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Section 2017 (Engine - 6.8L): Installation: Engine

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
Special Tools

Illustration Tool Name Tool Number
GF0005878
 Holding Wrench, Fan Clutch 303-478 (T94T-6312-AH)
GF0000628
 Installer Set, Teflon Seal 211-D027 (D90P-3517-A) or equivalent
GF0005784
 Wrench, Fan Clutch Hub Nut 303-214 (T83T-6312-B)
Material

Item Specification
Motorcraft SAE 5W-20 Premium Synthetic Blend Motor Oil
XO-5W20-QSP (US); Motorcraft SAE 5W-20 Super Premium Motor Oil CXO-5W20-LSP12 (Canada); or equivalent		 WSS-M2C930-A
  1. Position the engine in the vehicle.
  2. Remove the floor crane and the jack supporting the transmission.
    3. NOTE: Align the engine-to-transmission dowels before installing the engine-to-transmission bolts.
  3. Position the shifter cable support bracket and install the 2 transmission-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
    4. Fig 1: Transmission-To-Engine Bolts
    G03885559Courtesy of FORD MOTOR CO.
  4. Install the RH lower transmission-to-engine bolt.
    • Tighten to 47 Nm (35 lb-ft).
    5. Fig 2: Lower Right Transmission-To-Engine Bolt
    GF0011683Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  5. Install the 4 engine mount nuts.
    • Tighten to 90 Nm (66 lb-ft).
    6. Fig 3: Engine Support Insulator-To-Crossmember Nuts
    G03885561Courtesy of FORD MOTOR CO.
  6. Install the shift cable to the mounting bracket and shift linkage.
    7. Fig 4: Shift Cable At Mounting Bracket & Shift Linkage
    GF0011783Courtesy of FORD MOTOR CO.
  7. Install 4 new torque converter nuts.
    • Rotate the crankshaft to access all of the torque converter nuts.
    • Tighten to 40 Nm (30 lb-ft).
    8. Fig 5: Locating Torque Converter-To-Flexplate Nuts
    GF0002674Courtesy of FORD MOTOR CO.
  8. Install the cylinder block opening cover.
    9. Fig 6: Cylinder Block Opening Cover
    GF0011681Courtesy of FORD MOTOR CO.
  9. Position the flexplate inspection cover and install the 2 bolts.
    • Tighten to 34 Nm (25 lb-ft).
    10. Fig 7: Locating Flexplate Inspection Cover Bolts
    GF0002672Courtesy of FORD MOTOR CO.
  10. If equipped, install the A/C compressor and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
    11. Fig 8: A/C Compressor Bolts
    G04612406Courtesy of FORD MOTOR CO.
  11. Position the exhaust Y-pipe and install the 4 nuts.
    • Tighten to 40 Nm (30 lb-ft).
    12. Fig 9: Locating Exhaust Manifold-To-Catalytic Converter Nuts
    GF0002678Courtesy of FORD MOTOR CO.
    CAUTION: The oil cooler must be replaced or severe damage to the engine can occur.
    NOTE: Make sure the tab on the oil filter adapter nests into the notch in the oil cooler.
  12. Position a new oil cooler on the oil filter adapter and install the threaded insert.
    • Tighten to 58 Nm (43 lb-ft).
    13. Fig 10: Identifying Oil Cooler
    G03885413Courtesy of FORD MOTOR CO.
  13. Install a new oil filter.
    • Tighten to 16 Nm (12 lb-ft).
    14. Fig 11: Locating Oil Filter
    G03885412Courtesy of FORD MOTOR CO.
  14. Connect the 2 oil cooler coolant hoses.
    15. Fig 12: Locating Oil Cooler Coolant Hoses
    G03885411Courtesy of FORD MOTOR CO.
  15. Position the transmission fluid cooler tube support bracket and install the nut.
    • Tighten to 30 Nm (22 lb-ft).
    16. Fig 13: Identifying Transmission Fluid Cooler Tube Support Bracket Nut
    G03885563Courtesy of FORD MOTOR CO.
  16. Using the special tool, install a new Teflon® seal on the power steering pressure tube.
    17. Fig 14: Locating O-Ring Seal On Pressure Line Fitting
    GF0002615Courtesy of FORD MOTOR CO.
  17. Connect the power steering pressure tube and the power steering reservoir hose to the power steering pump.
    • Tighten to 20 Nm (15 lb-ft).
    18. Fig 15: Power Steering Reservoir Hose And Pressure Tube Retainers
    G03885562Courtesy of FORD MOTOR CO.
  18. Install and tighten the oil drain plug.
    • Tighten to 23 Nm (17 lb-ft).
    19. Fig 16: Engine Oil Drain Plug
    GF0002670Courtesy of FORD MOTOR CO.
  19. Position the fuel line and the LH heated oxygen sensor (HO2S) brackets. Install the 4 upper transmission-to-engine bolts.
    • Tighten to 47 Nm (35 lb-ft).
    20. Fig 17: Upper Transmission-To-Engine Bolts
    G03886655Courtesy of FORD MOTOR CO.
  20. Connect the transmission wiring harness and the LH and RH HO2S electrical connectors. Install the transmission wiring harness connector retainer in the bracket.
    21. Fig 18: View Of Transmission And Heated Oxygen Sensor (HO2S) Electrical Connectors
    G04612445Courtesy of FORD MOTOR CO.
    NOTE: Do not reuse the O-ring seals. Lubricate the new O-ring seals with clean engine coolant before installing the heater outlet tube.
  21. Insert the heater outlet tube over the new seals.
    22. Fig 19: Sliding Coolant Tube Forward With O-Ring Seals Into Cylinder Block
    GF0000368Courtesy of FORD MOTOR CO.
  22. Install the heater outlet tube studs.
    • Tighten to 40 Nm (30 lb-ft).
    23. Fig 20: Identifying Heater Outlet Tube Studs
    G03885600Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the O-ring seals with clean transmission fluid before installing the transmission fluid filler tube.
  23. Position the transmission fluid filler tube in the vehicle. Connect the HO2S electrical connector.
    24. Fig 21: Transmission Fluid Filler Tube & Heated Oxygen Sensor (HO2S) Electrical Connector
    GF0011785Courtesy of FORD MOTOR CO.
  24. Connect the hose to the heater outlet tube.
    25. Fig 22: View Of Hose To Heater Outlet Tube
    G03886137Courtesy of FORD MOTOR CO.
  25. Install the wiring retainers in the heater outlet tube bracket.
    1. Install the knock sensor (KS) electrical connector retainer.
    2. Install the engine harness routing clip retainer.
    26. Fig 23: Locating Engine Harness Routing Clip Retainers
    G04612441Courtesy of FORD MOTOR CO.
  26. Connect the evaporative emission (EVAP) canister purge valve electrical connector.
    27. Fig 24: Locating Evaporative Emission (EVAP) Canister Purge Valve Electrical Connector
    G03885596Courtesy of FORD MOTOR CO.
  27. Connect the attachments to the transmission fluid filler tube and install the fluid level indicator.
    1. Connect the rear heater hose hanger.
    2. Install the fluid level indicator.
    28. Fig 25: Transmission Fluid Level Indicator & Rear Heater Hose Hanger
    GF0011692Courtesy of FORD MOTOR CO.
  28. Install the engine oil filler tube support strap bolt.
    • Tighten to 10 Nm (89 lb-in).
    29. Fig 26: Engine Oil Filler Tube Support Strap Bolt
    G03885594Courtesy of FORD MOTOR CO.
  29. Position the mounting bracket, install the ground strap and nut, and connect the electrical connectors to the bracket.
    • Tighten to 25 Nm (18 lb-ft).
    30. Fig 27: Electrical Connectors And Ground Strap Bracket Retaining Nut
    G03885234Courtesy of FORD MOTOR CO.
  30. Connect the engine wiring harness electrical connectors.
    31. Fig 28: Identifying Engine Wiring Harness Electrical Connectors
    G03885233Courtesy of FORD MOTOR CO.
  31. Connect the PCM electrical connectors.
    32. Fig 29: Powertrain Control Module (PCM) Electrical Connectors
    G03885591Courtesy of FORD MOTOR CO.
  32. Connect the engine wiring harness to the PCM bracket.
    33. Fig 30: Identifying Engine Wiring Harness To PCM Bracket Retainer
    G03885211Courtesy of FORD MOTOR CO.
  33. Connect the lower radiator hose to the oil filter adapter coolant inlet.
    34. Fig 31: Identifying Lower Radiator Hose
    G03886149Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  34. Position the lower radiator support and install the 12 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    35. Fig 32: Identifying Lower Radiator Support Bolts
    G03886640Courtesy of FORD MOTOR CO.
  35. Position the RH side of the headlamp dash panel junction wiring harness.
    1. Connect the electrical connector.
    2. Tighten the ground cable nut to 10 Nm (89 lb-in).
    3. Connect the routing clips.
    36. Fig 33: Right Side Of Headlamp Dash Panel Junction Wiring Harness
    GF0011690Courtesy of FORD MOTOR CO.
  36. Position the LH side of the headlamp dash panel junction wiring harness.
    1. Tighten the ground cable nut to 10 Nm (89 lb-in).
    2. Connect the routing clips.
    37. Fig 34: Left Side Of Headlamp Dash Panel Junction Wiring Harness
    GF0011689Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  37. Position the RH and LH air deflectors and install the pin-type retainers.
    38. Fig 35: Locating Pin-Type Retainers
    G03886637Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  38. Position the upper radiator support and install the 8 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    39. Fig 36: Identifying Upper Radiator Support Bolts
    G03886636Courtesy of FORD MOTOR CO.
  39. Connect the horn electrical connector.
    40. Fig 37: Horn Electrical Connector
    G03885580Courtesy of FORD MOTOR CO.
  40. Connect the front impact severity sensor electrical connector.
    41. Fig 38: Front Impact Severity Sensor Electrical Connector
    G03885579Courtesy of FORD MOTOR CO.
  41. If equipped, connect the air temperature sensor electrical connector.
    42. Fig 39: Air Temperature Sensor Electrical Connector
    G03885578Courtesy of FORD MOTOR CO.
  42. Route the battery feed wiring harness to the power distribution box and insert the routing clips.
    43. Fig 40: Routing Battery Feed Wiring Harness
    G03886632Courtesy of FORD MOTOR CO.
    NOTE: Cover removed for clarity.
  43. Install the battery feed cable to the power distribution box and the 2 nuts.
    • Tighten to 8 Nm (71 lb-in).
    44. Fig 41: Locating Battery Feed Cable Nuts At Power Distribution Box
    G03885576Courtesy of FORD MOTOR CO.
  44. Position the power steering reservoir and install the 2 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    45. Fig 42: Power Steering Reservoir Bolts
    G03886630Courtesy of FORD MOTOR CO.
  45. Position the hood latch.
    1. Install the 2 bolts.
    2. Connect the cable position retainer.
      • Tighten to 12 Nm (9 lb-ft).
    46. Fig 43: Hood Latch & Clip
    GF0011688Courtesy of FORD MOTOR CO.
    NOTE: RH shown, LH similar.
  46. If equipped, position the A/C condenser core in the vehicle.
    1. Install the 2 bolts.
    2. Install A/C condenser bracket.
    3. Position the A/C condenser core.
      • Tighten to 12 Nm (9 lb-ft).
    47. Fig 44: A/C Condenser Core, Brackets & Bolts
    GF0011687Courtesy of FORD MOTOR CO.
    CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
  47. If equipped, connect the condenser core refrigerant tubes.
    1. Connect the condenser-to-evaporator tube.
      • Tighten to 18 Nm (13 lb-ft).
    2. Connect the A/C compressor discharge tube.
      • Tighten to 39 Nm (29 lb-ft).
    48. Fig 45: Condenser Core Refrigerant Tubes
    GF0011686Courtesy of FORD MOTOR CO.
    CAUTION: Use a wrench on each side of the fitting to prevent damage to the A/C fitting.
  48. If equipped, connect the A/C compressor suction tube.
    • Tighten to 47 Nm (35 lb-ft).
    49. Fig 46: A/C Compressor Suction Tube Fitting
    G03885571Courtesy of FORD MOTOR CO.
  49. If equipped, connect the A/C pressure cutoff switch electrical connector.
    50. Fig 47: A/C Pressure Cutoff Switch Electrical Connector
    G03886625Courtesy of FORD MOTOR CO.
  50. Position the radiator in the vehicle.
    51. Fig 48: Positioning Radiator In Vehicle
    G03886624Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  51. Position the radiator support brackets and install the 4 bolts.
    • Tighten to 20 Nm (15 lb-ft).
    52. Fig 49: Radiator Support Brackets Bolts
    G03886623Courtesy of FORD MOTOR CO.
  52. Position the fan shroud and the fan and fan clutch in the vehicle, and install the 2 bolts.
    • Tighten to 6 Nm (53 lb-in).
    53. Fig 50: Fan Shroud Bolts
    GF0011728Courtesy of FORD MOTOR CO.
  53. Insert the degas hose retainer in the fan shroud.
    54. Fig 51: Degas Bottle Coolant Hose Retainer
    G03885566Courtesy of FORD MOTOR CO.
  54. Install the fan blade assembly and fan clutch.
    • Install the fan blade and the fan clutch.
    • Using the special tool, hold the coolant pump pulley.
    • Using the special tool, tighten the fan clutch nut.
      • Tighten to 133 Nm (98 lb-ft).
    55. Fig 52: Fan Clutch Assembly Nut - 6.8L
    GF0005881Courtesy of FORD MOTOR CO.
  55. Connect the upper radiator coolant hose and the degas bottle coolant hose to the radiator.
    56. Fig 53: Radiator Upper Hose & Overflow Hose
    GF0011684Courtesy of FORD MOTOR CO.
  56. Install the radiator grille support. For additional information, refer to FRONT END BODY PANELS article.
  57. Connect the transmission cooler tubes.
    58. Fig 54: Identifying Transmission Cooler Hoses
    G03886172Courtesy of FORD MOTOR CO.
  58. Position the splash shield and install the push pin retainers.
    59. Fig 55: Identifying Push Pin Retainers And Splash Shield
    G03885266Courtesy of FORD MOTOR CO.
  59. Connect the lower radiator hose to the radiator.
    • Connect the hose.
    • Connect the hose hanger.
    60. Fig 56: Lower Radiator Hose And Retainers
    G03886599Courtesy of FORD MOTOR CO.
  60. Install the front bumper. For additional information, refer to BUMPERS article.
  61. Install the starter. For additional information, refer to STARTING SYSTEM - GASOLINE ENGINES article.
  62. Install the intake manifold. For additional information, refer to Intake Manifold .
  63. Fill the engine with clean engine oil.
  64. Fill the transmission with clean transmission fluid. For additional information, refer to AUTOMATIC TRANSAXLE/TRANSMISSION - 4R70E/4R75E article.
  65. Fill and bleed the power steering system. For additional information, refer to STEERING SYSTEM - GENERAL INFORMATION article.
  66. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
  67. If equipped, evacuate and recharge the air conditioning system. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
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