Ford F-Super Duty 250 2003

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Engine

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Installation

All vehicles

1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-02.

2. Raise the engine high enough to clear the No. 1 crossmember, then position the engine into the vehicle.

Vehicles with automatic transmission

3. Align the torque converter studs with the holes in the engine flywheel, then lower the engine onto the engine mount towers.

Vehicles with manual transmission

4. Lower the engine onto the engine mount towers.

All vehicles

5. Remove the Heavy Duty Floor Crane and the Diesel Engine Lifting Bracket.

Vehicles with automatic transmission

Remove the transmission jack.

SECTION 303-01D: Engine — 6.0L Diesel 2003 F-Super Duty 250-550/Excursion Workshop Manual

INSTALLATION

Procedure revision date: 04/07/2005

Special Tool(s)

Diesel Engine Lifting Bracket

(D83T-6000-B) 303-D043

Heavy Duty Floor Crane

014-00071

Adapter for 303-D043

303-D043-02

Adapter for 303-D043

303-D043-01

Wrench, Fan Clutch Nut

303-591

Material

Item Specification

SAE 15W-40 Super Duty Motor Oil

XO-15W40-QSD or equivalent

WSS-M2C171-

Motorcraft Premium Gold Engine Coolant

VC-7-A (in California, Oregon and New Mexico VC-7-B, in Canada CVC-

7-A) or equivalent (yellow color)

WSS-M97B51-

R-134a Refrigerant

YN-19

WSH-M17B19-

Page

2003 F

Super Duty 250

550/Excursion Workshop Manual

1/4/2010

http://www.fordtechservice.dealerconnection.com/pubs/content/~WS3O/~MUS~LEN/20/S3

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Summary

6.0 L Diesel Engine Installation

Special Tools for Engine Installation

Lists specialized tools required for the 6.0L diesel engine installation process.

Materials for Engine Installation

Lists required fluids and materials for the 6.0L diesel engine installation.

Engine Installation Procedure

Step-by-step instructions for installing the 6.0L diesel engine into the vehicle, covering various configurations.

Overview

Function Description
Important Technical Specifications
Torque Specifications (Nm and lb-ft/lb-in)
Special Tools
Materials
Usage Features
Maintenance Features (as related to installation)

This document is a section from the 2003 F-Super Duty 250-550/Excursion Workshop Manual, specifically focusing on the "Engine - 6.0L Diesel Installation" procedure. It provides detailed, step-by-step instructions for installing the 6.0L diesel engine in these vehicles, along with a list of special tools and materials required for the task.

Function Description:

The primary function of this manual section is to guide technicians through the correct and safe installation of a 6.0L diesel engine. It covers the entire process from positioning the engine in the vehicle to connecting various electrical, fuel, and cooling components, ensuring proper torque specifications are met for critical fasteners. The instructions are broken down into logical steps, often accompanied by diagrams and specific notes to aid in the procedure. It addresses both automatic and manual transmission configurations where applicable, highlighting differences in the installation process.

Important Technical Specifications:

Torque Specifications (Nm and lb-ft/lb-in):

Transmission-to-engine mounting bolts: 47 Nm (35 lb-ft)
Torque converter-to-flywheel retaining nuts: 35 Nm (26 lb-ft)
LH and RH side engine mount retaining nuts: 103 Nm (76 lb-ft)
Transmission cooler tube bracket and nut: 10 Nm (89 lb-in)
Left rear valve cover stud: 8 Nm (71 lb-in)
Starter bolts: 25 Nm (18 lb-ft)
Starter wiring (solenoid cap): 6 Nm (53 lb-in)
Starter wiring (main terminal): 12 Nm (9 lb-ft)
Ground strap on right head bolt: 10 Nm (89 lb-in)
Automatic transmission fluid indicator and tube: 8 Nm (71 lb-in)
A/C accumulator line nut: 8 Nm (71 lb-in)
A/C compressor bolts: 25 Nm (18 lb-ft)
Glow plug controller nuts: 8 Nm (71 lb-in)
Battery cable bracket and nut, RH standoff for stator: 47 Nm (35 lb-ft)
Power steering pump lower bolts, LH standoff for stator: 25 Nm (18 lb-ft)
Power steering pump upper bolts: 25 Nm (18 lb-ft)
Intake manifold bolts (initial loose, then final sequence): 9-16 Nm (8 lb-ft) (initial), then 11 Nm (8 lb-ft) (final sequence)
Turbocharger heat shield nuts: 11 Nm (8 lb-ft)
Fuel line (banjo fitting and bolt): 13 Nm (10 lb-ft) (banjo fitting), 38 Nm (28 lb-ft) (bolt)
Oil filter return tube and bolt: 6 Nm (53 lb-in) (new tubes), 3 Nm (27 lb-in) (used tubes)
Oil filter bolts: 15 Nm (11 lb-ft)
Fuel line fittings: 26 Nm (19 lb-ft) and 43 Nm (32 lb-ft) (two different fittings)
Ground wire retaining nut: 11 Nm (8 lb-ft)

Special Tools:

Diesel Engine Lifting Bracket (D83T-6000-B) 303-D043: Used for safely lifting the engine.
Heavy Duty Floor Crane 014-00071: Provides the lifting mechanism for the engine.
Adapter for 303-D043 (303-D043-02 and 303-D043-01): Adapters for the lifting bracket, likely for different engine configurations or lifting points.
Wrench, Fan Clutch Nut 303-591: Specific wrench for the fan clutch nut.

Materials:

SAE 15W-40 Super Duty Motor Oil (XO-15W40-QSD or equivalent): Engine lubricant.
Motorcraft Premium Gold Engine Coolant (VC-7-A or VC-7-B/CVC-7-A in specific regions, or equivalent, yellow color): Engine coolant.
R-134a Refrigerant (YN-19): Refrigerant for the A/C system.
Anti-seize lubricant: Recommended for turbocharger adapter pipe threads.
New sealing washers: For fuel line installation.
New oil filter: Required for installation.

Usage Features:

Step-by-step guidance: The manual provides a clear, numbered sequence of actions, making it easy to follow.
Visual aids: Diagrams accompany many steps, illustrating component locations and torque application points.
Regional variations: Coolant specifications account for different regions (California, Oregon, New Mexico, Canada).
Conditional instructions: Differentiates between automatic and manual transmission vehicles, and between new and used parts (e.g., oil filter return tubes).
Important notes: "NOTE" sections highlight critical information, potential difficulties, or specific techniques (e.g., positioning the turbocharger Marmon clamp stud, using a half-moon wrench, applying anti-seize).
Safety considerations: Implied through the use of lifting equipment and proper torque specifications to prevent component failure.
Cross-referencing: Refers to other sections of the workshop manual (e.g., Section 100-02 for hoist positioning, Section 310-00 for fuel line connections) for additional information.

Maintenance Features (as related to installation):

Component replacement: Specifies when new parts are required, such as new sealing washers for fuel lines and a new oil filter.
Reusability guidelines: Notes that intake manifold gaskets can be reused if not damaged, indicating a cost-saving or environmental consideration.
Lubrication instructions: Recommends applying anti-seize lubricant to specific threads to prevent seizing and facilitate future removal.
Proper torque application: Emphasizes the importance of tightening fasteners to specified torque values, which is crucial for component longevity and preventing leaks or loosening due to vibration. This is a key aspect of proper maintenance during installation to ensure the engine operates reliably.
Sequential tightening: For components like the intake manifold, a specific tightening sequence is provided to ensure even pressure distribution and prevent warping or leaks, contributing to long-term reliability.
Electrical connection integrity: Instructions for connecting various electrical connectors and ensuring proper routing of wiring harnesses are critical for the engine's electronic systems to function correctly and reliably.