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Section 249 (Engine - 7.3L Diesel): Assembly: Engine: Assembly

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.
  1. Install the short circuit valve check ball.
    Fig 1: Installing Short Circuit Valve Check Ball
    G01537858Courtesy of FORD MOTOR CO.
  2. Install the spring.
    Fig 2: Installing Spring
    G01537859Courtesy of FORD MOTOR CO.
  3. Install the short circuit valve check ball retainer cap.
    Fig 3: Installing Short Circuit Valve Check Ball Retainer Cap
    G01537860Courtesy of FORD MOTOR CO.
    4. NOTE: All eight piston oil cooling jets are installed the same way. Only one jet is shown.
    Fig 4: Installing Piston Oil Cooling Jets
    G01537861Courtesy of FORD MOTOR CO.
  4. Install the piston oil cooling jets.
    1. Install the cooling jet.
    2. Install the bolts.
  5. Install the upper half of the main bearings into the bearing bores.
    • Coat the main bearing halves with clean engine oil after installing them into the bearing bores.
    Fig 5: Installing Upper Half Of Main Bearings Into Bearing Bores
    G01537862Courtesy of FORD MOTOR CO.
  6. Install the crankshaft into the cylinder block.
    Fig 6: Installing Crankshaft Into Cylinder Block
    G01537863Courtesy of FORD MOTOR CO.
    7. NOTE: Do not turn the crankshaft while performing the main bearing clearance check.
  7. Install special tool 303-D031 (D81L-6002-B).
    • Install the lower main bearing halves into the main bearing caps.
    • Place a piece of the special tool in the center of each main bearing journal on the crankshaft, and install the main bearing caps.
    • Tighten the main bearing cap bolts to specification.
  8. Remove the main bearing caps and measure the clearance.
    • Install a new main bearing if not within specification.
    Fig 7: Removing Main Bearing Caps And Measuring Clearance
    G01537864Courtesy of FORD MOTOR CO.
  9. Install the main bearing caps.
    1. Coat the main bearing halves with clean engine oil. Position the main bearing caps.
    2. Install the bolts.
    Fig 8: Installing Main Bearing Caps
    G01537865Courtesy of FORD MOTOR CO.
  10. Tighten the main bearing cap bolts in the sequence shown in two stages.
    • Stage 1: Tighten the bolts to 102 Nm (76 lb-ft).
    • Stage 2: Tighten the bolts to 129 Nm (96 lb-ft).
    Fig 9: Identifying Tightening Sequence Of Main Bearing Cap Bolts
    G01537866Courtesy of FORD MOTOR CO.
  11. Using the special tool, measure the crankshaft end play by prying the crankshaft forward and back.
    Fig 10: Measuring Crankshaft End Play By Prying Crankshaft Forward And Back
    G01537867Courtesy of FORD MOTOR CO.
  12. Install new piston rings.
    • The intermediate compression ring is identified with two indentation marks and a square profile.
    • The top compression ring is identified with one indentation mark and has a 15-degree keystone profile.
    Fig 11: Identifying Intermediate Compression Ring
    G01537868Courtesy of FORD MOTOR CO.
    Fig 12: Identifying Top Compression Ring
    G01537869Courtesy of FORD MOTOR CO.
    13. NOTE: All eight pistons and connecting rods are installed into the cylinder block the same way. Only one piston and connecting rod is shown.
    Fig 13: Installing Piston/Rod Assembly
    G01537870Courtesy of FORD MOTOR CO.
  13. Using the special tool, install the piston and rod assemblies.
    1. Coat the inside diameter of the special tool with clean engine oil. Insert the piston into the special tool. Position the piston with the installation arrow pointing towards the camshaft, connecting rod and special tool into the correct cylinder bore.
    2. Using a wood or plastic hammer handle, push the connecting rod and piston assembly down into the cylinder bore.
    14. NOTE: Do not turn the crankshaft while performing the rod bearing clearance check.
    NOTE: All eight rod bearings are checked the same way. Only one rod bearing is shown.
    Fig 14: Checking Rod Bearing Clearance
    G01537871Courtesy of FORD MOTOR CO.
  14. Check the rod bearing clearance.
    • Insert the upper rod bearing half into the connecting rod. Install the lower rod bearing half into the rod cap.
    • Place a piece of special tool 303-D031 (D81L-6002-B) in the center of the rod bearing journal on the crankshaft. Install the connecting rod cap and nuts.
  15. Remove the rod bearing cap and measure the rod bearing clearance.
    • Install a new rod bearing if not within specification.
    Fig 15: Measuring Rod Bearing Clearance
    G01537872Courtesy of FORD MOTOR CO.
    16. NOTE: All eight connecting rod caps are installed the same way. Only one rod cap is shown.
    Fig 16: Tightening Connecting Rod Cap Bolts
    G01537873Courtesy of FORD MOTOR CO.
  16. Install the connecting rod cap.
    1. Coat the connecting rod bearing half with clean engine oil. Position the connecting rod cap onto the connecting rod and seat the cap onto the crankshaft journal.
    2. Install the bolts. Tighten the bolts in two stages.
      • Stage 1: Tighten the bolts to 70 Nm (52 lb-ft).
      • Stage 2: Tighten the bolts to 122 Nm (90 lb-ft).
  17. Using a feeler gauge, measure connecting rod to crankshaft assembled side clearance.
    Fig 17: Measuring Connecting Rod To Crankshaft Assembled Side Clearance
    G01537874Courtesy of FORD MOTOR CO.
    18. NOTE: Thoroughly coat the camshaft bearing journals with clean engine oil before installing the camshaft into the engine block.
    Fig 18: Installing Camshaft
    G01537875Courtesy of FORD MOTOR CO.
  18. Install the camshaft.
    1. Gently insert the camshaft into the engine block.
      • It may be necessary to rotate the camshaft during installation to aid in inserting the camshaft through the camshaft bearings.
    2. Before seating the camshaft drive gear with the crankshaft driven gear, rotate the crankshaft driven gear until the timing mark is in the 12 o'clock position. Align the timing mark on the camshaft drive gear with the timing mark on the crankshaft driven gear. Seat the camshaft drive gear with the crankshaft driven gear.
    3. Install the two camshaft retaining bolts.
    19. NOTE: All sixteen lifters are installed the same way. Only two lifters are shown.
    NOTE: Before installing the lifters into the lifter bores, thoroughly coat the lifters using clean engine oil.
    Fig 19: Installing Lifters
    G01537876Courtesy of FORD MOTOR CO.
  19. Install the lifters as noted during removal.
    1. Insert the lifters into the lifter bores.
    2. Install the retainer plate.
    3. Install the retaining bolt.
    20. CAUTION: Use caution when installing the engine rear cover. If the cover is bent, engine oil leaks will occur.
    CAUTION: Use care not to use too much RTV Silicone Sealant on the engine rear cover. Too much sealant can cause engine oil contamination and engine failure.
    NOTE: The engine rear cover must be installed within three minutes after applying the RTV Silicone Sealant. If the cover is not installed within three minutes, the RTV Silicone Sealant must be removed and a new bead of RTV Silicone Sealant must be applied.
  20. Install the engine rear cover.
    1. Apply a bead of RTV Silicone Sealant.

      Position the engine rear cover and install the bolts finger tight.

    2. Tighten the bolts.
      Fig 20: Installing Engine Rear Cover
      G01537877Courtesy of FORD MOTOR CO.
    21. NOTE: The engine front cover must be installed within three minutes after applying the RTV Silicone Sealant. If the cover is not installed within three minutes, the RTV Silicone Sealant must be removed and a new bead of RTV Silicone Sealant must be applied.
    Fig 21: Installing Engine Front Cover Gasket
    G01537878Courtesy of FORD MOTOR CO.
  21. Install the engine front cover gasket.
    1. Apply the RTV Silicone Sealant to the engine front cover.
    2. Install the engine front cover gaskets.
  22. Install the engine front cover.
    1. Position the engine front cover onto the engine block.
    2. Install the bolts.
    Fig 22: Installing Engine Front Cover
    G01537879Courtesy of FORD MOTOR CO.
  23. Install the oil pickup tube gasket.
    Fig 23: Installing Oil Pickup Tube Gasket
    G01537880Courtesy of FORD MOTOR CO.
  24. Install the oil pickup tube.
    1. Position the oil pickup tube and install the bolts.
    2. Install the nut.
    Fig 24: Installing Oil Pickup Tube
    G01537881Courtesy of FORD MOTOR CO.
    25. NOTE: The oil pan must be installed within three minutes after applying the RTV Silicone Sealant. If the oil pan is not installed within three minutes the RTV Silicone Sealant must be removed and a new bead of RTV Silicone Sealant must be applied.
    NOTE: A larger amount of RTV Silicone Sealant will be required on the front and rear areas of the oil pan.
    Fig 25: Applying RTV Silicone Sealant To Oil Pan
    G01537882Courtesy of FORD MOTOR CO.
  25. Apply RTV Silicone Sealant to the oil pan.
    1. Apply a bead of sealant.
    2. Apply a bead of sealant.
  26. Install the oil pan.
    1. Position the oil pan.
    2. Install the oil pan bolts.
    Fig 26: Installing Oil Pan
    G01537883Courtesy of FORD MOTOR CO.
    27. NOTE: Both the left and right engine mounts are installed the same way. Only the left side is shown.
    Fig 27: Installing Engine Mounts
    G01537884Courtesy of FORD MOTOR CO.
  27. Install the engine mounts.
    1. Position the engine mounts.
    2. Install the three bolts.
    28. CAUTION: The inner gerotor must be installed with the words "Out" or "Damper" facing away from the engine.
    NOTE: The inner gerotor gear must be installed onto the crankshaft nose before the oil pump is installed onto the engine front cover.
    Fig 28: Installing Oil Pump Inner Gerotor
    G01537885Courtesy of FORD MOTOR CO.
  28. Install the oil pump inner gerotor.
  29. Install the oil pump.
    1. Lubricate the oil pump with clean engine oil. With a new O-ring, position the oil pump housing with the outer gerotors onto the engine front cover.
    2. Install the four bolts.
    Fig 29: Installing Oil Pump
    G01537886Courtesy of FORD MOTOR CO.
  30. Install the crankshaft vibration damper.
    1. Using special tool 303-144 (T79T-6316-A), install the vibration damper onto the crankshaft.
    2. Install the vibration damper bolt and washer.
      • Apply RTV Silicone Sealant to the washer.
    Fig 30: Installing Crankshaft Vibration Damper
    G01537887Courtesy of FORD MOTOR CO.
  31. Install the camshaft position (CMP) sensor.
    1. Install the sensor into the engine front cover.
    2. Install the sensor retaining bracket.
    3. Install the bolt.
    Fig 31: Installing Camshaft Position (CMP) Sensor
    G01537888Courtesy of FORD MOTOR CO.
  32. Install the exhaust back pressure sensor and tube.
    1. Position the sensor and tube.
    2. Install the nut.
    Fig 32: Installing Exhaust Back Pressure Sensor And Tube
    G01537889Courtesy of FORD MOTOR CO.
  33. Install the high pressure oil pump.
    1. With a new gasket, position the high pressure oil pump.
    2. Install the bolts.
    Fig 33: Installing High Pressure Oil Pump
    G01537890Courtesy of FORD MOTOR CO.
    34. CAUTION: Make sure that the drive gear is fully seated on the high-pressure oil pump before installing the bolt and washer. Otherwise, the drive gear may not seat correctly, causing binding or slippage resulting in a no oil flow condition.
    Fig 34: Installing High Pressure Oil Pump Drive Gear
    G01537891Courtesy of FORD MOTOR CO.
  34. Install the high pressure oil pump drive gear.
    • Position the drive gear onto the high pressure oil pump. Install the bolt and washer.
  35. Check the high pressure oil pump drive gear backlash.
    1. Position the special tool onto the drive gear.
    2. Rock the drive gear and record the reading.
      • Install a new drive gear if not within specification.
    Fig 35: Checking High Pressure Oil Pump Drive Gear Backlash
    G01537892Courtesy of FORD MOTOR CO.
  36. Install the gasket onto the engine front cover.
    Fig 36: Installing Gasket Onto Engine Front Cover
    G01537893Courtesy of FORD MOTOR CO.
  37. Install the high pressure oil pump reservoir.
    1. Position the reservoir onto the engine front cover.
    2. Install the bolts.
    Fig 37: Installing High Pressure Oil Pump Reservoir
    G01537894Courtesy of FORD MOTOR CO.
  38. Install the access cover and bolts.
    • Apply RTV Silicone Sealant to the access cover.
    Fig 38: Installing Access Cover And Bolts
    G01537895Courtesy of FORD MOTOR CO.
  39. Install the fuel filter/water separator assembly.
    1. Position the fuel filter/water separator assembly.
    2. Install the bolts.
    Fig 39: Installing Fuel Filter/Water Separator Assembly
    G01537896Courtesy of FORD MOTOR CO.
  40. Position the fuel drain tube, and install the bolt.
    Fig 40: Installing Fuel Drain Tube
    G01537897Courtesy of FORD MOTOR CO.
  41. Install the engine oil cooler.
    1. Position the two header gaskets and the oil cooler.
    2. Install the five bolts.
    Fig 41: Installing Engine Oil Cooler
    G01537898Courtesy of FORD MOTOR CO.
  42. Position the cylinder head gaskets onto the engine block.
    Fig 42: Positioning Cylinder Head Gaskets Onto Engine Block
    G01537899Courtesy of FORD MOTOR CO.
    43. NOTE: Both the left side and right side heads are installed in the same way. Only the right side head is shown.
    Fig 43: Installing Cylinder Head
    G01537900Courtesy of FORD MOTOR CO.
  43. Using the special tools, install the cylinder head.
    44. CAUTION: Do not use too much engine oil on the threads of the cylinder head bolts, or damage to the threads and poor sealing can result. Do not use anti-seize compounds, grease or any other lubricants except engine oil on the cylinder head bolt threads because they will affect the true torque value reading of the bolts.
    Fig 44: Identifying Cylinder Head Bolts Tightening Sequence
    G01537901Courtesy of FORD MOTOR CO.
  44. Install the 18 cylinder head bolts.
    • Lightly lubricate the cylinder head bolt threads and flanges with clean engine oil.
    • Tighten the bolts in the sequence shown in three stages.
    • Stage 1: Using the first sequence, tighten the bolts to 88 Nm (65 lb-ft).
    • Stage 2: Using the first sequence, tighten the bolts to 115 Nm (85 lb-ft).
    • Stage 3: Using the second sequence, tighten the bolts to 129 Nm (95 lb-ft).
    45. NOTE: Make sure the bolt holes are free of contaminants prior to bolt installation.
    Fig 45: Installing Inboard Fuel Injector Hold-Down Bolts
    G01537902Courtesy of FORD MOTOR CO.
  45. Install the four inboard fuel injector hold-down bolts.
  46. Connect the exhaust back pressure tube.
    Fig 46: Connecting Exhaust Back Pressure Tube
    G01537903Courtesy of FORD MOTOR CO.
  47. Install the fuel tube.
    1. Position the fuel tube clamp onto the right hand cylinder head stud bolt.
    2. Install the nut.
    Fig 47: Installing Fuel Tube
    G01537904Courtesy of FORD MOTOR CO.
  48. Install the fuel supply hoses onto the cylinder heads.
    Fig 48: Installing Fuel Supply Hoses Onto Cylinder Heads (1 Of 2)
    G01537905Courtesy of FORD MOTOR CO.
    Fig 49: Installing Fuel Supply Hoses Onto Cylinder Heads (2 Of 2)
    G01537906Courtesy of FORD MOTOR CO.
  49. Install new O-ring seals and new copper gaskets on the fuel injectors. Lubricate fuel injectors, O-ring seals and copper gaskets with clean engine oil.
    50. NOTE: All eight fuel injectors are installed the same way. Only one fuel injector is shown.
    NOTE: Thoroughly coat the fuel injector O-ring seal with clean engine oil to aid in installation.
    Fig 50: Installing Fuel Injector
    G01537907Courtesy of FORD MOTOR CO.
  50. Install the fuel injector.
    1. Insert the fuel injector into the cylinder head fuel injector bore.
    2. Using the special tool, seat the fuel injector into the cylinder head fuel injector bore.
    51. NOTE: Make sure the bolt holes are free of contaminants prior to bolt installation.
    Fig 51: Installing Fuel Injector Hold-Down Bolts
    G01537908Courtesy of FORD MOTOR CO.
  51. Install the fuel injector hold-down bolts.
    52. NOTE: All eight oil deflectors are installed the same way. Only one oil deflector is shown.
    Fig 52: Installing Oil Deflector
    G01537909Courtesy of FORD MOTOR CO.
  52. Install the oil deflector.
    1. Position the oil deflector.
    2. Install the bolt.
    53. CAUTION: Make sure to follow the next step of this procedure to prevent bent valves.
  53. Rotate the engine until the mark on the crankshaft damper is at 11 o'clock, to prevent damage when installing the intake rocker arm and exhaust rocker arm.
    54. NOTE: All 16 push rods and rocker arms are installed the same way. Only one push rod and rocker arm is shown.
    NOTE: Install the push rods with the copper end up.
    Fig 53: Installing Rocker Arms
    G01537910Courtesy of FORD MOTOR CO.
  54. Install the rocker arms.
    1. Apply clean engine oil to the push rod, and insert the push rod, with the copper end up, into the engine. Make sure the push rod seats onto the lifter.
    2. Position the rocker arm onto the cylinder head.
    3. Install the bolts.
  55. Connect the high pressure oil hoses. Pull on the high pressure oil hoses to make sure the fitting is correctly connected.
    Fig 54: Connecting High Pressure Oil Hoses
    G01537911Courtesy of FORD MOTOR CO.
    56. NOTE: Both the left side and the right side valve cover gaskets are installed the same way. Only the right side gasket is shown.
    Fig 55: Installing Valve Cover Gasket
    G01537912Courtesy of FORD MOTOR CO.
  56. Install the valve cover gasket.
    1. Position the gasket onto the cylinder head.
    2. Install the four glow plug electrical leads.
    3. Install the four fuel injector electrical connectors.
    57. NOTE: Both the left side and the right side valve covers are installed the same way. Only the right side valve cover is shown.
    Fig 56: Installing Valve Cover
    G01537913Courtesy of FORD MOTOR CO.
  57. Install the valve cover.
    1. Position the valve cover onto the cylinder head.
    2. Install the bolts.
  58. Install the oil lever indicator tube.
    1. Position the indicator tube into the oil pan.
    2. Position the indicator tube retainer into the stud bolt.
    3. Install the nut.
    Fig 57: Installing Oil Lever Indicator Tube
    G01537914Courtesy of FORD MOTOR CO.
  59. Install two new O-ring seals onto the engine.
    Fig 58: Installing New O-Ring Seals Onto Engine
    G01537915Courtesy of FORD MOTOR CO.
  60. Install the turbocharger pedestal.
    1. Position the turbocharger pedestal.
    2. Install the bolts.
    Fig 59: Installing Turbocharger Pedestal
    G01537916Courtesy of FORD MOTOR CO.
  61. Position the engine harness onto the engine.
  62. Connect the camshaft position sensor (CMP) electrical connector.
    Fig 60: Connecting Camshaft Position Sensor (CMP) Electrical Connector
    G01537917Courtesy of FORD MOTOR CO.
  63. Install the engine harness.
    • Position the harness and install the pushpin retainer into the hole on the water pump.
    Fig 61: Installing Engine Harness
    G01537918Courtesy of FORD MOTOR CO.
  64. Connect the exhaust back pressure sensor and engine coolant temperature (ECT) electrical connectors.
    Fig 62: Connecting Exhaust Back Pressure Sensor And ECT Electrical Connectors
    G01537919Courtesy of FORD MOTOR CO.
  65. Connect the engine oil pressure sensor electrical connector.
    Fig 63: Connecting Engine Oil Pressure Sensor Electrical Connector
    G01537920Courtesy of FORD MOTOR CO.
  66. Connect the engine oil temperature sensor electrical connector.
    Fig 64: Connecting Engine Oil Temperature Sensor Electrical Connector
    G01537921Courtesy of FORD MOTOR CO.
  67. Connect the injection oil pressure sensor electrical connector.
    Fig 65: Connecting Injection Oil Pressure Sensor Electrical Connector
    G01537922Courtesy of FORD MOTOR CO.
  68. Connect the injection pressure regulator (IPR) electrical connector.
    Fig 66: Connecting Injection Pressure Regulator (IPR) Electrical Connector
    G01537923Courtesy of FORD MOTOR CO.
  69. Connect the fuel heater/water separator electrical connector.
    Fig 67: Connecting Fuel Heater/Water Separator Electrical Connector
    G01537924Courtesy of FORD MOTOR CO.
  70. Connect the exhaust back pressure solenoid electrical connector.
    Fig 68: Connecting Exhaust Back Pressure Solenoid Electrical Connector
    G01537925Courtesy of FORD MOTOR CO.
    71. NOTE: Both the left side and the right side nine pin connectors are installed the same way. Only the right side is shown.
    Fig 69: Connecting Fuel Injector/Glow Plug Nine Pin Connector
    G01537926Courtesy of FORD MOTOR CO.
  71. Connect the fuel injector/glow plug nine pin connector.
    • Install the connector and the retainer clip.
  72. Install the exhaust adapter pipes.
    1. Position the pipes.
    2. Install the four mounting bolts and nuts.
    Fig 70: Installing Exhaust Adapter Pipes
    G01537927Courtesy of FORD MOTOR CO.
  73. Remove the engine from the stand and install the engine lifting equipment.
  74. Install the flywheel.
    Fig 71: Installing Flywheel
    G01537928Courtesy of FORD MOTOR CO.
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