Engine - Enhanced Long Block: Assembly

WARNING: This page is about a different car, the 2013 Ford F-550 Super Duty, 2013 Ford F-450 Super Duty, 2013 Ford F-350 Super Duty, and 2013 Ford F-250 Super Duty. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: This procedure assumes the engine will be installed using the recommended body off engine installation procedure. If it will be necessary to install the engine using the alternate body on engine installation procedure, some of the components in this procedure should not be installed at this time. For additional information, refer to ENGINE - BODY ON .

NOTE: During the repair or installation of fuel-related components, cap, tape or otherwise appropriately protect all fuel opening to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

NOTE: For EXPORT ONLY vehicles (outside US/Canada) an Export Supplement is provided and should be referenced to identify differences that can impact service procedures. Vehicles can be identified by referring to the underhood Vehicle Emission Control Information (VECI) label which states, "Not certified for US EPA or CARB Regulations".

Using the Fold Away Floor Crane, remove the engine from the shipping crate. Position the engine on wood blocks as needed.
- Verify that the engine is stable on the wooden blocks.
If equipped with a block heater, remove the block heater plug.
If equipped with a block heater, install the block heater.
- Tighten to 41 Nm (30 lb-ft).
NOTE: Apply clean engine oil to the O-ring seal prior to installation.

Using a new O-ring seal, install the high-pressure fuel injection pump and the 3 high-pressure fuel injection pump spacers.
- Tighten to 24 Nm (18 lb-ft).
Install the fuel rail supply tube bracket and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).
NOTE: The crankshaft gear contains a single timing mark. The camshaft contains a single timing mark and a double timing mark. The high-pressure fuel injection pump drive gear contains a double timing mark. The engine is timed correctly when the single mark on the crankshaft drive gear is aligned with the double mark on the camshaft gear, and the single mark on the camshaft drive gear is aligned with the double mark on the high-pressure fuel injection pump drive gear. Additionally, the keyway on the high-pressure fuel injection pump drive gear must be at 12 o'clock position.

NOTE: Engine front cover removed for clarity.

Install the high-pressure fuel injection pump drive gear and nut.
- Tighten to 80 Nm (59 lb-ft).
- Verify the timing marks are aligned.
  
  Fig 1: Aligning Timing Marks
  Courtesy of FORD MOTOR CO.
Using the Dial Indicator Gauge with Holding Fixture and Clutch Housing Gauge, check the high-pressure fuel injection pump drive gear backlash.

Fig 2: Checking High-Pressure Fuel Injection Pump Drive Gear Backlash Using Dial Indicator Gauge
Courtesy of FORD MOTOR CO.
NOTE: Do not apply engine oil to the fuel injectors.

NOTE: Only one fuel injector shown.

NOTE: If the fuel injector is being reused, make sure to install it in the original location.

Install a new copper combustion gasket, O-ring seal and fuel injector return fuel O-ring on the 8 fuel injectors.
- Position the 8 fuel injectors into the engine.
NOTE: Failure to tighten the fuel injector correctly can lead to engine failure.

NOTE: Apply clean engine oil to the concave surface of the fuel injector hold-down clamp.

Install the 8 fuel injector hold-down clamps and 8 new fuel injector bolts. Tighten in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
Final tighten the LH valve cover bolts in the sequence shown in the illustration.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 3: Identifying LH Valve Cover And Mounting Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Final tighten the RH valve cover bolts in the sequence shown in the illustration.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 4: Identifying RH Valve Cover And Mounting Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
NOTE: Only one glow plug shown.

Install the 8 glow plugs.
- Tighten to 11 Nm (97 lb-in).
  
  Fig 5: Locating Glow Plugs
  Courtesy of FORD MOTOR CO.
Using a new gasket, install the RH exhaust manifold, 8 new spacers and 8 new nuts. Tighten the nuts in 3 stages, in the sequence shown in the illustration.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 30 Nm (22 lb-ft).
- Stage 3: Tighten a second time to 30 Nm (22 lb-ft).
  
  Fig 6: Identifying Tightening Sequence Of RH Exhaust Manifold Mounting Nuts
  Courtesy of FORD MOTOR CO.
Using a new gasket, install the LH exhaust manifold, 8 new spacers and 8 new nuts. Tighten the nuts in 3 stages, in the sequence shown in the illustration.
- Stage 1: Tighten to 20 Nm (177 lb-in).
- Stage 2: Tighten to 30 Nm (22 lb-ft).
- Stage 3: Tighten a second time to 30 Nm (22 lb-ft).
  
  Fig 7: Identifying Tightening Sequence Of LH Exhaust Manifold Mounting Nuts
  Courtesy of FORD MOTOR CO.
NOTE: RH side shown, LH side similar.

Install the 6 new exhaust manifold studs.
- Tighten to 13 Nm (115 lb-in).
Install the RH exhaust manifold heat shield and 5 new bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 8: Locating RH Exhaust Manifold Heat Shield Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the LH exhaust manifold heat shield and 4 new bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 9: Locating LH Exhaust Manifold Heat Shield Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the crankshaft sensor pulse ring.
Install the flexplate and 10 new bolts. Tighten the bolts in 2 stages, in the sequence shown in the illustration.
- Stage 1: Tighten to 5 Nm (44 lb-in).
- Stage 2: Tighten to 100 Nm (74 lb-ft).
  
  Fig 10: Locating Tightening Sequence Of Flexplate Mounting Bolts
  Courtesy of FORD MOTOR CO.
Using a new gasket, install the vacuum pump and 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 11: Locating Vacuum Pump Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, always install 4 new bolts when installing the crankshaft pulley.

NOTE: Use the Strap Wrench to prevent the engine from turning while tightening the bolts.

Position the crankshaft pulley and install 4 new bolts. Tighten in 2 stages, in the sequence shown in the illustration.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 90 degrees.
Using new gaskets, install the coolant crossover manifold assembly and 5 bolts.
- Finger-tighten the bolts.
  
  Fig 12: Locating Coolant Crossover Manifold Assembly Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Inspect the thermostat seal for tears, nicks or cuts. Replace if necessary.

Install the new thermostat, thermostat housing and 3 bolts.
- Finger-tighten the bolts.
  
  Fig 13: Locating Thermostat Housing Mounting Bolts
  Courtesy of FORD MOTOR CO.
Tighten the 5 coolant crossover bolts and the 3 thermostat housing bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 14: Locating Coolant Crossover Bolts And Thermostat Housing Bolts
  Courtesy of FORD MOTOR CO.
Position the RH fuel rail and loosely install the 2 bolts.

Fig 15: Locating RH Fuel Rail Mounting Bolts
Courtesy of FORD MOTOR CO.
Position the LH fuel rail and loosely install the 2 bolts.

Fig 16: Locating LH Fuel Rail Mounting Bolts
Courtesy of FORD MOTOR CO.
NOTE: LH side shown, other connectors similar.

Position the new fuel rail supply tube assembly. Hand start the 6 fuel rail supply tube assembly connectors.

Fig 17: Locating Fuel Rail Supply Tube Assembly
Courtesy of FORD MOTOR CO.
NOTE: Only 1 fuel injector supply tube shown.

Install the 8 new fuel injector supply tubes.
- Start from front to rear of engine.
- Hand start only.
  
  Fig 18: Locating Fuel Injector Supply Tube Fittings
  Courtesy of FORD MOTOR CO.
Install the 5 fuel rail supply tube assembly bolts.
- Hand start only.
NOTE: LH side shown, RH side similar.

Tighten the 4 fuel rail bolts.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 19: Locating Fuel Rail Mounting Bolts
  Courtesy of FORD MOTOR CO.
Tighten the 4 LH fuel injector supply tubes in the sequence shown in the illustration.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 20: Identifying Tightening Sequence Of LH Fuel Injector Supply Tubes
  Courtesy of FORD MOTOR CO.
Tighten the 4 RH fuel injector supply tubes in the sequence shown in the illustration.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 21: Identifying Tightening Sequence Of RH Fuel Injector Supply Tubes
  Courtesy of FORD MOTOR CO.
Tighten the 6 fuel rail supply tube assembly connectors in the sequence shown in the illustration.
- Tighten to 20 Nm (177 lb-in).
  
  Fig 22: Identifying Tightening Sequence Of Fuel Rail Supply Tube Assembly Connectors
  Courtesy of FORD MOTOR CO.
Tighten the 4 LH fuel injector supply tubes in the sequence shown in the illustration.
- Tighten to 35 Nm (26 lb-ft).
  
  Fig 23: Identifying Tightening Sequence Of LH Fuel Injector Supply Tubes
  Courtesy of FORD MOTOR CO.
Tighten the 4 RH fuel injector supply tubes in the sequence shown in the illustration.
- Tighten to 35 Nm (26 lb-ft).
  
  Fig 24: Identifying Tightening Sequence Of RH Fuel Injector Supply Tubes
  Courtesy of FORD MOTOR CO.
Tighten the 6 fuel rail supply tube assembly connectors in the sequence shown in the illustration.
- Tighten to 35 Nm (26 lb-ft).
  
  Fig 25: Identifying Tightening Sequence Of Fuel Rail Supply Tube Assembly Connectors
  Courtesy of FORD MOTOR CO.
Tighten the 2 fuel rail supply tube connectors at the high-pressure fuel injection pump.
- Tighten to 40 Nm (30 lb-ft).
Tighten the 5 fuel rail supply tube assembly bolts in the sequence shown in the illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 26: Identifying Tightening Sequence Of Fuel Rail Supply Tube Assembly Bolts
  Courtesy of FORD MOTOR CO.
NOTE: RH valve cover shown, other retaining clips similar.

Position the fuel injector return hose and vacuum hose assembly on the engine and connect the retaining clips.
Connect the 8 fuel injector return hose fittings to the fuel injectors.
- Push down on the center of the fuel injector return hose fitting to lock the fitting.
  
  Fig 27: Pushing Down Fuel Injector Return Hose Fitting
  Courtesy of FORD MOTOR CO.
NOTE: Lubricate the O-ring seal with coolant prior to installing the heater supply tube.

Using a new O-ring seal, install the heater supply tube and 2 bolts.
- Tighten to 10 Nm (89 lb-in).
Install the turbocharger coolant tube.
Install the secondary fuel filter bracket and 3 bolts.
- Tighten to 10 Nm (89 lb-in).
NOTE: Early build fuel filter bracket shown.

NOTE: On late build fuel filter brackets, rotate the fuel filter clockwise to install.

Install the new secondary fuel filter. Tighten the bolt on the fuel filter bracket.
- Tighten to 5 Nm (44 lb-in).
Install the fuel filter-to-fuel injection pump supply tube. Refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
NOTE: Only 2 bolts shown.

Using new gaskets, install the crankcase vent oil separator and 4 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 28: Locating Crankcase Vent Oil Separator Mounting Bolt
  Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the O-ring seal prior to installing the fuel injection pump supply tube.

Using a new O-ring seals, install the fuel injection pump supply tube and bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 29: Locating Fuel Injection Pump Supply Tube Assembly Mounting Bolt
  Courtesy of FORD MOTOR CO.
Install the fuel injection pump supply tube assembly stud bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 30: Locating Fuel Injection Pump Supply Tube Assembly Stud Bolt
  Courtesy of FORD MOTOR CO.
Install the 2 fuel injection pump supply tube assembly bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 31: Locating Fuel Injection Pump Supply Tube Assembly Bolts
  Courtesy of FORD MOTOR CO.
Connect the fuel injector return hose and retainer to the secondary fuel filter. Connect the secondary outlet hose to the fuel injection pump supply tube.
Connect the fuel injection pump hose to the fuel rail.
Install the power steering pump mounting bracket and the 4 bolts.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 32: Locating Power Steering Mounting Bracket Mounting Bolts
  Courtesy of FORD MOTOR CO.
Position the engine wire harness over the engine. Connect the 2 retainers and install the bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 33: Locating Engine Wire Harness And Mounting Bolt
  Courtesy of FORD MOTOR CO.
NOTE: Only one retainer shown.

Connect the 6 retainers to the fuel supply manifolds.

Fig 34: Locating Fuel Supply Manifold Retainer
Courtesy of FORD MOTOR CO.
Position the engine wire harness on the LH valve cover and connect the 3 wire retainers.

Fig 35: Locating LH Valve Cover Wire Retainers
Courtesy of FORD MOTOR CO.
NOTE: Only one fuel injector and glow plug electrical connector shown.

Connect the 8 fuel injectors and the 8 glow plug electrical connectors.
NOTE: Only one wire retainer shown.

Connect the CKP sensor electrical connector and the 3 wire retainers.

Fig 36: Locating Crankshaft Position Sensor Electrical Connector And Wire Retainer
Courtesy of FORD MOTOR CO.
Install the cylinder block opening cover.
Connect the fuel pressure control valve electrical connector.

Fig 37: Locating Fuel Pressure Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the Fuel Rail Pressure (FRP) sensor electrical connector and 2 retainers.

Fig 38: Locating Fuel Rail Pressure Sensor Electrical Connector And Wire Harness Retainer
Courtesy of FORD MOTOR CO.
Connect the fuel pressure switch and the fuel temperature sensor electrical connectors. Connect the wire retainer.
Connect the Engine Coolant Temperature (ECT) sensor electrical connector and wire retainer.

Fig 39: Locating ECT Sensor Electrical Connector And Wire Retainer
Courtesy of FORD MOTOR CO.
Connect the turbocharger wastegate control valve vacuum and electrical connector.

Fig 40: Locating Turbocharger Wastegate Control Vacuum And Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the vacuum hose retainer to the secondary fuel filter stud.
Connect the fuel volume control valve electrical connector.

Fig 41: Locating Fuel Volume Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the Camshaft Position (CMP) sensor electrical connector and the 3 pin type retainers.

Fig 42: Locating Camshaft Position Sensor Electrical Connector And Pin Type Retainers
Courtesy of FORD MOTOR CO.
Install the lower intake manifold and the 3 bolts.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 43: Locating Lower Intake Manifold Mounting Bolts
  Courtesy of FORD MOTOR CO.
Using a new gasket, install the throttle body and the 4 bolts. Tighten the 4 bolts in a crisscross pattern.
- Tighten to 10 Nm (89 lb-in).
NOTE: It may be necessary to rotate the locking collar to connect the oil separator hose to the lower intake.

Connect the crankcase vent oil separator hose to the lower intake manifold. If equipped, connect the crankcase vent oil separator outlet hose sensor electrical connector.
Connect the Throttle Body (TB) electrical connector.
Using new gaskets, install the EGR cooler assembly and the 7 bolts. Tighten the bolts in the sequence shown in the illustration.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 44: Identifying Tightening Sequence Of EGR Cooler Assembly Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the 2 engine wire harness bolts to the EGR cooler.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 45: Locating EGR Cooler Engine Wire Harness Bolts
  Courtesy of FORD MOTOR CO.
Connect the wire retainer and the vacuum hose. Connect the EGR valve, bypass solenoid and EGR ECT sensor electrical connectors.
Connect the 2 wire harness retainers.

Fig 46: Locating Wire Harness Retainers
Courtesy of FORD MOTOR CO.
NOTE: LH side shown, RH side similar.

Install the 2 ground straps and 2 bolts to the back of the cylinder heads.
- Tighten to 10 Nm (89 lb-in).
Using new gaskets, install the EGR bypass outlet tube and the 4 new bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 47: Locating EGR Bypass Outlet Tube Mounting Bolts
  Courtesy of FORD MOTOR CO.
Connect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector and wire retainer.

Fig 48: Locating Exhaust Gas Recirculation Temperature Electrical Connector And Wire Retainer
Courtesy of FORD MOTOR CO.
NOTE: Exhaust side shown, EGR cooler side similar.

Using new gaskets, install the EGR valve inlet tube and the 4 new bolts. Tighten the bolts in the following sequence.
- Tighten the bolts at the exhaust manifold to 10 Nm (89 lb-in).
- Tighten the bolts at the EGR cooler to 10 Nm (89 lb-in).
NOTE: Apply threadlock to the EGR cooler side bolt threads prior to installation.

Install the EGR valve inlet tube bracket and the 2 new bolts. Tighten in 4 stages:
- Stage 1: Tighten the EGR valve inlet tube bracket bolt at the EGR cooler to 10 Nm (89 lb-in).
- Stage 2: Tighten the EGR valve inlet tube bracket bolt at the EGR cooler an additional 45 degrees.
- Stage 3: Tighten the EGR valve inlet tube bracket bolt to 10 Nm (89 lb-in).
- Stage 4: Tighten the EGR valve inlet tube bracket bolt an additional 45 degrees.
  
  Fig 49: Locating EGR Valve Inlet Tube Bracket Mounting Bolts
  Courtesy of FORD MOTOR CO.
NOTE: Apply clean engine oil to the O-ring seals prior to installing the oil level indicator tube.

NOTE: Verify that the oil level indicator tube is fully seated in the rear engine cover.

Using new O-ring seals, install the oil level indicator tube.
Using a new O-ring seal, install the oil fill pipe and bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 50: Locating Oil Fill Pipe Mounting Bolt
  Courtesy of FORD MOTOR CO.
Position the lower engine wire harness on the engine. Install the 2 front retaining nuts.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 51: Locating Front Retaining Nuts
  Courtesy of FORD MOTOR CO.
Install the lower engine wire harness nut.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 52: Locating Lower Engine Wire Harness Nut
  Courtesy of FORD MOTOR CO.
Install the lower engine wire harness nut at the oil filter adapter.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 53: Locating Oil Filter Adapter Lower Engine Wire Harness Nut
  Courtesy of FORD MOTOR CO.
Connect the Engine Oil Temperature (EOT) sensor and the Engine Oil Pressure (EOP) switch electrical connectors.

Fig 54: Locating Engine Oil Temperature Sensor And Engine Oil Pressure Switch Electrical Connectors
Courtesy of FORD MOTOR CO.
NOTE: Power steering pump mounting bracket removed for clarity.

Install the 2 lower engine wire harness bolts.
- Tighten to 12 Nm (108 lb-in).
  
  Fig 55: Locating Lower Engine Wire Harness Bolts
  Courtesy of FORD MOTOR CO.
Connect the power steering tube into the retainer.

Fig 56: Locating Power Steering Tube Retainer
Courtesy of FORD MOTOR CO.
NOTE: RH side shown, LH side similar.

Install the 2 lower engine wire harness ground bolts.
- Tighten to 25 Nm (18 lb-ft).
Connect the lower engine wire harness retainer to the power steering bracket.

Fig 57: Locating Engine Wire Harness Retainer
Courtesy of FORD MOTOR CO.
NOTE: Boot positioned back for clarity.

Connect the generator electrical connector and the generator B+ terminal and install the terminal nut.
- Tighten to 12 Nm (108 lb-in).
Install the upper radiator hose and clip.

Fig 58: Locating Upper Radiator Hose Clip
Courtesy of FORD MOTOR CO.
Install engine fill hose to the engine front cover.

Fig 59: Locating Engine Fill Hose Clip
Courtesy of FORD MOTOR CO.
Install the lower radiator hose and clip.
NOTE: Hose retainer not shown.

Connect the oil cooler outlet hose to the lower radiator hose and the hose retainer.

Fig 60: Locating Lower Radiator Hose Retainer
Courtesy of FORD MOTOR CO.
Install the 2 stator standoffs.
- Tighten to 22 Nm (16 lb-ft).
  
  Fig 61: Locating Stator Standoffs
  Courtesy of FORD MOTOR CO.
Connect the engine vacuum hose at the tee. If equipped, install the brake booster vacuum hose.

Fig 62: Locating Engine Vacuum Hose Connector And Brake Booster Vacuum Hose
Courtesy of FORD MOTOR CO.
Install the cooling fan drive assembly and the 4 bolts. Tighten in the sequence shown in the illustration.
- Tighten to 24 Nm (18 lb-ft).
  
  Fig 63: Identifying Tightening Sequence Of Cooling Fan Drive Assembly Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the secondary coolant pump assembly and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 64: Locating Secondary Coolant Pump Assembly Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the accessory drive belt tensioner and the bolt.
- Tighten to 48 Nm (35 lb-ft).
  
  Fig 65: Locating Accessory Drive Belt Tensioner Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the A/C compressor and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 66: Locating A/C Compressor Mounting Bolts
  Courtesy of FORD MOTOR CO.
Connect the A/C compressor electrical connectors and the wire retainer.

Fig 67: Locating A/C Compressor Electrical Connectors And Wire Retainers
Courtesy of FORD MOTOR CO.
NOTE: Single generator shown, dual generator similar.

Install the accessory drive belt.

Courtesy of
Using the Fan Clutch Nut Wrench and Wrench, install the fan clutch.
- Calculate the correct torque wrench setting for the following torque. Refer to the chart below.
- Tighten the fan clutch to 133 Nm (98 lb-ft).
  
  Courtesy of
Install the fan clutch electrical connector bolt.
- Tighten to 25 Nm (18 lb-ft).
  
  Fig 68: Locating Fan Clutch Electrical Connector Bolt
  Courtesy of FORD MOTOR CO.
Connect the fan clutch electrical connector.
Position the EGR cooler hose and vent hose on the engine. Connect the EGR cooler hose and the vent hose.

Fig 69: Locating EGR Cooler Hose And Vent Hose Retainers
Courtesy of FORD MOTOR CO.
Connect the coolant hose to the vacuum hose retainer.

Fig 70: Locating Vacuum Hose Retainer
Courtesy of FORD MOTOR CO.
Install the EGR cooler hose on the EGR cooler.

Fig 71: Locating EGR Cooler Hose Clamp
Courtesy of FORD MOTOR CO.
Connect the EGR cooler hose retainer.

Fig 72: Locating EGR Cooler Hose Retainer
Courtesy of FORD MOTOR CO.
NOTE: Discard the engine support insulator bracket bolts and install new bolts or damage to the engine bolt may occur. They are torque-to-yield design and cannot be reused.

NOTE: Do not tighten the engine support insulator bracket bolts more than 90 degrees after initial torque or damage to the bolts may occur.

NOTE: Clean the engine support insulator mating surfaces of any dirt or foreign material prior to installation. Failure to follow these instructions may result in engine support insulator bracket or engine support insulator damage.

NOTE: Place a visible mark on the engine support insulator bracket and bracket bolts. Turning the bolt 1 flat of the bolt head is equal to 60 degrees.

NOTE: Left side shown, right side similar.

Install the LH and RH engine support insulator brackets and the 8 new bolts. Tighten in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).
- Stage 2: Tighten an additional 60 degrees.
  
  Fig 73: Locating Engine Support Insulator Brackets Mounting Bolts
  Courtesy of FORD MOTOR CO.
Install the Engine Removal Bracket and the 4 bolts.
- Tighten to 55 Nm (41 lb-ft).
  
  Fig 74: Locating Engine Removal Bracket And Bolts
  Courtesy of FORD MOTOR CO.
Using the Fold Away Floor Crane, remove the engine from the wooden blocks.
NOTE: The following steps are done on the body before the engine is installed.
NOTE: Make an alignment mark on the Charge Air Cooler (CAC) tube and CAC to aid in assembly.

Loosen the clamp and remove the CAC tube.
Remove the 2 bolts and the CAC.
Flush the CAC and the CAC tubes with Simple Green® Pro HD. Refer to INTAKE AIR DISTRIBUTION & FILTERING .
Install the CAC and the 2 bolts.
- Tighten to 12 Nm (106 lb-in).
Position the CAC tube and tighten the clamp.
- Tighten to 9 Nm (80 lb-in).
NOTE: Ensure the fuel is free of contaminants.

Replace the fuel conditioning module fuel filter. Refer to FUEL TANK AND LINES - GASOLINE AND DIESEL .
NOTE: Only use NEW Motorcraft® Orange Antifreeze/Coolant Prediluted VC-3DIL-B (US); CVC-3DIL-B (Canada) and the Radiator Refiller (078-00592) to fill the cooling system and ensure integrity. Failure to follow these instructions may result in cooling system damage.

NOTE: If Motorcraft® Orange Antifreeze/Coolant Prediluted VC-3DIL-B (US); CVC-3DIL-B (Canada) is not available, Motorcraft® Orange Antifreeze/Coolant Concentrated VC-3-B (US); CVC-3-B2 (Canada) may be used if it is diluted with distilled water.

Install the engine. Refer to ENGINE - BODY OFF or ENGINE - BODY ON .