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Section 302 (Engine - 7.3L Diesel): Installation: Engine: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

ALL VEHICLES 

  1. Raise the engine high enough to clear the No. 1 crossmember, and position the engine into the vehicle.
  2. Align the torque converter studs with the holes in the flywheel. Lower the engine onto the engine mount towers.
  3. Remove the floor crane and the lifting fixture from the engine.
  4. Install the transmission-to-engine mounting bolts.
    • Do not install the top RH bolt at this time.
    Fig 1: Installing Transmission-To-Engine Mounting Bolts
    G01537931Courtesy of FORD MOTOR CO.
  5. Position the transmission fill tube and install the top RH transmission-to-engine mounting bolt.
    Fig 2: Positioning Transmission Fill Tube And Installing Top RH Transmission-To-Engine Mounting Bolt
    G01537932Courtesy of FORD MOTOR CO.
  6. Install the retaining nut and the transmission fluid indicator.
    Fig 3: Installing Transmission Fluid Indicator
    G01537933Courtesy of FORD MOTOR CO.
  7. Remove the jack from under the transmission.
  8. Raise and support the vehicle.
  9. Install the lower transmission-to-engine mounting bolts.
    Fig 4: Installing Lower Transmission-To-Engine Mounting Bolts
    G01537934Courtesy of FORD MOTOR CO.
  10. Install the oil filter.
  11. Connect the block heater.
    Fig 5: Connecting Block Heater
    G01537935Courtesy of FORD MOTOR CO.
  12. Install the torque converter-to-flywheel retaining nuts.
    Fig 6: Installing Torque Converter-To-Flywheel Retaining Nuts
    G01537936Courtesy of FORD MOTOR CO.
  13. Install the flywheel housing cover.
    Fig 7: Installing Flywheel Housing Cover
    G01537937Courtesy of FORD MOTOR CO.
    14. NOTE: E-250 - E-450 shown, E-550 similar.
    Fig 8: Installing Engine Mounting Nuts
    G01537938Courtesy of FORD MOTOR CO.
  14. Install the engine mounting nuts.
  15. Install the starter motor. For additional information, refer to STARTERS - DIESEL .
  16. Lower the vehicle.
  17. Remove the lifting eye from the right side cylinder head.
  18. Remove the two engine lift adapters.
    Fig 9: Removing Engine Lift Adapters
    G01537939Courtesy of FORD MOTOR CO.
  19. Position the fuel tube and install the bolt.
    Fig 10: Installing Fuel Tube
    G01537940Courtesy of FORD MOTOR CO.
  20. Position the transmission sensor harness and install the bolt.
    Fig 11: Installing Transmission Sensor Harness
    G01537941Courtesy of FORD MOTOR CO.
  21. Connect the transmission sensor harness inline electrical connector.
    Fig 12: Connecting Transmission Sensor Harness Inline Electrical Connector
    G01537942Courtesy of FORD MOTOR CO.
  22. Connect the fuel tubes.
    Fig 13: Connecting Fuel Tubes
    G01537943Courtesy of FORD MOTOR CO.
  23. Connect the maxifuse.
    1. Position the wire.
    2. Install the nut.
    Fig 14: Connecting Maxifuse
    G01537944Courtesy of FORD MOTOR CO.
  24. Connect the heater supply hose.
    Fig 15: Connecting Heater Supply Hose
    G01537945Courtesy of FORD MOTOR CO.
    25. NOTE: If equipped with an auxiliary heater, connect the heater hose on the rear of the LH cylinder head.
    Fig 16: Connecting Auxiliary Heater Hose
    G01537946Courtesy of FORD MOTOR CO.
  25. Connect the auxiliary heater hose.
    26. NOTE: The water pump pulley is removed for clarity.
    Fig 17: Connecting Heater Hose
    G01537947Courtesy of FORD MOTOR CO.
  26. Connect the heater hose.
  27. Connect the lower radiator hose at the water pump and the fill hose.
    Fig 18: Connecting Lower Radiator Hose At Water Pump And Fill Hose
    G01537948Courtesy of FORD MOTOR CO.
  28. Position the bracket and install the retaining nuts.
    Fig 19: Positioning Bracket And Installing Retaining Nuts
    G01537949Courtesy of FORD MOTOR CO.
  29. Connect the engine control sensor wiring.
    Fig 20: Connecting Engine Control Sensor Wiring
    G01537950Courtesy of FORD MOTOR CO.
  30. Position the glow plug relay/intake air heater relay and bracket assembly and the three nuts.
    Fig 21: Positioning Glow Plug Relay/Intake Air Heater Relay And Bracket Assembly
    G01537951Courtesy of FORD MOTOR CO.
  31. Connect the electrical leads and position the covers.
    Fig 22: Connecting Electrical Leads And Positioning Covers
    G01537952Courtesy of FORD MOTOR CO.

    VEHICLES EQUIPPED WITH A DUAL GENERATOR 

  32. Install the upper generator mounting bracket and connect the upper generator electrical connector.
    Fig 23: Installing Upper Generator Mounting Bracket And Connecting Upper Generator Electrical Connector
    G01537953Courtesy of FORD MOTOR CO.
  33. Install the lower generator mounting bracket.
    Fig 24: Installing Lower Generator Mounting Bracket
    G01537954Courtesy of FORD MOTOR CO.
  34. Install the engine ground cables.
    1. Position the engine ground cable.
    2. Position the starter wire retaining bracket.
    3. Install the nut.
    Fig 25: Installing Engine Ground Cables
    G01537955Courtesy of FORD MOTOR CO.
  35. Connect the lower generator quick connector and push pins.
    Fig 26: Connecting Lower Generator Quick Connector And Push Pins
    G01537956Courtesy of FORD MOTOR CO.
  36. Connect the lower generator electrical connector and push pin.
    Fig 27: Connecting Lower Generator Electrical Connector And Push Pin
    G01537957Courtesy of FORD MOTOR CO.

    VEHICLES EQUIPPED WITH A SINGLE GENERATOR 

  37. Install the generator mounting bracket.
    Fig 28: Installing Generator Mounting Bracket
    G01537958Courtesy of FORD MOTOR CO.
  38. Connect the generator electrical connectors.
    Fig 29: Connecting Generator Electrical Connectors
    G01537959Courtesy of FORD MOTOR CO.

    ALL VEHICLES 

  39. Install the accessory drive belt tensioner assembly.
    Fig 30: Installing Accessory Drive Belt Tensioner Assembly
    G01537960Courtesy of FORD MOTOR CO.
  40. Install the A/C compressor or idler pulley mounting bracket.
    Fig 31: Installing A/C Compressor Or Idler Pulley Mounting Bracket
    G01537961Courtesy of FORD MOTOR CO.

    E-250 - E-450 ONLY 

  41. Install a new power steering seal on the power steering pressure fitting by stretching the seal over the seal replacer until it is large enough to slip over the threads of the fitting.
    Fig 32: Installing New Power Steering Seal On Power Steering Pressure Fitting
    G01537962Courtesy of FORD MOTOR CO.

    ALL VEHICLES 

    42. NOTE: E-250 - E-450 shown, E-550 similar.
    Fig 33: Connecting Power Steering Pressure Fitting To Power Steering Pump
    G01537963Courtesy of FORD MOTOR CO.
  42. Connect the power steering pressure fitting to the power steering pump.
    43. NOTE: E-250 - E-450 shown, E-550 similar.
    Fig 34: Installing Power Steering Reservoir Pump Hose To Power Steering Pump
    G01537964Courtesy of FORD MOTOR CO.
  43. Install the power steering reservoir pump hose to the power steering pump.

    E-250 - E-450 ONLY 

  44. Connect the vacuum pump hose.
    Fig 35: Connecting Vacuum Pump Hose
    G01537965Courtesy of FORD MOTOR CO.

    ALL VEHICLES 

  45. Connect the A/C manifold tube to the tee block and the high pressure switch electrical connector, if so equipped.
    Fig 36: Connecting A/C Manifold Tube To Tee Block And High Pressure Switch Electrical Connector
    G01537966Courtesy of FORD MOTOR CO.
    46. NOTE: Always use new O-rings when installing A/C system components.
    Fig 37: Connecting Air Conditioning Manifold To A/C Compressor
    G01537967Courtesy of FORD MOTOR CO.
  46. Connect the air conditioning manifold to the A/C compressor, if so equipped.
  47. Connect the A/C electrical connector, if equipped.
    Fig 38: Connecting A/C Electrical Connector
    G01537968Courtesy of FORD MOTOR CO.
  48. Install the oil filler tube.
    Fig 39: Installing Oil Filler Tube
    G01537969Courtesy of FORD MOTOR CO.

    E-550 ONLY 

  49. Connect the vacuum hose and secure to the oil filler tube.
    Fig 40: Connecting Vacuum Hose And Secure To Oil Filler Tube
    G01537970Courtesy of FORD MOTOR CO.

    ALL VEHICLES 

  50. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
  51. Install the front bumper. For additional information, refer to BUMPERS .
  52. Install the hood latch.
    Fig 41: Installing Hood Latch
    G01537971Courtesy of FORD MOTOR CO.
  53. Install the radiator core supports.
  54. Install the valance panel.
    Fig 42: Installing Valance Panel
    G01537972Courtesy of FORD MOTOR CO.
  55. Install the power steering fluid reservoir. For additional information, refer to POWER STEERING .
  56. Install the radiator grille support. For additional information, refer to FRONT END BODY PANELS .
  57. Install the A/C condenser assembly, if so equipped. For additional information, refer to AIR CONDITIONING .
  58. Install the radiator. For additional information, refer to ENGINE COOLING .
  59. Install the parking lamp and the headlamp assemblies. For additional information, refer to EXTERIOR LIGHTING .
  60. Install the intake air tube bracket assembly.
  61. Position the exhaust inlet Y-pipe and install the bolts.
    Fig 43: Positioning Exhaust Inlet Y-Pipe And Installing Bolts
    G01537973Courtesy of FORD MOTOR CO.
  62. Position the turbocharger manifold.
  63. Connect the intake air warmer, MAP hose and wiring harness.
    Fig 44: Connecting Intake Air Warmer, MAP Hose And Wiring Harness
    G01537974Courtesy of FORD MOTOR CO.
  64. Install the turbocharger. For additional information, refer to TURBOCHARGER .
  65. Fill the engine with clean engine oil.
  66. Connect both battery ground cables. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  67. Fill and bleed the power steering system. For additional information, refer to POWER STEERING .
  68. Check and top off the automatic transmission.
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