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Home >> Ford >> 2012 >> F 550 2WD Super Duty V8-6.7L DSL Turbo >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Service and Repair >> Overhaul >> Engine Assembly >> Part 4

Part 4




Engine














Crankshaft, Camshaft, Piston and Engine Covers










Cylinder Heads and Oil Pans










Fuel Injection Pump, Engine Wire Harness and Misc.










Upper Engine View














Upper Engine View with Under 14,000 Gross Vehicle Weight Rating (GVWR) Lower Intake and Turbocharger














Over 14,000 GVWR (Gross Vehicle Weight Rating) Lower Intake and Turbocharger









Assembly

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 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".

137. Connect the Throttle Body (TB) electrical connector.





138. Using new gaskets, install the EGR cooler assembly and the 7 bolts. Tighten the bolts in the sequence shown.
- Tighten to 10 Nm (89 lb-in).






139. Install the 2 engine wire harness bolts to the EGR cooler.
- Tighten to 10 Nm (89 lb-in).






140. Connect the wire retainer and the vacuum hose. Connect the EGR valve, bypass solenoid and EGR ECT (Engine Coolant Temperature) sensor electrical connectors.





141. Connect the 2 wire harness retainers.





142. 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).






143. Using new gaskets, install the EGR bypass outlet tube and the 4 bolts.
- Tighten to 10 Nm (89 lb-in).






144. Connect the Exhaust Gas Recirculation Temperature (EGRT) sensor electrical connector and wire retainer.





145. NOTE: Exhaust side shown, EGR cooler side similar.
Using new gaskets, install the EGR valve inlet tube and the 4 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).






146. 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.






147. 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.






148. Using a new O-ring seal, install the oil fill pipe and bolt.
- Tighten to 10 Nm (89 lb-in).






149. Position the lower engine wire harness on the engine. Install the 2 front retaining nuts.
- Tighten to 12 Nm (108 lb-in).






150. Install the lower engine wire harness nut.
- Tighten to 12 Nm (108 lb-in).






151. Install the lower engine wire harness nut at the oil filter adapter.
- Tighten to 12 Nm (108 lb-in).






152. Connect the Engine Oil Temperature (EOT) sensor and the Engine Oil Pressure (EOP) switch electrical connectors.





153. NOTE: Power steering pump mounting bracket removed for clarity.
Install the 2 lower engine wire harness bolts.

- Tighten to 12 Nm (108 lb-in).






154. Connect the power steering tube into the retainer.





155. NOTE: RH side shown, LH side similar.
Install the 2 lower engine wire harness ground bolts.

- Tighten to 25 Nm (18 lb-ft).






156. Connect the lower engine wire harness retainer to the power steering bracket.





157. 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).






158. NOTE: Use care when installing the hose to the oil cooler, damage to the oil cooler may occur during installation.
Install the oil cooler inlet hose.






159. Install the upper radiator hose and clip.





160. Install engine fill hose to the engine front cover.





161. Install the lower radiator hose and clip.





162. NOTE: Hose retainer not shown.
Connect the oil cooler outlet hose to the lower radiator hose and the hose retainer.






163. Install the 2 stator standoffs.
- Tighten to 22 Nm (16 lb-ft).






164. Connect the engine vacuum hose at the tee. If equipped, install the brake booster vacuum hose.





165. Install the cooling fan drive assembly and the 4 bolts. Tighten in the sequence shown.
- Tighten to 24 Nm (18 lb-ft).






166. Install the secondary coolant pump assembly and the 4 bolts.
- Tighten to 25 Nm (18 lb-ft).






167. Install the accessory drive belt tensioner and the bolt.
- Tighten to 48 Nm (35 lb-ft).






168. Install the A/C compressor and the 3 bolts.
- Tighten to 25 Nm (18 lb-ft).






169. Connect the A/C compressor electrical connectors and the wire retainer.





170. NOTE: Single generator shown, dual generator similar.
Install the accessory drive belt.






171. Using the Fan Clutch Nut Wrench and Wrench, install the fan clutch.
- Calculate the correct torque wrench setting for the following torque.

- Tighten the fan clutch to 133 Nm (98 lb-ft).






172. Install the fan clutch electrical connector bolt.
- Tighten to 25 Nm (18 lb-ft).






173. Connect the fan clutch electrical connector.





174. Position the EGR cooler hose and vent hose on the engine. Connect the EGR cooler hose and the vent hose.





175. Connect the coolant hose to the vacuum hose retainer.





176. Install the EGR cooler hose on the EGR cooler.





177. Connect the EGR cooler hose retainer.





178. Install the Engine Removal Bracket and the 4 bolts.
- Tighten to 55 Nm (41 lb-ft).






179. Using a Floor Crane, remove the engine from the Engine Stand.

180. NOTICE: 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.

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

NOTICE: 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 bolts. Tighten in 2 stages.
- Stage 1: Tighten to 30 Nm (22 lb-ft).

- Stage 2: Tighten an additional 60 degrees.






181. Install the engine. For additional information, refer to Engine- Body Off or Engine- Body On .
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