FixVault
Home › Ford › 2005 › Excursion 5.4 L, RWD › Repair and Diagnosis › External Pages › Different variant/trim › Section 5 (Engine - 6.0L Diesel) › Assembly › Engine

Section 5 (Engine - 6.0L Diesel): Assembly: Engine

WARNING: This page is about a different variant/trim than selected.
SPECIAL TOOLS

G03887504
 Lifting Bracket, Cylinder Head
303-759
G03887620
 Installer, Crankshaft Front Seal and Wear Ring
303-761
G03878636
 Dial Indicator with Bracketry
(D78P-4201-B) 100-002 or equivalent
G03907291
 Service Set, Camshaft
(T65L-6250-A) 303-017
G03898823
 Heavy Duty Floor Crane
014-00072
G03887624
 Alignment Tool, Camshaft
303-772
G03887324
 Installer, Crankshaft Rear Seal and Wear Ring
303-770
G03920362
 Piston Ring Compressor
(D81L-6002-C) 303-D032
G03887507
 Adapter for 303-D043-02
303-D043-01
G03887478
 Adapter for 303-D043-01
303-D043-02
G03906984
 Remover/Installer, Glow Plug Connector
303-1114
G03888035
 Socket, Injection Pressure Regulator (IPR) Valve
303-1112
MATERIAL REFERENCE

Item Specification
SAE 15W-40 Super Duty Motor Oil
XO-15W40-QSD or equivalent		 WSS-M2C171-D
RTV Silicone Sealant
TA-31		 -
Threadlock 262
TA-26		 WSK-M2G351-A6

    All vehicles 

    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.
    NOTE: Late build shown, early build similar.
    Fig 1: Installing New D-Ring Seals
    G03899308Courtesy of FORD MOTOR CO.
  1. Install new D-ring seals on the crankcase-to-head tube assemblies.

    2. All vehicles 

    NOTE: Check alignment of the oil holes after installing the bearings.
    Fig 2: Installing Camshaft Bearings
    G03887632Courtesy of FORD MOTOR CO.
  2. If removed, install the camshaft bearings.
    3. 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 3: Installing Piston Cooling Tubes Bolts With Torque Specifications
    G03887633Courtesy of FORD MOTOR CO.
  3. Install the 8 piston cooling tubes and bolts.
    4. 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 4: Installing Camshaft And Gear Assembly With Torque Specifications
    G03887634Courtesy of FORD MOTOR CO.
  4. Install the camshaft and gear assembly. Install the thrust plate mounting bolts.
    5. NOTE: Apply clean engine oil to all the bearings.
    Fig 5: Installing Crankshaft Upper Bearings
    G03887601Courtesy of FORD MOTOR CO.
  5. Install the crankshaft upper bearings and the crankshaft upper thrust bearing.
  6. Using the special tool, align the camshaft timing mark as shown.
    Fig 6: Aligning Camshaft Timing Mark
    G03887636Courtesy of FORD MOTOR CO.
  7. With the timing peg in the special tool over the camshaft timing mark, install the crankshaft.
    Fig 7: Installing Crankshaft
    G03887637Courtesy of FORD MOTOR CO.
    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. Install the lower bearings into the lower crankcase.
    Fig 8: Installing Lower Bearings Into Lower Crankcase
    G03887638Courtesy of FORD MOTOR CO.
    10. 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.
    Fig 9: Tightening Bolts In Sequence
    G03887639Courtesy of FORD MOTOR CO.
  10. Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten the mounting bolts in the following sequence.
    1. Tighten to 122 Nm (90 lb-ft) in numerical sequence.
    2. Tighten to 163 Nm (120 lb-ft) in numerical sequence.
    3. Tighten to 231 Nm (170 lb-ft) in the numerical sequence.
  11. Install 8 M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence shown.
    Fig 10: Tightening Bolts In Sequence With Torque Specifications
    G03887640Courtesy of FORD MOTOR CO.
  12. Remove the 28 bolts and the lower crankcase.
    Fig 11: Removing Bolts Lower Crankcase
    G03887598Courtesy of FORD MOTOR CO.
  13. Measure the clearances for the main bearings.

    Remove the Plastigage.

    Fig 12: Removing Plastigage
    G03887642Courtesy of FORD MOTOR CO.
    14. NOTE: Apply clean engine oil to the lower main bearings.
    Fig 13: Installing New Lower Crankcase Seals
    G03887599Courtesy of FORD MOTOR CO.
  14. Install new lower crankcase seals.
    15. 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.
    Fig 14: Tightening Bolts In Sequence
    G03887639Courtesy of FORD MOTOR CO.
  15. Install the lower crankcase. Install all 20 lower crankcase main bearing mounting bolts. Tighten mounting bolts in the following sequence.
    1. Tighten to 122 Nm (90 lb-ft) in numerical sequence.
    2. Tighten to 163 Nm (120 lb-ft) in numerical sequence.
    3. Tighten to 231 Nm (170 lb-ft) in the numerical sequence.
  16. Install 8 M8 x 30 bolts around the outside of the lower crankcase. Tighten bolts to the special torque using the sequence shown.
    Fig 15: Tightening Bolts In Sequence With Torque Specifications
    G03887640Courtesy of FORD MOTOR CO.
  17. Remove the bolt and special tool.
    Fig 16: Removing Bolt
    G03907443Courtesy of FORD MOTOR CO.
    18. 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 17: Measuring Crankshaft End Play
    G03887646Courtesy of FORD MOTOR CO.
  18. Install the special tool and measure the crankshaft end play.
  19. Install the special tool and measure the camshaft end play.
    Fig 18: Measuring Camshaft End Play
    G03887593Courtesy of FORD MOTOR CO.
  20. Install the special tool and measure the camshaft gear backlash.
    Fig 19: Measuring Camshaft Gear Backlash
    G03887592Courtesy of FORD MOTOR CO.
  21. Install the block heater.
    Fig 20: Installing Block Heater With Torque Specifications
    G03887649Courtesy of FORD MOTOR CO.
  22. Install the camshaft position (CMP) sensor and the bolt.
    Fig 21: Installing Camshaft Position Sensor Bolt With Torque Specifications
    G03887650Courtesy of FORD MOTOR CO.
  23. Install the crankshaft position (CKP) sensor and the bolt.
    Fig 22: Installing Crankshaft Position Sensor And Bolt With Torque Specifications
    G03907449Courtesy of FORD MOTOR CO.
    24. NOTE: Lubricate with clean engine oil.
    Fig 23: Installing Connecting Rod Bearings
    G03887591Courtesy of FORD MOTOR CO.
  24. Install the connecting rod bearings.
    25. NOTE: Make sure the ring openings are 120 degrees from each other, or engine damage can occur.
    Fig 24: Installing Oil Control Ring
    G03887590Courtesy of FORD MOTOR CO.
  25. Install new piston rings.
    1. The top compression 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.
    26. NOTE: Cam V8 is toward the inside of the engine.
    NOTE: Coat the cylinder walls and piston assembly with clean engine oil before installing.
    Fig 25: Installing Piston Rod Assemblies
    G03887654Courtesy of FORD MOTOR CO.
  26. 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.
  27. Position a piece of Plastigage across the bearing surface.
    Fig 26: Positioning Piece Of Plastigage Across Bearing Surface
    G03900006Courtesy of FORD MOTOR CO.
  28. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
    • Tighten to 45 Nm (33 lb-ft).
    • Tighten to 68 Nm (50 lb-ft).
    Fig 27: Identifying Connecting Rod Cap Bolts
    G03887588Courtesy of FORD MOTOR CO.
  29. Remove the bolts and the connecting rod cap.
  30. Measure the clearances for the connecting rod cap. Remove the plastigage.
    Fig 28: Measuring Clearances
    G03887657Courtesy of FORD MOTOR CO.
  31. Install the connecting rod cap and the bolts. Tighten the bolts in the following sequence.
    • Tighten to 45 Nm (33 lb-ft).
    • Tighten to 68 Nm (50 lb-ft).
    Fig 29: Identifying Connecting Rod Cap Bolts
    G03887588Courtesy of FORD MOTOR CO.
  32. Using a feeler gauge, check for connecting rod side clearance.
    Fig 30: Checking Connecting Rod Side Clearance
    G04519326Courtesy of FORD MOTOR CO.
  33. Install the upper oil pan.
    • Install the upper oil pan gasket.
    • Install the upper oil pan.
    • Install the bolts.
    Fig 31: Installing Upper Oil Pan With Torque Specifications
    G03887279Courtesy of FORD MOTOR CO.
  34. Install the oil pickup tube and screen.
    • Install a new O-ring.
    • Install the oil pickup tube and screen.
    • Install the bolts.
    Fig 32: Installing Oil Pickup Tube Screen With Torque Specifications
    G03907459Courtesy of FORD MOTOR CO.
    35. NOTE: Install a new press-in-place gasket.
    Fig 33: Installing Bolts With Torque Specifications
    G03887267Courtesy of FORD MOTOR CO.
  35. Position the oil pan and install the bolts.
    1. Install the longer oil pan bolts.
    2. Install the remaining bolts.
      • Tighten to 13 Nm (10 lb-ft).
    36. 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.
    Fig 34: Applying Clean Engine Oil To Hydraulic Cam Followers With Torque Specifications
    G03887661Courtesy of FORD MOTOR CO.
  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.

    37. Early build vehicles 

  37. Install the rear engine tube assembly and the bolt.
    Fig 35: Installing Rear Engine Tube Assembly Bolt With Torque Specifications
    G03907462Courtesy of FORD MOTOR CO.
  38. Install the rear engine tube assembly bolts.
    Fig 36: Installing Rear Engine Tube Assembly Bolts With Torque Specifications
    G03887662Courtesy of FORD MOTOR CO.

    39. Late build vehicles 

    NOTE: RH side shown, LH side similar.
    Fig 37: Installing Rear Engine Tube Assembly Bolts With Torque Specifications
    G03887662Courtesy of FORD MOTOR CO.
  39. Install the rear engine tube assembly and bolts.
    • Position the rear engine tube assembly and install the right side bolt hand-tight.
    • Install the left side bolt hand-tight.
    • Tighten both rear engine tube assembly bolts.

    40. All vehicles 

  40. Install the 4 cylinder head dowels.
    Fig 38: Installing Cylinder Head Dowels
    G03887582Courtesy of FORD MOTOR CO.
    41. 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 39: Cleaning And Inspecting Gasket Sealing Surfaces
    G03887503Courtesy of FORD MOTOR CO.
  41. Place the new cylinder head gasket over the dowel sleeves and onto the crankcase.
  42. Using the special tool, install the cylinder heads.
    1. Install the lifting brackets.
    2. Install the bolts.
      • Install the cylinder heads.
    Fig 40: Installing Cylinder Heads
    G03887502Courtesy of FORD MOTOR CO.
  43. Install the 5 outer bolts for each cylinder head (finger-tight).
    Fig 41: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
    44. 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: Higher mileage engines require push rods to be cleaned so the copper colored end of the push rod can be identified.
    NOTE: If a push rod has been replaced, it may not have a copper-colored end and can be installed with either end up.
    Fig 42: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
  44. Apply clean engine oil to each end of the push rods. Insert them into their respective position with the copper colored end up.
    45. NOTE: Coat the end of each valve stem with clean engine oil.
    Fig 43: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
  45. Install the 16 valve bridges.
    46. 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.
    Fig 44: Locating Rocker Arm Assembly Bolts With Torque Specification
    G03887670Courtesy of FORD MOTOR CO.
  46. Install the rocker arm assemblies and the 16 bolts.
    47. 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 new cylinder head bolt threads and flanges with clean engine oil.
    NOTE: Left cylinder head shown, right cylinder head similar.
    Fig 45: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
  47. Install the 10 new cylinder head retaining bolts for each cylinder head (finger-tight).
  48. Tighten the head bolts in the following sequence.
    1. Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
    2. Tighten bolts 1 through 10 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, a second time, clockwise 90 degrees.
    5. Tighten bolts in sequence 1 through 10, a third time, 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 46: Tightening Cylinder Head Retaining Bolts In Sequence
    G03887672Courtesy of FORD MOTOR CO.

    49. Early build vehicles 

    CAUTION: To prevent engine damage, check that the crankcase-to-head tube assemblies bottom out in the branch tube assembly. The oil rail, crankcase-to-head tube and the fuel injectors will not function correctly if these tubes are not bottomed out.
    Fig 47: Identifying Crankcase-To-Head Tube
    G03887400Courtesy of FORD MOTOR CO.
  49. Apply clean engine oil and install a crankcase-to-head tube assembly.

    50. All vehicles 

    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 48: Identifying Fuel Injector O Rings And Electrical Connector
    G03887397Courtesy of FORD MOTOR CO.
  50. Install new O-rings and a copper washer on the fuel injector.
    51. 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.
    Fig 49: Installing Fuel Injector Hold-Down Clamp Bolt With Torque Specification
    G03887398Courtesy of FORD MOTOR CO.
  51. Install the fuel injector, the fuel injector hold-down and bolt.
    52. CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
    Fig 50: Identifying Fuel Injector Electrical Connector At Rocker Carrier
    G03887399Courtesy of FORD MOTOR CO.
  52. Install the fuel injector electrical connector into the rocker carrier.
    53. NOTE: Apply clean engine oil to the top fuel injector O-rings before installing the high-pressure oil rail.
    Fig 51: Locating High-Pressure Oil Rail On Injector Bolts
    G03887401Courtesy of FORD MOTOR CO.
  53. 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.
    • 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.
  54. Install the remaining bolts and tighten.
    • Remove the 3 guide bolts.
    • Loosely install the 3 remaining bolts.
    • Tighten the 9 bolts in the sequence shown.
    Fig 52: Installing Oil Rail Retaining Bolts In Sequence With Torque Specifications
    G03887402Courtesy of FORD MOTOR CO.

    55. Late build vehicles 

    NOTE: Apply clean engine oil to the crankcase-to-head tube prior to installing.
    Fig 53: Crankcase-To-Head Tube With Torque Specification
    G03887403Courtesy of FORD MOTOR CO.
  55. Install the crankcase-to-head tube assembly.

    56. All vehicles 

  56. Apply a bead of sealant at the back seam of the upper and lower crankcase.
    Fig 54: Applying Bead Of Sealant
    G03887338Courtesy of FORD MOTOR CO.
  57. Install the rear engine cover.
    • Install the press-in-place gasket.
    • Install the rear engine cover.
    • Install the bolts.
    Fig 55: Installing Rear Engine Cover With Torque Specifications
    G03887340Courtesy of FORD MOTOR CO.
    58. 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.
    NOTE: The rear main seal and wear sleeve are correctly seated when the crankshaft begins to rotate.
    Fig 56: Installing Crankshaft Rear Oil Seal Using Special Tool
    G03887293Courtesy of FORD MOTOR CO.
  58. Using the special tools, install the crankshaft rear oil seal.
  59. Install the flywheel adapter.
    Fig 57: Installing Flywheel Adapter
    G03907484Courtesy of FORD MOTOR CO.
  60. If removed, install the front cover crankcase dowels into the cylinder block.
    Fig 58: Installing Front Cover Crankcase Dowels
    G03887308Courtesy of FORD MOTOR CO.
  61. Apply a bead of sealant at the front seam of the upper and lower crankcase.
    Fig 59: Applying Bead Of Sealant
    G03887687Courtesy of FORD MOTOR CO.
    62. NOTE: Use guide studs to aid in installation. Studs must be fabricated locally.
    Fig 60: Installing Guide Studs
    G03887688Courtesy of FORD MOTOR CO.
  62. Install the guide studs and the front cover gasket.
  63. Install the engine front cover and bolts.
    Fig 61: Installing Engine Front Cover Bolts With Torque Specifications
    G03887312Courtesy of FORD MOTOR CO.
    64. NOTE: Install oil pump drive rotors with marks pointing outward.
    Fig 62: Identifying Inner And Outer Oil Pump Drive Rotors With Alignment Marks
    G03887281Courtesy of FORD MOTOR CO.
  64. 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.
    65. NOTE: Install a new O-ring seal.
    Fig 63: Installing Oil Pump Body With Torque Specifications
    G03887283Courtesy of FORD MOTOR CO.
  65. Install the oil pump body and the bolts.
    66. 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 64: Installing Oil Seal Wear Sleeve Assembly
    G03907068Courtesy of FORD MOTOR CO.
  66. Using the special tool, install the oil seal and wear sleeve assembly.
    67. CAUTION: To prevent engine damage, you must 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.
    Fig 65: Installing Crankshaft Vibration Damper Bolts
    G03887214Courtesy of FORD MOTOR CO.
  67. Install the crankshaft vibration damper and bolts.
    • Tighten in the sequence shown.
    • Tighten to 68 Nm (50 lb-ft).
    • Tighten an additional 90 degrees.
  68. If equipped, install the dual generator pulley and bolts.
    Fig 66: Installing Dual Generator Pulley Bolts With Torque Specifications
    G03887216Courtesy of FORD MOTOR CO.
    69. NOTE: Install a new O-ring on the coolant pump.
    Fig 67: Installing Coolant Pump Bolts With Torque Specifications
    G03887313Courtesy of FORD MOTOR CO.
  69. Install the coolant pump and bolts.
  70. Install the coolant pump pulley and the bolts.
    Fig 68: Installing Coolant Pump Pulley Bolts With Torque Specifications
    G03887314Courtesy of FORD MOTOR CO.
  71. Install the RH high-pressure oil rail to valve cover gasket.
    Fig 69: Identifying High-Pressure Oil Rail
    G03887197Courtesy of FORD MOTOR CO.
    72. CAUTION: To prevent engine damage, do not use air powered tools when installing the valve cover.
    NOTE: RH side shown, LH side similar.
    Fig 70: RH Valve Cover With Torque Specification
    G03887405Courtesy of FORD MOTOR CO.
  72. Install the valve covers.
    • Install the gaskets.
    • Install the valve covers.
    • Install the bolts and stud bolts.
    73. NOTE: Clean and inspect the O-ring.
    Fig 71: Installing Injection Control Pressure Sensor With Torque Specifications
    G03907498Courtesy of FORD MOTOR CO.
  73. Install the injection control pressure (ICP) sensor.
  74. Install the 8 glow plugs.
    Fig 72: Glow Plugs With Torque Specification
    G03887699Courtesy of FORD MOTOR CO.
    75. NOTE: Clean and apply clean engine oil to the O-rings.
    Fig 73: Removing/Installing Glow Plug Harness Using Special Tool
    G03887483Courtesy of FORD MOTOR CO.
  75. Using the special tool, install the glow plug harness.

    76. Early build vehicles 

  76. Install a new O-ring seal.
    Fig 74: Installing New O-Ring Seal
    G03907320Courtesy of FORD MOTOR CO.
  77. Install the high-pressure oil pump and the bolts.
    Fig 75: Installing High-Pressure Oil Pump Bolts With Torque Specifications
    G03907502Courtesy of FORD MOTOR CO.
  78. Install the high-pressure pump O-ring seal.
    Fig 76: Installing High-Pressure Pump O-Ring Seal
    G03907318Courtesy of FORD MOTOR CO.
  79. Position back the high-pressure discharge pipe and install the bolts.
    Fig 77: Installing Bolts With Torque Specifications
    G03907504Courtesy of FORD MOTOR CO.
  80. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
    Fig 78: Positioning Dial Indicator With Bracketry
    G03907316Courtesy of FORD MOTOR CO.
  81. Install a new D-ring seal on the high-pressure discharge pipe.
    Fig 79: Installing New D-Ring Seal
    G03907506Courtesy of FORD MOTOR CO.
  82. Clean the cover mounting surface and apply sealant at the seams.
    Fig 80: Applying Sealant
    G03907507Courtesy of FORD MOTOR CO.
  83. Install the high-pressure pump cover.
    • Install the press-in-place gasket.
    • Install the high-pressure pump cover.
    • Install the bolts.
    Fig 81: Installing High-Pressure Pump Cover With Torque Specifications
    G03907508Courtesy of FORD MOTOR CO.

    84. Late build vehicles 

    CAUTION: To prevent engine damage, use only approved pump cover seal. Substitution can cause damage to the pump cover.
    Fig 82: Locating High-Pressure Oil Pump O-Ring Seal
    G03887542Courtesy of FORD MOTOR CO.
  84. Install a new O-ring seal on the high-pressure oil pump.
  85. Install the high-pressure tube assembly.
    Fig 83: Installing High-Pressure Tube Assembly
    G03887702Courtesy of FORD MOTOR CO.
  86. Install new lower O-ring seals.
    Fig 84: Identifying O-Ring Seals
    G03887540Courtesy of FORD MOTOR CO.
  87. Install the high-pressure pump and bolts.
    Fig 85: Installing High-Pressure Pump Bolts With Torque Specifications
    G03887704Courtesy of FORD MOTOR CO.
  88. Tighten the bolts for the high-pressure tube assembly.
    Fig 86: Tightening High-Pressure Tube Assembly Bolts With Torque Specifications
    G03907513Courtesy of FORD MOTOR CO.
  89. Position the dial indicator with bracketry onto the oil pump drive and check the oil pump drive gear backlash.
    Fig 87: Checking Oil Pump Drive Gear Backlash
    G03887537Courtesy of FORD MOTOR CO.
  90. Install a new press-in-place gasket in the high-pressure pump cover.
    Fig 88: Installing A New Press-In-Place Gasket In High-Pressure Pump Cover
    G03887707Courtesy of FORD MOTOR CO.
  91. Clean the cover mounting surface and apply sealer at the seams.
    Fig 89: Applying Sealer
    G03887708Courtesy of FORD MOTOR CO.
    92. 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.
    Fig 90: High-Pressure Oil Pump Cover Bolts With Torque Specifications
    G03887709Courtesy of FORD MOTOR CO.
  92. Install the high-pressure oil pump cover and bolts.
  93. Install the IPR valve.
    Fig 91: Injection Pressure Regulator Valve With Torque Specifications
    G03887710Courtesy of FORD MOTOR CO.
  94. Install the heat insulating wrap and fasten the snap.
    Fig 92: Identifying Heat Insulating Wrap
    G03887533Courtesy of FORD MOTOR CO.

    95. All vehicles 

  95. Install the oil pump inlet strainer.
    Fig 93: Identifying Oil Pump Inlet Strainer
    G03887232Courtesy of FORD MOTOR CO.
    96. 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.
    Fig 94: Oil Cooler Assembly With Torque Specifications
    G03907057Courtesy of FORD MOTOR CO.
  96. Install the oil cooler assembly.
    • Install the gasket.
    • Install the oil cooler assembly.
    • Install the bolts.
    97. 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.
    Fig 95: Oil Filter Base With Torque Specifications
    G03907059Courtesy of FORD MOTOR CO.
  97. Install the oil filter base.
    • Install the gasket.
    • Install the oil filter base.
    • Install the bolts.
  98. 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 96: Exhaust Gas Recirculation (EGR) Cooler Coolant Supply Port Cover Bolts With Torque Specifications
    G03887239Courtesy of FORD MOTOR CO.
  99. Install new O-ring in the oil filter base.
    Fig 97: Installing New O-Ring
    G03887527Courtesy of FORD MOTOR CO.
  100. Install the serpentine belt idler and bolt.
    Fig 98: Serpentine Belt Idler Bolt With Torque Specifications
    G03887719Courtesy of FORD MOTOR CO.
  101. Install the belt tensioner and bolts.
    Fig 99: Accessory Drive Belt Tensioner Bolt With Torque Specification
    G03887315Courtesy of FORD MOTOR CO.
    102. NOTE: Install new sealing washers.
    Fig 100: Left Cylinder Head Fuel Line With Torque Specifications
    G03887721Courtesy of FORD MOTOR CO.
  102. Install the left cylinder head fuel line.
    103. NOTE: Install a new O-ring on the thermostat.
    Fig 101: Locating Stud Bolts And Thermostat Housing Assembly With Torque Specifications
    G03887322Courtesy of FORD MOTOR CO.
  103. Install the thermostat housing and the stud bolts.

    104. Early build vehicles 

  104. Position the exhaust pressure bracket assembly and install the retaining nuts.
    Fig 102: Locating Retaining Nuts And Exhaust Backpressure Assembly With Torque Specification
    G03906879Courtesy of FORD MOTOR CO.
  105. Tighten the exhaust pressure tube at the exhaust manifold.
    Fig 103: Exhaust Pressure Tube Fitting With Torque Specifications
    G03906880Courtesy of FORD MOTOR CO.

    106. All vehicles 

  106. Install the fuel lines and bracket bolt.
    Fig 104: Fuel Lines Bracket Bolt With Torque Specifications
    G03907030Courtesy of FORD MOTOR CO.
    107. NOTE: Install a new O-ring on the oil indicator and tube. Apply clean engine oil to the O-ring.
    Fig 105: Locating Wire Harness Retainer
    G03907047Courtesy of FORD MOTOR CO.
  107. Install the oil level indicator tube and nut. Connect the wiring harness retainer.
    108. NOTE: LH shown, RH similar.
    NOTE: Lightly lubricate the O-ring seal with clean engine oil prior to installing.
    Fig 106: Cylinder Block Coolant Drain Plugs With Torque Specifications
    G03907050Courtesy of FORD MOTOR CO.
  108. Install the cylinder block coolant drain plugs.
  109. Install the starter and the 3 bolts.
    Fig 107: Starter Bolts With Torque Specifications
    G03907534Courtesy of FORD MOTOR CO.
  110. Install the special tool.
    Fig 108: Identifying Special Tool
    G03887258Courtesy of FORD MOTOR CO.
  111. Install the special tool.
    Fig 109: Installing Special Tool
    G03887726Courtesy of FORD MOTOR CO.
  112. Install the lifting crane and remove the engine from the engine stand.
    113. NOTE: LH side shown, RH side similar.
    Fig 110: LH And RH Motor Mounts And Bolts With Torque Specifications
    G03907227Courtesy of FORD MOTOR CO.
  113. Install the LH and RH motor mounts and bolts.
  114. Install the flexplate and the new bolts.
    • Tighten in the following sequence.
    • Tighten to 5 Nm (44 lb-in).
    • Tighten to 94 Nm (69 lb-ft) in the sequence shown.
    Fig 111: Flexplate Bolts Tightening Sequence
    G03907158Courtesy of FORD MOTOR CO.
About FixVault