
    Fig 21: Installing Connecting Rod Bearings
    G01549795Courtesy of FORD MOTOR CO.
  23. Install new piston rings.
    NOTE: Make sure the ring openings are 120 degrees from each other, or engine damage can occur.
    1. The top compression ring is identified with one indentation mark and has a 15-degree keystone profile.
    2. The intermediate compression ring is identified with two indentation marks and a square profile.
    3. Install the oil control ring.
    Fig 22: Installing New Piston Rings
    G01549796Courtesy of FORD MOTOR CO.
  24. Install the piston and rod assemblies.
    NOTE: Cam V8 is toward the inside of the engine.
    NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.
    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 23: Installing Piston & Rod Assemblies
    G01549797Courtesy of FORD MOTOR CO.
  25. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
    1. Tighten to 45 Nm (33 lb-ft).
    2. Tighten to 68 Nm (50 lb-ft).
    Fig 24: Installing Connecting Rod Caps
    G01549798Courtesy of FORD MOTOR CO.
  26. Using a feeler gauge, check for connecting rod side clearance.
    Fig 25: Checking Connecting Rod Side Clearance
    G01549799Courtesy of FORD MOTOR CO.
  27. Install the upper oil pan.
    • Install the upper oil pan gasket.
    • Install the upper oil pan.
    • Install the bolts.
    Fig 26: Installing Upper Oil Pan
    G01549800Courtesy of FORD MOTOR CO.
  28. Install the oil pick-up tube and screen.
    • Install a new O-ring.
    • Install the oil pick-up tube and screen.
    • Install the bolts.
    Fig 27: Installing Oil Pick-Up
    G01549801Courtesy of FORD MOTOR CO.
  29. Install the oil pan.
    • Install the press-in-place gasket.
    • Install the oil pan.
    • Install the bolts.
    Fig 28: Installing Oil Pan
    G01549802Courtesy of FORD MOTOR CO.
  30. Apply clean engine oil to the hydraulic cam followers and install into the roller follower guide. Install the roller follower guide and the bolts.
    NOTE: Only the front guides use bolts.
    Fig 29: Installing Roller Follower Guides & Bolts
    G01549803Courtesy of FORD MOTOR CO.
  31. Install the rear engine tube assembly and the bolt.
    Fig 30: Installing Rear Engine Tube Assembly
    G01549804Courtesy of FORD MOTOR CO.
  32. Install the rear engine tube assembly bolts.
    Fig 31: Installing Rear Engine Tube Assembly Bolts
    G01549805Courtesy of FORD MOTOR CO.
  33. Install the four cylinder head dowels.
    Fig 32: Identifying Four Cylinder Head Dowels
    G01549806Courtesy of FORD MOTOR CO.
  34. Place the new cylinder head gasket over the dowel sleeves and onto the crankcase.
    NOTE: Install a new cylinder head gasket with the part number facing up. Verify the top five 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 33: Installing New Cylinder Head Gasket
    G01549807Courtesy of FORD MOTOR CO.
  35. Using the special tool, install the cylinder heads.
    1. Install the lifting brackets.
    2. Install the bolts.
      • Install the cylinder heads.
    Fig 34: Installing Cylinder Head
    G01549808Courtesy of FORD MOTOR CO.
  36. Install the 10 outer head bolts (finger-tight).
    Fig 35: Installing Outer Head Bolts
    G01549809Courtesy of FORD MOTOR CO.
  37. Install the 16 push rods.
    NOTE: Make sure the copper ends of the push rods are inserted in the hydraulic roller follower sockets before installing the rocker arm carrier assembly.
    Fig 36: Installing Push Rods
    G01549810Courtesy of FORD MOTOR CO.
  38. Install the 16 valve bridges.
    Fig 37: Installing Valve Bridges
    G01549811Courtesy of FORD MOTOR CO.
  39. Install the rocker arm carrier to the cylinder head.
    • Install the press-in-place gasket.
    • Install the rocker arm carrier.
    • Install the bolts.
    Fig 38: Installing Rocker Arm Carrier
    G01549812Courtesy of FORD MOTOR CO.
  40. Install the rocker arm assemblies and the 16 bolts.
    NOTE: Rotate the crankshaft until the damper locating dowel notch is in the six o'clock position.
    Fig 39: Installing Rocker Arm Assemblies
    G01549813Courtesy of FORD MOTOR CO.
  41. Install the cylinder head retaining bolts finger-tight.
    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: Lightly lubricate the cylinder head bolt threads and flanges with clean engine oil.
    Fig 40: Identifying Cylinder Head Bolts
    G01549814Courtesy of FORD MOTOR CO.
  42. Tighten the head bolts in the following sequence.
    1. Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
    2. Tighten bolts 1, 3, 5, 7 and 9 to 115 Nm (85 lb-ft).
    3. Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
    4. Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
    5. Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
    6. Tighten bolts 11 through 15 to 24 Nm (18 lb-ft).
    7. Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
    Fig 41: Cylinder Head Bolts Torque Sequence
    G01549815Courtesy of FORD MOTOR CO.
  43. Install a new crankcase-to-head tube assembly.
    NOTE: Install a new lower O-ring.
    Fig 42: Installing Crankcase-To-Head Tube Assembly
    G01549816Courtesy of FORD MOTOR CO.
  44. Install new O-rings and a copper washer on the fuel injector.
    NOTE: Lubricate the fuel injector and O-rings liberally with clean engine oil.
    Fig 43: Identifying Fuel Injector
    G01549817Courtesy of FORD MOTOR CO.
  45. Install the fuel injector, the fuel injector hold-down and bolt.
    CAUTION: To prevent engine damage, Do not  use air tools to install the fuel injectors. The clip that extracts the injector can dislodge and fall into the oil drain hole.
    Fig 44: Installing Fuel Injector
    G01549818Courtesy of FORD MOTOR CO.
  46. Install the fuel injector electrical connector into the rocker carrier.
    Fig 45: Installing Fuel Injector Electrical Connector Into The Rocker Carrier
    G01549819Courtesy of FORD MOTOR CO.
  47. Install the high pressure oil rail.
    NOTE: Apply clean engine oil to the top fuel injector O-rings before installing the high pressure oil rail.
    • Install the high pressure oil rail.
    • Install the bolts finger-tight.
    Fig 46: Identifying High Pressure Oil Rail Bolts
    G01549820Courtesy of FORD MOTOR CO.
  48. Tighten the bolts in the sequence shown.
    Fig 47: High Pressure Oil Rail Bolts Torque Sequence
    G01549821Courtesy of FORD MOTOR CO.
  49. Install the high pressure oil line.
    Fig 48: Installing High Pressure Oil Line
    G01549822Courtesy of FORD MOTOR CO.
  50. Install the left exhaust manifold and the bolts.
    Fig 49: Installing Left Exhaust Manifold
    G01549823Courtesy of FORD MOTOR CO.
  51. Install the right exhaust manifold and the bolts.
    Fig 50: Installing Right Exhaust Manifold
    G01549824Courtesy of FORD MOTOR CO.
  52. Apply a bead of sealant at the back seam of the upper and lower crankcase.
    Fig 51: Identifying Bead Of Sealant
    G01549825Courtesy of FORD MOTOR CO.
  53. Install the rear engine cover.
    • Install the press-in-place gasket.
    • Install the rear engine cover.
    • Install the bolts.
    Fig 52: Installing Rear Engine Cover
    G01549826Courtesy of FORD MOTOR CO.
  54. Using the special tools, install the crankshaft rear oil seal.
    NOTE: The crankshaft rear oil seal and wear sleeve are installed as an assembly.
    NOTE: Apply a bead of threadlock around the circumference of the outer rear edge of the secondary crankshaft flange.
    Fig 53: Installing Rear Crankshaft Oil Seal
    G01549827Courtesy of FORD MOTOR CO.
  55. Install the flywheel adapter.
    Fig 54: Installing Flywheel Adapter
    G01549828Courtesy of FORD MOTOR CO.
  56. Apply a bead of sealant at the front seam of the upper and lower crankcase.
    Fig 55: Identifying Bead Of Sealant
    G01549829Courtesy of FORD MOTOR CO.
  57. Install the guide bolts and the front cover gasket.
    Fig 56: Installing Front Cover Gasket
    G01549830Courtesy of FORD MOTOR CO.
  58. Install the engine front cover and bolts.
    Fig 57: Installing Engine Front Cover
    G01549831Courtesy of FORD MOTOR CO.
  59. Lubricate inner gear with a suitable lithium assembly grease and install onto crankshaft. Lubricate outer gear with lithium assembly grease and mesh with inner gear rotor in oil pump housing. Wipe off excess assembly grease.
    NOTE: Install gears with marks pointing outward.
    Fig 58: Installing Inner & Outer Gerotors
    G01549832Courtesy of FORD MOTOR CO.
  60. Install the gerotor cover and the bolts.
    NOTE: Install a new O-ring seal.
    Fig 59: Installing Gerotor Cover & Bolts
    G01549833Courtesy of FORD MOTOR CO.
  61. Using the special tool, install the oil seal and wear sleeve assembly.
    NOTE: Apply threadlock to the outer circumference of the leading edge of the crankshaft.
    NOTE: The seal and wear sleeve must not be separated.
    Fig 60: Installing Oil Seal & Wear Sleeve Assembly
    G01549834Courtesy of FORD MOTOR CO.
  62. Install the crankshaft vibration damper and bolts.
    NOTE: New bolts must always be installed.
    • Tighten the bolts in the sequence shown.
    • Tighten the bolts to 68 Nm (50 lb-ft).
    • Tighten the bolts an additional 90 degrees.
    Fig 61: Installing Crankshaft Vibration Damper
    G01549835Courtesy of FORD MOTOR CO.
  63. Install the coolant pump and bolts.
    NOTE: Install a new O-ring on the coolant pump.
    Fig 62: Installing Coolant Pump
    G01549836Courtesy of FORD MOTOR CO.
  64. Install the coolant pump pulley and the bolts.
    Fig 63: Installing Coolant Pump Pulley
    G01549837Courtesy of FORD MOTOR CO.
  65. Install the valve covers.
    NOTE: Left side shown; right side similar.
    • Install the gaskets.
    • Install the valve covers.
    • Install the bolts and stud bolts.
    Fig 64: Identifying Valve Cover Assembly
    G01549838Courtesy of FORD MOTOR CO.
  66. Install the eight glow plugs.
    Fig 65: Installing Glow Plugs
    G01549839Courtesy of FORD MOTOR CO.
  67. Install the glow plug buss bar.
    NOTE: Left side shown, right side similar.
    NOTE: Inspect the buss bar O-rings and replace as needed.
    NOTE: Apply clean engine oil to the O-rings.
    Fig 66: Installing Glow Plug Buss Bar
    G01549840Courtesy of FORD MOTOR CO.
  68. Install a new O-ring seal.
    Fig 67: Identifying O-Ring Seal
    G01549841Courtesy of FORD MOTOR CO.
  69. Install the high-pressure oil pump and the bolts.
    Fig 68: Installing High-Pressure Oil Pump
    G01549842Courtesy of FORD MOTOR CO.
  70. Install the high-pressure pump O-ring seal.
    Fig 69: Installing High-Pressure Pump O-Ring Seal
    G01549843Courtesy of FORD MOTOR CO.
  71. Install the oil discharge pipe and the bolts.
    Fig 70: Installing Oil Discharge Pipe
    G01549844Courtesy of FORD MOTOR CO.
  72. Position the dial indicator with brackets onto the oil pump drive and check the oil pump drive gear backlash.
    Fig 71: Checking Oil Pump Drive Gear Backlash
    G01549845Courtesy of FORD MOTOR CO.
  73. Install a new D-ring seal on the high-pressure discharge pipe.
    Fig 72: Identifying D-ring seal
    G01549846Courtesy of FORD MOTOR CO.
  74. Clean the cover mounting surface and apply sealant at the seams.
    Fig 73: Identifying Sealant Locations
    G01549847Courtesy of FORD MOTOR CO.
  75. Install the high-pressure pump cover.
    • Install the press-in-place gasket.
    • Install the high pressure pump cover.
    • Install the bolts.
    Fig 74: Installing High Pressure Pump Cover
    G01549848Courtesy of FORD MOTOR CO.
  76. Install the turbocharger heat shield and bolts.
    Fig 75: Installing Heat Shield
    G01549849Courtesy of FORD MOTOR CO.
  77. Install the oil pump inlet strainer.
    Fig 76: Installing Oil Pump Inlet Strainer
    G01549850Courtesy of FORD MOTOR CO.
  78. Install the oil cooler assembly.
    • Install the gasket.
    • Install the oil cooler assembly.
    • Install the bolts.
    Fig 77: Installing Oil Cooler Assembly
    G01549851Courtesy of FORD MOTOR CO.
  79. Install the oil filter base.
    • Install the gasket.
    • Install the oil filter base.
    • Install the bolts.
    Fig 78: Installing Oil Filter Base
    G01549852Courtesy of FORD MOTOR CO.
  80. Install the exhaust gas recirculation (EGR) cooler coolant supply port cover.
    • Install the gasket.
    • Install the EGR cooler coolant supply port cover.
    • Install the bolts.
    Fig 79: Installing EGR Cooler Coolant Supply Port Cover
    G01549853Courtesy of FORD MOTOR CO.
  81. Install new O-ring in the oil filter base.
    Fig 80: Installing O-Ring In Oil Filter Base
    G01549854Courtesy of FORD MOTOR CO.
  82. Install the belt idler and bolt.
    Fig 81: Installing Idler Pulley
    G01549855Courtesy of FORD MOTOR CO.
  83. Install the belt tensioner and bolts.
    Fig 82: Installing Belt Tensioner
    G01549856Courtesy of FORD MOTOR CO.
  84. Install the left cylinder head fuel line.
    NOTE: Install new sealing washers.
    Fig 83: Installing Left Cylinder Head Fuel Line
    G01549857Courtesy of FORD MOTOR CO.
  85. Install the fuel lines and bracket bolt.
    Fig 84: Installing Fuel Line Bracket
    G01549858Courtesy of FORD MOTOR CO.
  86. Install the thermostat housing, the bolt and the stud bolt.
    NOTE: Install a new O-ring on the thermostat.
    Fig 85: Installing Thermostat Housing
    G01549859Courtesy of FORD MOTOR CO.
  87. Position the exhaust backpressure assembly and install the retaining nut.
    Fig 86: Installing Exhaust Backpressure Assembly
    G01549860Courtesy of FORD MOTOR CO.
  88. Tighten the exhaust backpressure tube at the exhaust manifold.
    Fig 87: Tightening Exhaust Backpressure Tube At Exhaust Manifold
    G01549861Courtesy of FORD MOTOR CO.
  89. Install the oil level indicator tube and nut.
    NOTE: Install a new O-ring on the oil indicator and tube.
    Fig 88: Installing Oil Level Indicator Tube & Nut
    G01549862Courtesy of FORD MOTOR CO.
  90. Install the glow plug mounting bracket and the nuts.
    Fig 89: Installing Glow Plug Mounting Bracket
    G01549863Courtesy of FORD MOTOR CO.
  91. Install the LH and RH motor mounts and bolts.
    NOTE: Left side shown; right side similar.
    Fig 90: Identifying Motor Mount
    G01549864Courtesy of FORD MOTOR CO.
  92. Install the starter and the three bolts.
    Fig 91: Installing Starter
    G01549865Courtesy of FORD MOTOR CO.
  93. Install the special tool.
    Fig 92: Installing Special Tool
    G01549866Courtesy of FORD MOTOR CO.
  94. Install the special tool.
    Fig 93: Installing Special Tool
    G01549867Courtesy of FORD MOTOR CO.
  95. Install the lifting crane and remove the engine from the engine stand.
  96. Install the flexplate flywheel and the bolts.
    • Tighten the bolts in the following sequence.
    • Tighten all bolts to 5 Nm (44 lb-in)
    • Tighten all bolts to 94 Nm (69 lb-ft) in the sequence shown.
    Fig 94: Identifying Flywheel/Flexplate Torque Sequence
    G01549868Courtesy of FORD MOTOR CO.
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