# Engine Mechanical

## Engine

### REMOVAL & INSTALLATION

In the process of removing the engine, you will come across a number of steps which call for the removal of a separate component or system, such as "disconnect the exhaust system" or "remove the radiator." In most instances, a detailed removal procedure can be found elsewhere in this manual.

It is virtually impossible to list each individual wire and hose which must be disconnected, simply because so many different model and engine combinations have been manufactured. Careful observation and common sense are the best possible approaches to any repair procedure.

Removal and installation of the engine can be made easier if you follow these basic points:

- If you have to drain any of the fluids, use a suitable container.
- Always tag any wires or hoses and, if possible, the components they came from before disconnecting them.
- Because there are so many bolts and fasteners involved, store and label the retainers from components separately in muffin pans, jars or coffee cans. This will prevent confusion during installation.
- After unbolting the transmission, always make sure it is properly supported.
- If it is necessary to disconnect the air conditioning system, have this service performed by a qualified technician using a recovery/recycling station. If the system does not have to be disconnected, unbolt the compressor and set it aside.
- When unbolting the engine mounts, always make sure the engine is properly supported. When removing the engine, make sure that any lifting devices are properly attached to the engine. It is recommended that if your engine is supplied with lifting hooks, your lifting apparatus be attached to them.
- Lift the engine from its compartment slowly, checking that no hoses, wires or other components are still connected.
- After the engine is clear of the compartment, place it on an engine stand or workbench.
- After the engine has been removed, you can perform a partial or full teardown of the engine using the procedures outlined in this manual.

#### 4.2L Engine

CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. Disconnect the negative battery cable.
2. Mark the position of the hood on the hinges and remove the hood.
3. Drain the engine cooling system into a suitable container.
4. Have the A/C system discharged by an EPA-certified technician.
5. Properly relieve the fuel system pressure.
6. Remove the engine cooling fan, shroud and radiator.
7. Remove the engine air cleaner outlet tube.
8. Disconnect the accelerator and cruise control cables at the throttle body.
9. Disconnect the Vapor Management Valve (VMV) hose.
10. Detach the manifold vacuum connection.
11. Detach the Intake Manifold Runner Control (IMRC) vacuum connectors, fuel pressure regulator vacuum connector, IMRC solenoid vacuum connector and vacuum reservoir connector.
12. Detach the EGR valve vacuum connector.
13. Remove the three power steering reservoir retaining bolts and position aside.
14. If equipped with air conditioning, remove the A/C compressor manifold bolt and disconnect, then position the A/C lines aside.
15. Remove the four power steering pump retaining bolts and position the pump aside.
16. Detach the alternator electrical harness connectors. Remove the positive battery cable nut and disconnect the battery cable.
17. Detach the electrical harness connectors to the fuel injectors.
18. Tag and disconnect the ignition wires at the spark plugs.
19. Disconnect both heater hoses.
20. Disconnect the brake booster vacuum hose.
21. Disconnect the EGR Differential Pressure Feedback (DPFE) transducer hose.
22. Remove the breather tube from the cylinder head cover.
23. Remove the upper intake manifold.
24. Disconnect and plug the fuel supply and return lines and remove the fuel injection supply manifold.
25. Raise and safely support the vehicle.
26. If equipped, disconnect the block heater cable.
27. Disconnect the exhaust system from the exhaust manifolds and support with wire hung from the crossmember.
28. Remove the starter motor.
29. Remove the transmission from the vehicle. If equipped with a manual transmission, remove the clutch assembly.
30. Remove the right-hand and left-hand engine support insulator through-bolts.
31. Lower the vehicle.
32. Install a suitable engine lifting bracket and connect suitable engine lifting equipment to the lifting brackets.
33. Carefully raise the engine out of the engine compartment and position on a work stand. Remove the engine lifting equipment.

To install:

34. Install the engine lifting brackets. Support the engine using a suitable floor crane installed to the lifting equipment and remove the engine from the work stand.
35. Carefully lower the engine into the engine compartment aligning the engine support insulators.
36. Remove the engine lifting equipment and brackets.
37. Raise and safely support the vehicle.
38. Install the left-hand and right-hand engine support insulator through-bolts and tighten them to 51-67 ft. lbs. (68-92 Nm).
39. If equipped with a manual transmission, install the clutch assembly.
40. Install the transmission.
41. The balance of the installation is the reverse of the removal.

#### 4.6L, 5.4L and 6.8L Engines

CAUTION
Fuel injection systems remain under pressure, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury.

1. Disconnect the negative battery cable.
2. Mark the position of the hood on the hinges and remove the hood.
3. Drain the engine cooling system into a suitable container.
4. Have the A/C system discharged by an EPA-certified technician.
5. Properly relieve the fuel system pressure.
6. Remove the engine cooling fan, shroud and radiator.
7. Remove the accessory drive belt.
8. Remove the engine air cleaner outlet tube.
9. Remove the intake manifold assembly.
10. Remove the bulkhead connector cover and detach the bulkhead connector.
11. Remove the three power steering reservoir bracket retaining bolts and move the reservoir aside.
12. Disconnect two DPFE transducer hoses.
13. Disconnect the upper and lower EGR valve to exhaust manifold tube fittings and remove the tube.
14. Slide the heater water hose clamp back and remove the hose.
15. Remove the ignition coil, radio capacitor and Camshaft Position (CMP) sensor electrical harness connectors.
16. Remove both ignition coils and mounting bracket bolts and remove the coil and bracket assemblies.
17. Raise and safely support the vehicle.
18. Remove the starter motor.
19. Remove the three lower radiator air deflector screws. Remove the five clips and remove the air deflector.
20. Detach the A/C compressor electrical harness connector.
21. Remove the A/C manifold-to-compressor bolt and remove the manifold and tube assembly.
22. Remove the three A/C compressor retaining bolts and remove the A/C compressor.
23. Remove the fluid cooler hoses from the block mounted clip.
24. On vehicles with automatic transmissions, remove the inspection cover, torque converter bolts and transmission-to-engine retaining bolts.
25. On vehicles with manual transmission, remove the transmission and the clutch assembly.
26. Remove the upper and lower power steering pump bolts and move the power steering pump aside.
27. Disconnect the exhaust system from the exhaust manifolds and support with wire hung from the crossmember.
28. Remove the right-hand and left-hand engine support insulator (mount) through-bolts.
29. Lower the vehicle.
30. Install a suitable engine lifting bracket and connect suitable engine lifting equipment to the lifting brackets.
31. Carefully raise the engine out of the engine compartment and place on a work stand. Remove the engine lifting equipment.

To install:

32. Install the engine lifting brackets. Support the engine using a suitable floor crane installed to the lifting equipment and remove the engine from the work stand.
33. Carefully lower the engine into the engine compartment. Start the converter pilot into the flywheel and align the paint marks on the flywheel and torque converter. Be sure the studs on the torque converter align with the holes in the flywheel.
34. Fully engage the engine to the transmission and lower onto the engine support insulators.
35. Remove the engine lifting equipment and brackets.
36. Raise and safely support the vehicle.
37. If equipped with a manual transmission, install the clutch and transmission assemblies.
38. Install the six engine-to-transmission retaining bolts and tighten to 30-44 ft. lbs. (40-60 Nm).
39. Install the engine support insulator through-bolts and tighten to 15-22 ft. lbs. (20-30 Nm).
40. Install the four torque converter retaining nuts and tighten to 22-25 ft. lbs. (20-30 Nm).
41. Install the transmission housing cover to the cylinder block.
42. The balance of the installation is the reverse of the removal.

#### 5.8L and 7.5L Engines

1. Remove the hood.
2. Drain the cooling system and crankcase.
3. Disconnect the negative battery cable.
4. Remove the air intake hoses, PCV tube and carbon canister hose.
5. Disconnect the upper and lower radiator hoses.
6. Have the A/C system discharged by an EPA-certified technician.
7. Disconnect the refrigerant lines at the compressor. Cap all openings immediately.
8. If so equipped, disconnect the automatic transmission oil cooler lines.
9. Remove the fan shroud and lay it over the fan.
10. Remove the radiator and fan, shroud, fan, spacer, pulley and belt.
11. Remove the alternator pivot and adjusting bolts. Remove the alternator.
12. Detach the oil pressure sending unit lead from the sending unit.
13. Disconnect the fuel tank-to-pump fuel line at the fuel pump and plug the line.
14. Disconnect the chassis fuel line at the fuel rails.
15. Disconnect the accelerator linkage and speed control linkage at the throttle body.
16. Disconnect the automatic transmission kick-down rod and remove the return spring, if so equipped.
17. Disconnect the power brake booster vacuum hose.
18. Disconnect the throttle bracket from the upper intake manifold and swing it out of the way with the cables still attached.
19. Disconnect the heater hoses from the water pump and intake manifold or tee.
20. Disconnect the temperature sending unit wire from the sending unit.
21. Remove the upper bell housing-to-engine attaching bolts.
22. Remove the wiring harness from the left rocker arm cover and position the wires out of the way.
23. Disconnect the ground strap from the cylinder block.
24. Disconnect the air conditioning compressor clutch wire.
25. Raise and safely support the front of the vehicle and disconnect the starter cable from the starter.
26. Remove the starter.
27. Disconnect the exhaust pipe from the exhaust manifolds.
28. Disconnect the engine mounts from the brackets on the frame.
29. On vehicles with automatic transmissions, remove the converter inspection plate and remove the torque converter-to-flywheel attaching bolts.
30. Remove the remaining bell housing-to-engine attaching bolts.
31. Lower the vehicle and support the transmission with a jack.
32. Install an engine lifting device.
33. Raise the engine slightly and carefully pull it out of the transmission. Lift the engine out of the engine compartment.

To install:

34. Remove the engine mount brackets from the frame and attach them to the engine mounts. Tighten the mount-to-bracket nuts just enough to hold them securely.
35. Lower the engine carefully into the transmission. Be sure that the dowel in the engine block engage the holes in the bell housing through the rear cover plate. If the engine hangs up after the transmission input shaft enters the clutch disc (manual transmission only), turn the crankshaft with the transmission in gear until the input shaft splines mesh with the clutch disc splines.
36. Install the engine mount nuts and washers. Tighten the nuts to 80 ft. lbs. Tighten the bracket-to-frame bolts to 70 ft. lbs. (95 Nm).
37. Remove the engine lifting device.
38. Install the lower bell housing-to-engine attaching bolts. Tighten the bolts to 50 ft. lbs. (68 Nm).
39. Remove the transmission support jack.
40. On vehicles with automatic transmissions, install the torque converter-to-flywheel attaching bolts. Tighten the bolts to 30 ft. lbs. (41 Nm).
41. Install the converter inspection plate. Tighten the bolts to 60 inch lbs. (7 Nm).
42. The balance of the installation is the reverse of the removal.

#### 7.3L Diesel Engine

1. Disconnect the negative battery cable(s).
2. Remove the hood.
3. Drain and recycle the engine coolant.
4. Properly relieve the fuel system pressure.
5. If equipped with air conditioning, have the A/C system discharged by an EPA-certified technician.
6. On automatic transmission equipped vehicles, remove the turbocharger. Refer to the procedure in this section.
7. Remove the air cleaner and intake duct assembly and cover the air intake opening with a clean rag to keep out the dirt.
8. Remove the engine fan and the fan shroud.
9. Remove the radiator.
10. Remove the alternator.
11. Detach the A/C compressor electrical connector.
12. Disconnect the lines from the A/C compressor.
13. Disconnect the vacuum pump hose from the vacuum pump.
14. Disconnect the power steering pump lines from the power steering pump.
15. Disconnect the A/C lines at the condenser and position the lines aside.
16. Disconnect the heater hoses at the water pump and the right cylinder head.
17. Disconnect the radiator hose from the water pump.
18. Detach the MAP sensor vacuum hose from the engine.
19. Detach the driver's side engine compartment components and lay the wiring harness to the side.
20. Remove the jack handle.
21. Remove the engine charge exhaust pipe-to-turbocharger clamp.
22. Disconnect the wiring harness from the starter relay.
23. Raise and support the vehicle.
24. On manual transmission equipped vehicles, remove the transmission.
25. Remove the right and left turbocharger inlet pipe bolts and nuts.
26. Disconnect the engine block heater.
27. Remove the starter.
28. Remove the oil filter.
29. Remove the right and left side engine mount nuts.
30. On automatic transmission equipped vehicles:
    1. Remove the transmission housing cover.
    2. Remove the four converter-to-flywheel attaching nuts.
    3. Remove the four lower transmission attaching bolts.
31. Lower the vehicle.
32. On automatic transmission equipped vehicles:
    1. Remove the ground strap bolt at the rear of the engine.
    2. Remove the two upper transmission retaining bolts.
33. Support the transmission using a suitable jack.
34. Remove the front lamp harness plastic fasteners and lay the harness aside.
35. Make sure no other component interferes with the engine removal.
36. Attach an engine lifting device and remove the engine from the truck.

To install:

37. Lower the engine into vehicle.
38. Align the converter to the flexplate and the engine dowels to the transmission.
39. Install the engine mount bolts and tighten them to 71-94 ft. lbs. (96-127 Nm).
40. Remove the engine lifting sling.
41. Install the four lower transmission attaching bolts. Tighten the bolts to 65 ft. lbs. (88 Nm).
42. Remove transmission jack.
43. Raise and support the front end.
44. If equipped with an automatic transmission, install the four converter-to-flywheel attaching nuts. Tighten the nuts to 89 ft. lbs. (121 Nm).
45. Install the flywheel inspection plate. Tighten the bolts to 13-17 ft. lbs. (17-23 Nm).
46. The balance of the installation is the reverse of the removal.

## Rocker Arm (Valve) Cover

### REMOVAL & INSTALLATION

#### 4.2L Engine

The valve cover mounting—4.2L engine

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##### DRIVER'S SIDE VALVE COVER

1. Disconnect the negative battery cable.
2. Remove the positive crankcase ventilation valve.
3. Loosen the valve cover retaining bolts and studs.
4. Remove the valve cover.
5. Remove and discard the valve cover gasket.

To install:

6. Install the valve cover onto the cylinder head.
7. Tighten the two bolts and the three stud bolts retaining the valve cover to 6-8 ft. lbs. (8-11 Nm).
8. Install the positive crankcase ventilation valve.
9. Connect the negative battery cable.
10. Check the oil level and add as necessary.

##### PASSENGER SIDE VALVE COVER

1. Disconnect the negative battery cable.
2. Remove the bolts and position the EGR bracket aside.
3. Remove the crankcase ventilation hose.
4. Loosen the valve cover retaining bolts and studs.
5. Remove the valve cover.
6. Remove and discard the valve cover gasket.

To install:

7. Install a new valve cover gasket.
8. Install the valve cover onto the cylinder head.
9. Tighten the two bolts and the three stud bolts retaining the valve cover to 6-8 ft. lbs. (8-11 Nm).
10. Install the crankcase ventilation hose.
11. Install the EGR bracket.
12. Connect the negative battery cable.
13. Check the oil level and add as necessary.

#### 4.6L, 5.4L and 6.8L Engines

##### DRIVER'S SIDE VALVE COVER

Remove the power steering reservoir retaining bolts and ...

... position the reservoir out of the way

Remove the EGR valve-to-exhaust manifold tube

Loosen the valve cover retaining studs and remove the valve cover from the engine

Driver's side valve cover tightening sequence—4.6L Romeo engine

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Driver's side valve cover tightening sequence—4.6L Windsor engine

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Driver's side valve cover tightening sequence—5.4L engine

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Driver's side valve cover tightening sequence—6.8L engine

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1. Disconnect the negative battery cable.
2. Remove the engine air cleaner and the air cleaner outlet tube.
3. On the 5.4L DOHC engine, remove the upper intake manifold. Refer to the procedure outlined in this section.
4. Remove the bolts and position the power steering fluid reservoir and bracket aside.
5. Remove the crankcase ventilation tube from the valve cover.
6. Disconnect the EGR valve-to-exhaust manifold tube fittings and the two DPFE hoses and remove the EGR valve-to-exhaust manifold tube.
7. Detach the fuel injector electrical connections on the driver's side.
8. On 5.4L and 6.8L engines, detach the ignition coil electrical connections on the driver's side.
9. Detach the camshaft position (CMP) sensor connector.
10. Remove the engine sensor control wiring harness from the valve cover studs.

The bolts are part of the valve cover and should not be removed.

11. Loosen the valve cover retaining bolts and remove the valve cover.
12. Inspect the valve cover gasket and clean the mating surface of the cylinder head.

The valve cover gasket can be reused, however if the gasket appears to be cracked, dry-rotted, or signs of leakage appeared before the tear-down, replace the gasket.

To install:

If not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-M5B392-RA. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

13. Apply a bead of silicone in two places where the engine front cover meets the cylinder head. Use Silicone Gasket and Sealer F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.
14. Position the valve cover and the valve cover gasket on the cylinder head, and loosely install the bolts.
15. Tighten the valve cover retaining bolts in sequence, referring to the graphics in this section, to 71-106 inch lbs. (8-12 Nm).
16. Position the engine sensor control wiring harness onto the valve cover studs.
17. Attach the CMP electrical connector.
18. On 5.4L and 6.8L engines, attach the ignition coil electrical connectors.
19. Connect the fuel injector electrical connectors.
20. On the 5.4L DOHC engine, install the upper intake manifold.
21. Connect the EGR valve to exhaust manifold tube upper fitting.
22. Connect the crankcase ventilation tube to the valve cover.
23. Install the power steering fluid reservoir and bracket.
24. Install the engine air cleaner and air cleaner outlet tube.
25. Connect the negative battery cable.
26. Check the oil level and add as necessary.

##### PASSENGER SIDE VALVE COVER

Passenger side valve cover tightening sequence—4.6L Romeo engine

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Passenger side valve cover tightening sequence—4.6L Windsor engine

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Passenger side valve cover tightening sequence—5.4L engine

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Passenger side valve cover tightening sequence—6.8L engine

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1. Disconnect the negative battery cable.
2. Remove the engine air cleaner.
3. On the 5.4L DOHC engine, remove the upper intake manifold. Refer to the procedure outlined in this section.
4. Remove the bolts and remove the accelerator control splash shield.
5. Disconnect the crankcase ventilation hose from the valve cover.
6. Disconnect the two fuse block cable ends from the starter relay.
7. Detach the two 42-pin bulkhead electrical connections and remove them from the junction block bracket.
8. Detach the 16-pin electrical connection and the single pin electrical connection.
9. Remove the bolts and the junction block bracket.
10. Disconnect the heater water hose.
11. Disconnect the heater water hose.
12. Disconnect the heater water hose from the heater core and remove the heater water hose.
13. Detach the fuel injector electrical connections on the passenger side.
14. On 5.4L and 6.8L engines, detach the ignition coil electrical connections on the passenger side.
15. Detach the climate control vacuum connection.
16. Raise and support the vehicle.
17. Detach the A/C compressor electrical connection.
18. Detach the crankshaft position (CKP) sensor electrical connection.
19. Position the wiring harness aside.
20. Lower the vehicle.

The bolts are part of the valve cover and should not be removed.

21. Loosen the valve cover retaining bolts and remove the valve cover.
22. Inspect the valve cover gasket and clean the mating surface of the cylinder head.

CAUTION
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make cause leak paths to develop. Use a plastic scraping tool to remove all traces of old sealant.

The valve cover gasket can be reused, however if the gasket appears to be cracked, dry-rotted, or signs of leakage appeared before the tear-down, replace the gasket.

To install:

If not secured within four minutes, the sealant must be removed and the sealing area cleaned with Metal Surface Cleaner F4AZ-19A536-A or equivalent meeting Ford specification WSE-M5B392-RA. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.

23. Apply a bead of silicone in two places where the engine front cover meets the cylinder head. Use Silicone Gasket and Sealer F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.
24. Position the valve cover and the valve cover gasket on the cylinder head, and loosely install the bolts.
25. Tighten the valve cover retaining bolts in sequence, referring to the graphics in this section, to 71-106 inch lbs. (8-12 Nm).
26. Connect the heater water hose to the heater core.
27. Connect the heater water hose and position the clamp.
28. Connect the heater water hose and position the clamp.
29. Install the junction block bracket and the bolts.
30. Attach the 16-pin electrical connection and the single pin electrical connection.
31. Attach the two 42-pin bulkhead electrical connections.
32. Connect the two fuse cable leads to the starter relay.
33. Raise and support the vehicle.
34. Attach the crankshaft position sensor electrical connection.
35. Connect the A/C compressor electrical connection.
36. Lower the vehicle.
37. On the 5.4L DOHC engine, install the upper intake manifold.
38. Install the positive crankcase ventilation valve and crankcase ventilation hose into the valve cover.
39. Install the accelerator control splash shield.
40. Install the engine air cleaner.
41. Connect the negative battery cable.
42. Check the oil level and add as necessary.

#### 5.8L Engine

Valve cover tightening sequence—5.8L engine

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1. Disconnect the negative battery cable.
2. Remove the air cleaner and inlet duct.
3. Remove the coil.
4. For the right cover, remove the lifting eye; for the left cover, remove the oil filler pipe attaching bolt and the lifting eye.
5. Mark and remove the spark plug wires.
6. Remove any vacuum lines, wires or pipes in the way. Make sure that you tag them for identification.
7. Remove the cover bolts and lift off the cover. It may be necessary to break the cover loose by rapping on it with a rubber mallet. NEVER pry the cover off!

To install:

8. Thoroughly clean the mating surfaces of both the cover and head.
9. Place the new gasket(s) in the cover(s) with the locating tabs engaging the slots.
10. Place the cover on the head making sure the gasket is evenly seated. Tighten the bolts in sequence to 12-15 ft. lbs. (16-20 Nm). After 2 minutes, retighten the bolts to the same specifications.
11. Install the vacuum lines, wires and pipes.
12. Install the spark plug wires.
13. For the right cover, install the lifting eye; for the left cover, install the oil filler pipe attaching bolt.
14. Install the coil.
15. Install the air cleaner and inlet duct.
16. Connect the negative battery cable.
17. Check the oil level and add as necessary.

#### 7.5L Engine

1. Disconnect the negative battery cable(s).
2. Remove the air cleaner and inlet duct.
3. Remove the coil.
4. Mark and remove the spark plug wires.
5. Remove any vacuum lines, wires or pipes in the way. Make sure that you tag them for identification.
6. Remove the cover bolts and lift off the cover. It may be necessary to break the cover loose by rapping on it with a rubber mallet. NEVER pry the cover off!

To install:

7. Thoroughly clean the mating surfaces of both the cover and head.
8. Place the new cover seal(s) in the cover(s) with the locating tab engaging the slot.
9. Place the cover on the head. Tighten the bolts to 6-9 ft. lbs. (8-12 Nm) from right to left.
10. Install the vacuum lines, wires and pipes.
11. Install the spark plug wires.
12. Install the coil.
13. Install the air cleaner and inlet duct.
14. Connect the negative battery cable(s).
15. Check the oil level and add as necessary.

#### 7.3L Diesel Engine

##### PASSENGER SIDE VALVE COVER

1. Disconnect the negative battery cables.
2. Remove the alternator bolt and move the heater hose out of the way.
3. Remove the drive belt.
4. Remove the alternator.
5. Remove the oil level indicator bracket and dipstick.
6. Remove the fuel injector harness clip and disengage the engine harness connectors from the valve covers.
7. Remove the valve cover bolts and lift off the covers. It may be necessary to break the covers loose by rapping on them with a rubber mallet. NEVER pry a cover off!
8. Disconnect the fuel injectors and glow plugs.
9. Remove the valve cover gasket.

To install:

10. Clean the mating surfaces of the cover and head thoroughly. Install a new gasket.
11. Connect the fuel injectors and glow plugs.
12. Install the valve cover. Tighten the bolts to 8 ft. lbs. (11 Nm).
13. Install the oil tube and dipstick.
14. Install the alternator.
15. Install the drive belt.
16. Position the heater hose as specified and install the alternator bolt. Tighten the bolt to 30-40 ft. lbs. (40-54 Nm).
17. Connect both negative battery cables.
18. Check the oil level and add as necessary.

##### DRIVER'S SIDE VALVE COVER

1. Disconnect both negative battery cables.
2. Remove the air inlet duct assembly between the turbocharger and air cleaner.
3. Remove the crankcase breather assembly.
4. Remove the intake duct and retaining nuts.
5. Remove the vacuum pump hose at the pump.
6. Remove the cover bolts and lift off the covers. It may be necessary to break the covers loose by rapping on them with a rubber mallet. NEVER pry a cover off!
7. Disconnect the fuel injectors and glow plugs.
8. Remove the valve cover gasket.

To install:

9. Clean the mating surfaces of the cover and head thoroughly. Install a new gasket.
10. Connect the fuel injectors and glow plugs.
11. Install the valve cover. Tighten the bolts to 8 ft. lbs. (11 Nm).
12. Connect the vacuum pump hose to the pump.
13. Install the intake duct bracket.
14. Install the crankcase breather assembly.
15. Install the intake duct tube assembly.
16. Connect both negative battery cables.
17. Check the oil level and add as necessary.

## Rocker Arm/Shafts

### REMOVAL & INSTALLATION

#### 4.2L Engine

If removing more than one rocker arm, mark the components for proper location.

1. Disconnect the negative battery cable.
2. Remove the lower intake manifold.
3. Remove the rocker arm cover.
4. Remove the rocker arm hold-down bolt, then remove the rocker arm from the cylinder head.

To install:

5. Position the rocker arms in place, then install the hold-down bolts. Tighten the bolts to 23-29 ft. lbs. (30-40 Nm).
6. Install the rocker arm cover and the lower intake manifold.
7. Connect the negative battery cable.

#### 4.6L and 5.4L Engines

1. Disconnect the negative battery cable.
2. Remove the camshaft covers.
3. Position the cylinder being serviced at the bottom of it's travel.

Two different valve spring compressor tools are used for this procedure. Valve Spring Compressor (T91P-6565-A) is used on the exhaust camshaft and Valve Spring Compressor (T93P-6565-A) is used on the intake camshaft.

4. Compress the valve spring using the appropriate spring compressor and remove the rocker arm.

To install:

5. Position the cylinder being serviced at the bottom of it's travel.
6. Apply clean engine oil to the rocker arm, valve stem tip and tappet bore.

Valve tappet should have no more than 1/16 inch (1.5mm) of travel before installing the rocker arm.

7. Compress the valve spring using the correct tool and install the rocker arm.
8. Install the valve covers.
9. Connect the negative battery cable.

Using the proper tool, compress the valve spring and remove the rocker arm—4.6L and 5.4L engine

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#### 5.8L Engine

5.8L engine rocker arm assembly

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1. Remove the upper intake manifold. Refer to the procedure in this section.
2. Remove the rocker arm covers.
3. Loosen the rocker arm fulcrum bolts, fulcrum seats and rocker arms; keep all parts in order for installation.

To install:

4. Apply multipurpose grease to the valve stem tips, the fulcrum seats and sockets.
5. Install the fulcrum guides, rocker arms, seats and bolts. Tighten the bolts to 18-25 ft. lbs. (25-34 Nm).
6. Install the rocker arm covers.
7. Install the intake manifold. Refer to the procedure in this section.

#### 6.8L Engine

1. Disconnect the negative battery cable.
2. Remove the valve covers.
3. Position the base circle of the camshaft lobe on the rocker arm to be serviced. Also, be sure the piston is not at the top of it's travel near the valve.
4. Compress the valve spring using Valve Spring Compressor 303-381(TJ91P-6565-A) and remove the rocker arm.

To install:

5. Position the base circle of the camshaft lobe over the place where the rocker arm is to be installed.
6. Apply clean engine oil to the rocker arm, valve stem tip and tappet bore.
7. Compress the valve using the special tool and install the rocker arm.
8. Install the valve covers.
9. Connect the negative battery cable.

Compress the valve spring and remove the rocker arm—6.8L engine

Click to enlarge

#### 7.5L Engine

7.5L engine rocker arm assembly

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1. Remove the intake manifold.
2. Remove the rocker arm covers.
3. Loosen the rocker arm fulcrum bolts, fulcrum, oil deflector, seat and rocker arms; keep everything in order for installation.

To install:

4. Coat each end of each pushrod with multipurpose grease.
5. Coat the top of the valve stems, the rocker arms and the fulcrum seats with multipurpose grease.
6. Rotate the crankshaft by hand until No. 1 piston is at TDC of compression. The firing order marks on the damper will be aligned at TDC with the timing pointer.
7. Install the rocker arms, seats, deflectors and bolts on the following valves:

- No. 1 intake and exhaust
- No. 3 intake
- No. 8 exhaust
- No. 7 intake
- No. 5 exhaust
- No. 8 intake
- No. 4 exhaust

8. Engage the rocker arms with the pushrods and tighten the rocker arm fulcrum bolts to 18-25 ft. lbs. (25-34 Nm).
9. Rotate the crankshaft one full turn—360 degrees—and realign the TDC mark and pointer. Install the parts and tighten the bolts on the following valves:

- No. 2 intake and exhaust
- No. 4 intake
- No. 3 exhaust
- No. 5 intake
- No. 6 intake and exhaust
- No. 7 exhaust

10. Install the rocker arm covers.
11. Install the intake manifold.
12. Check the valve clearance as outlined in Section 1.

#### 7.3L Diesel Engine

Exploded view of the rocker arm assembly—7.3L diesel engine

Click to enlarge

1. Disconnect the ground cables from both batteries.
2. Remove the valve covers.
3. Remove the valve rocker arm mounting bolts.
4. Remove the rocker arms assembly in order and mark them with tape so they can be installed in their original positions.
5. Remove the pushrods. Make a holder for the pushrods out of a piece of wood or cardboard and remove the pushrods in order. It is very important that the pushrods be reinstalled in their original order. The pushrods can remain in position if no further disassembly is required.

WARNING
Be careful when removing the rocker arm retaining clip. Do not lose the steel ball.

6. Remove the rocker arm retaining clip.
7. Remove the rocker arm and steel ball from the rocker arm pedestal.

To install:

8. Assemble the rocker arms as follows:
   1. Place the steel ball in the rocker arm cup and lubricate with clean engine oil.
   2. Place the rocker arm pedestal on the steel ball.
   3. Snap the retaining clip over the pedestal groove.
9. If the pushrods were removed, install them in their original locations. be sure they are fully seated in the tappet seats.

The copper colored end of the pushrod goes toward the rocker arm.

10. Apply a polyethylene grease to the valve stem tips. Install the rocker arms and posts in their original positions.
11. Turn the engine over by hand until the valve timing mark is at the 11:00 o'clock position, as viewed from the front of the engine. Install all of the rocker arm post attaching bolts and tighten to 20 ft. lbs. (27 Nm).
12. Install new valve cover gaskets and install the valve cover.
13. Install the battery cables.
14. Start the engine and check for leaks.

## Thermostat

### REMOVAL & INSTALLATION

#### 4.2L Engine

Thermostat mounting—4.2L engine

Click to enlarge

1. Disconnect the negative battery cable.
2. Allow the engine to cool, then drain the engine cooling system to a level below the water outlet housing.
3. Remove 2 water outlet housing retaining bolts and slide the housing with the hose attached to one side.
4. Remove the thermostat and gasket.

To install:

5. Clean the gasket sealing surfaces.
6. Install the thermostat with the bridge (opposite end of the spring) inside the elbow connection. Ensure that the notch is properly positioned.
7. Coat a new housing gasket with water resistant sealer and position it on the water outlet connection. Ensure that the notch is properly positioned.
8. Place the water outlet connection on the lower intake manifold and install 2 retaining bolts. Tighten the bolts to 103 inch lbs. (12 Nm).
9. Fill the engine cooling system.
10. Connect the negative battery cable.
11. Start the engine and allow it to reach normal operating temperature while checking for coolant leaks.
12. Road test the vehicle and check for proper engine operation.
13. Check the coolant level and adjust if necessary.

#### 4.6L, 5.4L And 6.8L Engines

Remove the power steering reservoir retaining bolts and ...

... remove the bracket from the engine

Remove the thermostat housing bolts and ...

... remove the housing from the intake manifold

The thermostat sits in the intake manifold, grasp the top of the thermostat and ...

... remove the thermostat from the intake manifold

thoroughly clean the thermostat mounting surface before installing a new thermostat

Always replace the thermostat O-ring with a new one

Make sure that the air valve is positioned in the 3 O'clock position after the thermostat is installed

1. Disconnect the negative battery cable.
2. Drain and recycle the engine coolant.
3. Remove the power steering reservoir support bracket.
4. Remove the upper radiator hose at the thermostat housing.
5. Remove 2 thermostat housing retaining bolts and remove the housing.
6. Remove the thermostat and O-ring from the lower intake manifold. Discard the O-ring.

To install:

7. Clean the O-ring sealing surfaces.
8. Install a new O-ring, on the thermostat and position the thermostat in the lower intake manifold.
9. Place the thermostat housing on the lower intake manifold and install 2 retaining bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
10. Install the power steering reservoir support bracket.
11. Fill the engine cooling system.
12. Connect the negative battery cable.
13. Start the engine and allow it to reach normal operating temperature while checking for coolant leaks.
14. Road test the vehicle and check for proper engine operation.
15. Check the coolant level and add if necessary.

#### 5.8L And 7.5L Engines

Thermostat installation for the 5.8L and 7.5L engines

Click to enlarge

1. Disconnect the negative battery cable.
2. Drain the engine cooling system below the level of the thermostat housing.
3. Disconnect the bypass hose at the thermostat housing and the intake manifold. Remove the bypass hose.
4. Remove the upper radiator hose at the thermostat housing.
5. Remove 2 thermostat housing retaining bolts.
6. Remove the thermostat housing from the intake manifold.
7. Remove the thermostat and gasket.
8. Clean the thermostat housing and intake manifold gasket sealing surfaces.

To install:

9. Coat a new thermostat housing gasket with a suitable sealing compound and place the gasket on the intake manifold. The gasket must be in place before the thermostat is installed.
10. Install the thermostat to the intake manifold opening with the copper pellet or opening towards the engine and the thermostat flange positioned in the recess.
11. Place the thermostat housing in position and install 2 retaining bolts. Tighten the bolts to 12-18 ft. lbs. (16-24 Nm) on the 5.8L engine, and 22-38 ft. lbs. (32-37 Nm) for the 7.5L engine.
12. Install the bypass and upper radiator hoses.
13. Connect the negative battery cable.
14. Fill and bleed the engine cooling system.
15. Start the engine and allow to reach normal operating temperature while checking for leaks.
16. Road test the vehicle and check for proper engine operation.
17. Check the coolant level and add if needed.

#### 7.3L Diesel Engine

Thermostat mounting—7.3L diesel engine

Click to enlarge

CAUTION
The factory specified thermostat does not contain an internal bypass. On these engines, an internal bypass is located in the block. The use of any replacement thermostat other than that meeting the manufacturer's specifications will result in engine overheating. Use only thermostats meeting the specifications of Ford or Navistar International.

1. Disconnect both battery ground cables.
2. Drain the coolant to a point below the thermostat housing.
3. Remove the upper radiator hose from the thermostat housing.
4. Remove the thermostat housing attaching bolts.
5. Remove the thermostat and gasket.
6. Clean the thermostat housing and block surfaces thoroughly.

To install:

7. Coat a new gasket with sealer and position the gasket on the manifold outlet opening.
8. Install the thermostat in the manifold opening with the spring downward and the flange positioned in the recess in the manifold.
9. Place the outlet housing into position and install the bolts. Torque the bolts to 15 ft. lbs. (20 Nm).
10. Install the upper radiator hose onto the thermostat housing and tighten the hose clamp.
11. Fill and bleed the cooling system.
12. Connect both battery cables.
13. Run the engine and check for leaks.

## Intake Manifold

### REMOVAL & INSTALLATION

When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy.

#### 4.2L Engine

1. Remove the engine air cleaner outlet tube.
2. Detach the following ignition coil electrical connections:
   1. Ignition coil electrical connector.
   2. Radio ignition interference capacitor electrical connector.
3. Label, then detach the six spark plug wires.
4. Remove the accelerator control splash shield.
5. Disconnect the accelerator cable end, if equipped, the speed control actuator cable end.
6. Remove the accelerator cable and actuator cable aside, after removing the hold-down bolts.
7. Disconnect the Vapor Management Valve (VMV) hose.
8. Disconnect the brake booster vacuum hose.
9. Disengage the manifold vacuum connection.
10. Remove the PCV valve from the rocker arm cover.
11. Position the Engine Vacuum Regulator (EVR) bracket aside.
12. Detach the throttle position sensor and idle air control valve electrical connectors.
13. Remove the breather from the rocker arm cover.
14. Remove the 12 upper intake manifold retaining bolts, then lift the manifold off of the engine. Discard the intake manifold upper gasket.
15. Detach the six fuel injector electrical connectors.
16. Detach the engine coolant temperature sensor and the water temperature indicator sending unit electrical connectors.
17. Disconnect the EGR valve vacuum hose.
18. Remove the EGR valve tube upper fitting.
19. Remove the radiator hose from the lower intake manifold.
20. Position the Intake Manifold Runner Control (IMRC) actuator brackets aside.
21. Disconnect the fuel pressure regulator vacuum line.
22. Disconnect the fuel lines.
23. Disconnect the water pump bypass hose.

Remove the lower intake manifold with the fuel injection supply manifold and fuel injectors as one unit.

24. Remove the six long bolts and the eight short bolts, then lift the lower intake manifold off of the engine.
25. Remove and discard the lower intake manifold sealing components.

To install:

26. Clean all components of dirt, grease and old gasket material.
27. Install the lower intake manifold front and rear end seals as follows:
    1. Apply a bead of sealant (Silicone Gasket and Sealant F6AZ-19562-A or equivalent) to the intake manifold front and rear end seal mounting points.
    2. Install the lower intake manifold front and rear end seals.
28. Install new lower intake manifold gaskets onto the cylinder heads.

The lower intake manifold must be installed within 15 minutes of applying sealant.

Make certain to install the long bolts (A) and the short bolts (B) in the correct lower intake manifold holes—4.2L engine

Click to enlarge

Tighten the lower manifold bolts in the sequence shown—4.2L engine

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Tighten the upper intake manifold mounting bolts in the sequence shown—4.2L engine

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29. Apply a bead of the same sealant to the end of the lower intake manifold end seals, where they stop on the cylinder head surface. Position the intake manifold onto the engine block and cylinder heads.
30. Install the lower intake manifold mounting bolts in the correct positions. Refer to the illustration for the correct placement of the long (A) and the short (B) mounting bolts.

Be sure to tighten the intake manifold bolts in two steps.

31. Tighten the lower intake manifold mounting bolts in the sequence shown, first to 44 inch lbs. (5 Nm), then to 71-101 inch lbs. (8-12 Nm).
32. Connect the water bypass hose.
33. Attach the fuel lines.
34. Connect the fuel pressure regulator vacuum line.
35. Install the IMRC actuators. Tighten the bolts on the brackets to 71-102 inch lbs. (8-12 Nm).
36. Install the upper radiator hose to the lower intake manifold.
37. Connect the EGR valve vacuum hose.
38. Install the EGR tube upper fitting to 25-34 ft. lbs. (37-47 Nm).
39. Attach the engine coolant temperature sensor and water temperature indicator sending unit electrical connectors.
40. Install the six fuel injector electrical connectors.
41. Install a new intake manifold upper gasket.

Be sure to tighten the upper intake manifold bolts in the sequence shown.

42. Position the upper intake manifold onto the lower intake manifold, then tighten the upper intake manifold bolts in the sequence shown to 59 inch lbs. (6 Nm). Tighten the upper intake manifold bolts to 6-8 ft. lbs. (8-12 Nm) in the sequence shown.
43. Install the breather into the rocker arm cover.
44. Attach the throttle position sensor and idle air control valve electrical connectors.
45. Install the Engine Vacuum Regulator (EVR) bracket.
46. Attach the manifold vacuum connection.
47. Install the PCV valve.
48. Connect the brake booster vacuum hose.
49. Connect the Vapor Management Valve (VMV) hose.
50. Install the accelerator and speed actuator cables.
51. Install the accelerator control splash shield.
52. Install the spark plug wires.
53. Attach the ignition coil and the radio ignition interference capacitor electrical connectors.
54. Install the engine air cleaner outlet tube.

#### 4.6L, 5.4L and 6.8L Engines, Except 5.4L Lightning and 5.4L DOHC

Remove the accelerator cable bracket retaining bolt and remove the bracket

Disconnect the PCV hose from the nipple on the back of the intake manifold

Disconnect the fuel feed and return line quick connect fittings

Disconnect the heater hose to facilitate intake manifold removal

After the bolts are removed and all necessary components are disconnected, lift the intake manifold from the engine

Remove the throttle body adapter retaining bolts and ...

... remove the assembly from the intake manifold

Remove the eight upper manifold-to-lower manifold retaining bolts and ...

... separate the upper intake manifold from the lower manifold

Remove the intake manifold gaskets from the cylinder head

Thoroughly clean the mating surfaces of the cylinder head and the intake manifold

Install new gaskets on the cylinder heads aligning the retaining nipple with the holes in the cylinder head

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure.
3. Drain the cooling system.
4. Disconnect the upper radiator hose from the intake manifold.
5. Remove the engine air cleaner outlet tube.
6. Disconnect the accelerator cable from the bracket and the throttle body cam.
7. If equipped, remove the speed control actuator cable from the throttle body.
8. Disconnect all vacuum hoses, fuel lines and electrical wires from the throttle body and intake manifold.
9. Remove the brake booster vacuum hose bracket.
10. Remove the EGR valve-to-exhaust manifold tube.
11. Detach the fuel injector electrical connectors.
12. On the 6.8L engine, remove the radio interference capacitors from the left side of the intake manifold.
13. Label, then remove the spark plug wires, if necessary.
14. Remove the accessory drive belt.
15. Remove the alternator.
16. Remove the power steering oil reservoir bracket and set aside.
17. Disconnect the heater water hose from the intake manifold.
18. Remove the intake manifold bolts.
19. Lift the intake manifold off of the engine, then detach the Intake Manifold Tuning Valve (IMTV) electrical connector. Remove and discard the upper intake manifold gaskets.
20. Remove the upper-to-lower intake manifold bolts, then separate the upper intake manifold from the lower intake manifold. Discard the old gasket.

To install:

21. Position the lower intake manifold gasket and the upper intake manifold onto the lower intake manifold, then loosely install the upper-to-lower intake manifold bolts.

Be sure to tighten the lower-to-upper manifold bolts in two steps.

22. Tighten the eight lower-to-upper intake manifold bolts in two steps following the tightening sequence shown. The first step should be to 18 inch lbs. (2 Nm) and the second step to 6-8 ft. lbs. (8-12 Nm).

Tighten the lower-to-upper intake manifold bolts in two steps following the sequence shown—4.6L engine

Click to enlarge

Tighten the upper intake manifold-to-cylinder head mounting bolts in the sequence shown—4.6L engine

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Tighten the lower-to-upper intake manifold bolts in two steps following the sequence shown—5.4L engine

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Tighten the upper intake manifold-to-cylinder head mounting bolts in the sequence shown—5.4L engine

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Tighten the upper-to-lower intake manifold bolts in the sequence shown—6.8L engine

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Tighten the upper intake manifold-to-cylinder head bolts using the sequence shown—6.8L engine

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23. Position the two upper intake manifold gaskets on the cylinder heads. Set the upper intake manifold in place on the engine, then loosely install the nine intake manifold-to-cylinder head bolts.
24. Attach the IMTV electrical connector.

Check that the thermostat housing is in the correct position before the thermostat housing is installed.

25. Install the thermostat housing and start the two housing bolts.

Make certain to tighten the intake manifold in two steps.

26. Tighten the thermostat housing bolts in the sequence shown, first to 18 inch lbs. (2 Nm), then to 15-22 ft. lbs. (20-30 Nm).
27. Install the heater water hose.
28. Position the power steering bracket and install the power steering pump bracket bolts to 71-107 inch lbs. (8-12 Nm).
29. Attach all electrical connections, fuel lines, vacuum tubes and coolant hoses to the intake manifold, fuel injectors and throttle body assembly.
30. Install the alternator and the accessory drive belt.
31. Install the spark plug wires.
32. Install the EGR valve-to-exhaust manifold tube. The tube fittings should be tightened to 26-33 ft. lbs. (35-45 Nm).
33. Install the speed actuator cable, if equipped, and the accelerator cable to the throttle body.
34. Install the engine air cleaner outlet tube.
35. Install the heater water hose.
36. Fill the cooling system with the correct amount and type of coolant.
37. Connect the negative battery cable.
38. Start the engine and check for fuel, vacuum or coolant leaks.

#### 5.4L DOHC Engine

##### UPPER INTAKE MANIFOLD

Remove the three bolts and the engine appearance cover

Click to enlarge

Remove the balance tube from the engine and ...

Click to enlarge

... discard and replace the balance tube gaskets

Click to enlarge

Remove the upper intake manifold retaining bolts and remove the manifold from the engine

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Upper intake manifold tightening sequence—5.4L DOHC engine

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Relieve the fuel system pressure before starting any work that involves disconnecting the fuel lines. Refer to Fuel System .

1. Remove the air cleaner outlet tube.
2. Remove the three bolts and the engine appearance cover.
3. Disconnect the accelerator cable, speed control cable, and the return spring.
4. Remove the bolts and position the cables and bracket out of the way.
5. Disconnect the evaporative emission return line.
6. Disconnect the positive crankcase ventilation tube from the upper intake manifold.
7. Remove the PCV valve from the valve cover.
8. Disconnect the PCV valve tube from the water heated fitting and remove the tube assembly.
9. Disconnect the coolant lines and plug the lines.
10. Detach the electrical connector from the communication valve.
11. Remove the bolts and the communication valve.
12. Remove the wiring harness shield bolts and five clips and remove the shield.
13. Remove the balance tube from the engine.
14. Detach the throttle position (TP) sensor and the idle air control (IAC) motor.
15. Disconnect the vacuum lines and detach the electrical connector from the EGR vacuum regulator (EVR).
16. Detach the two hoses and detach the electrical connector from the differential pressure feedback EGR.
17. Remove the bolts from the power steering reservoir bracket and position it aside.
18. Remove the stud and position the oil fill tube aside.
19. Disconnect the brake booster vacuum line.
20. Disconnect the vacuum line from the exhaust gas recirculation (EGR) valve.
21. Remove the bolts from the EGR adapter.
22. Remove the retaining bolts and remove the upper intake manifold.

To install:

23. Clean and inspect the sealing surfaces.
24. Install the upper intake manifold:
25. Install the bolts.
26. Tighten the bolts to 89 inch lbs. (10 Nm) and then an additional 90 degrees in the sequence shown.
27. Install the EGR adapter with a new gasket.
28. Connect the vacuum line to the EGR valve.
29. Connect the brake booster vacuum line.
30. Position the oil fill tube and install the stud.
31. Position the power steering reservoir bracket and install the bolts.
32. Tighten the EGR valve at the exhaust manifold.
33. Attach the two hoses and the electrical connector to the differential pressure feedback EGR.
34. Attach the vacuum lines and the electrical connector to the EVR.
35. Connect the IAC valve and the TP sensor.
36. Install the balance tube on the engine.
37. Install the communication valve and the bolts.
38. Install the wiring harness shield, the bolts and five clips.
39. Attach the electrical connector to the communication valve.
40. Install the tube assembly and connect the PCV valve tube to the water heated fitting.
41. Connect the coolant hoses.
42. Install the PCV valve in the valve cover.
43. Connect the EVAP return line.
44. Position the cables and bracket and install the bolts.
45. Connect the accelerator cable, speed control cable, and the return spring.
46. Install the engine appearance cover and the three bolts.
47. Install the engine air cleaner and outlet tube

##### LOWER INTAKE MANIFOLD

Remove the lower intake manifold retaining bolts and remove the intake manifold from the engine

Click to enlarge

Lower intake manifold tightening sequence—5.4L DOHC engine

Click to enlarge

1. Drain and recycle the engine coolant.
2. Remove the upper intake manifold.
3. Disconnect the fuel lines.
4. Disconnect the engine water bypass hose.
5. Detach the electrical connector from the water temperature indicator sender.
6. Disconnect the upper radiator hose, the heater water inlet hose and the heated Positive Crankcase Ventilation (PCV) water fitting inlet hose.
7. Remove the four bolts and the upper generator support bracket.
8. Disconnect the eight fuel injectors.
9. Disconnect the vacuum line from the fuel injector pressure regulator and position out of the way.
10. Remove the bolts and the lower intake manifold.
11. Remove the bolts and the radio ignition interference capacitors.

To install:

12. Remove and inspect the gaskets, install new gaskets if necessary.
13. Clean the sealing surfaces.
14. Install the radio ignition interference capacitors.

Bolts should be hand-started, positions 7-12 first then 1-6.

15. Install the lower intake manifold:
16. Position the gaskets.
17. Install the intake manifold and the retaining bolts.
18. Tighten the bolts to 89 inch lbs. (10 Nm) and then an additional 90 degrees in the sequence shown.
19. Connect the water temperature indicator sensor.
20. Position the vacuum harness and connect the vacuum line to the fuel injector pressure regulator.
21. Connect the eight fuel injectors.
22. Install the upper generator support bracket and the four bolts.
23. Connect the heater water inlet hose, the upper radiator hose and the water heated fitting inlet hose.
24. Connect the engine water bypass return hose.
25. Connect the fuel lines.
26. Install the upper intake manifold.
27. Fill the cooling system.

#### 5.4L Lightning

Remove the retaining bolts for the intake manifold and remove the manifold from the engine

Click to enlarge

Make sure that the PCV system hose is securely connected

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Intake manifold retaining bolt tightening sequence—5.4L Lightning

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1. Remove the charge air cooler.
2. Properly relieve the fuel system pressure.
3. Disconnect the fuel lines.
4. Drain and recycle the engine coolant.
5. Remove the accelerator cable bracket retaining bolts and remove the bracket.
6. Disconnect the upper radiator hose from the thermostat housing.

CAUTION
Do not disconnect the Positive Crankcase Ventilation (PCV) hose system from the intake. Installation cannot be carried out without the intake in place.

7. Disconnect the PCV system.
8. Disconnect the ground strap and both radio ignition interference capacitors.
9. Disconnect the vacuum line.
10. Detach the charge air cooler temperature sensor connector.
11. Disconnect the heater hose.
12. Detach the eight fuel injector electrical connectors.
13. Disconnect the vapor management valve vacuum line.
14. Disconnect the vacuum line near the brake vacuum booster.
15. Remove the fuel injection supply manifold.
16. Detach the eight ignition coil connectors.
17. Remove the eight ignition coils.
18. Release the tension from the accessory drive belt.
19. Remove the generator bracket.
20. Remove the retaining bolts and remove the intake manifold.
21. Remove the gaskets.

CAUTION
Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to clean the sealing surfaces.

22. Clean the sealing surfaces.

To install:

23. Position the gaskets.

WARNING
If the PCV system hose becomes disconnected, the intake manifold will have to be removed to reattach the hose.

24. Make sure that the PCV system hose is securely connected.
25. Install the intake manifold.
26. Position the manifold.
27. Position the thermostat outlet.
28. Install the intake manifold bolts. Tighten the bolts in two stages in the sequence shown.
    1. Stage 1: tighten to 18 inch lbs. (2 Nm).
    2. Stage 2: tighten to 19 ft. lbs. (25 Nm).
29. Install the generator bracket.
30. Install the accessory drive belt.
31. Install the eight ignition coils.
32. Attach the eight ignition coil connectors.
33. Position the fuel injection supply manifold and install the bolts.
34. Connect the vacuum line near the brake vacuum booster.
35. Connect the vapor management valve vacuum line.
36. Connect the fuel injector electrical connectors.
37. Connect the heater hose.
38. Attach the charge air cooler temperature sensor.
39. Connect the vacuum line.
40. Connect the ground strap and both radio ignition interference capacitors.
41. Connect the positive crankcase ventilation (PCV) system.
42. Connect the upper radiator hose.
43. Position the accelerator cable bracket and tighten the bolts.
44. Connect the fuel lines.
45. Install the charge air cooler.
46. Fill and bleed the engine cooling system.

#### 5.8L and 7.5L Engines

Relieve the fuel system pressure before starting any work that involves disconnecting fuel system lines.

##### UPPER INTAKE MANIFOLD

Upper intake manifold and throttle body for the 5.8L engine

Click to enlarge

1. Disconnect the negative battery cable.
2. Remove the air cleaner.
3. Disengage the electrical connectors at the air bypass valve, throttle position sensor and EGR position sensor.
4. Disconnect the throttle linkage at the throttle ball and the AOD transmission linkage from the throttle body. Remove the bolts that secure the bracket to the intake and position the bracket and cables out of the way.
5. Disengage the upper manifold vacuum fitting connections by removing all the vacuum lines at the vacuum tree (label lines for position identification). Remove the vacuum lines to the EGR valve and fuel pressure regulator.
6. Disengage the PCV system by disconnecting the hose from the fitting at the rear of the upper manifold.
7. Remove the two canister purge lines from the fittings at the throttle body.
8. Disconnect the EGR tube from the EGR valve by loosening the flange nut.
9. Remove the bolt from the upper intake support bracket to upper manifold.
10. Remove the upper manifold retaining bolts and remove the upper intake manifold and throttle body as an assembly.
11. Clean and inspect all mounting surfaces of the upper and lower intake manifolds.

To install:

12. Position a new mounting gasket on the lower intake manifold.
13. Install the upper intake manifold and throttle body as an assembly.
14. Install the upper manifold retaining bolts and install the bolt at the upper intake support bracket. Mounting bolts are tightened to 12-18 ft. lbs. (16-25 Nm).
15. Connect the EGR tube at the EGR valve.
16. Install the two canister purge lines at the fittings at the throttle body.
17. Connect the PCV system hose at the fitting at the rear of the upper manifold.
18. Connect the upper manifold vacuum lines at the vacuum tree. Install the vacuum lines at the EGR valve and fuel pressure regulator.
19. Install the throttle bracket on the intake manifold. Attach the throttle linkage at the throttle ball and the transmission linkage at the throttle body.
20. Attach the electrical connectors at the air bypass valve, throttle position sensor and EGR position sensor.
21. Install the air cleaner.

##### LOWER INTAKE MANIFOLD

Lower intake manifold assembly for the 5.8L engine

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Lower intake manifold bolt tightening sequence— 5.8L engine

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7.5L engine lower intake manifold gasket installation

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Lower intake manifold bolt tightening sequence— 7.5L engine

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1. Upper manifold and throttle body must be removed first.
2. Drain the cooling system.
3. Remove the distributor assembly, cap and wires.
4. Disengage the electrical connectors at the engine, coolant temperature sensor and sending unit, at the air charge temperature sensor and at the knock sensor.
5. Disconnect the injector wiring harness from the main harness assembly.
6. Remove the ground wire from the intake manifold stud. The ground wire must be installed at the same position it was removed from.
7. Disconnect the fuel supply and return lines from the fuel rails.
8. Remove the upper radiator hose from the thermostat housing. Remove the bypass hose. Remove the heater outlet hose at the intake manifold.
9. Remove the air cleaner mounting bracket.
10. Remove the intake manifold mounting bolts and studs. Pay attention to the location of the bolts and studs for reinstallation.
11. Remove the lower intake manifold assembly.

To install:

12. Clean and inspect the mounting surfaces of the heads and manifold.
13. Apply a 1/16 in. (1.5mm) bead of RTV sealer to the ends of the manifold seal (the junction point of the seals and gaskets).
14. Install the end seals and intake gaskets on the cylinder heads. The gaskets must interlock with the seal tabs.
15. Install locator bolts at opposite ends of each head and carefully lower the intake manifold into position.
16. Install and tighten the mounting bolts and studs in sequence to 23-25 ft. lbs. (31-34 Nm).
17. Install the air cleaner mounting bracket.
18. Install the heater outlet hose at the intake manifold.
19. Install the bypass hose.
20. Install the upper radiator hose.
21. Connect the fuel supply and return lines at the fuel rails.
22. Connect the injector wiring harness from the main harness assembly.
23. Install the ground wire onto the intake manifold stud.
24. Attach the electrical connectors at the engine, coolant temperature sensor and sending unit, at the air charge temperature sensor and at the knock sensor.
25. Install the distributor assembly, cap and wires.
26. Fill the cooling system.

#### 7.3L Diesel Engine

The intake manifold on the 7.3L DIT engine is integral to the cylinder heads. Refer to cylinder head removal and installation in this section.

## Exhaust Manifold

### REMOVAL & INSTALLATION

#### 4.2L Engine

Tighten the driver's side exhaust manifold bolts in the order shown—4.2L engine

Click to enlarge

Tighten the passenger side exhaust manifold bolts in the order shown—4.2L engine

Click to enlarge

1. Disconnect the negative battery cable.
2. For the right-hand manifold, remove the EGR valve-to-exhaust manifold tube.
3. For the left-hand manifold, remove the oil level indicator tube bracket nut, then remove the oil level indicator tube. Remove and discard the oil level indicator tube O-ring.
4. Raise and safely support the front of the vehicle.
5. Detach the heated oxygen sensor electrical connector.
6. Remove the two catalytic converter-to-exhaust manifold nuts, then disconnect the Y-pipe from the left-hand exhaust manifold.
7. Remove the exhaust manifold stud bolts, then remove the manifold mounting bolts.
8. Remove the exhaust manifold. Remove and discard the exhaust manifold gasket.

To install:

9. Position the new exhaust manifold gasket onto the engine, then install the exhaust manifold.
10. Tighten the bolts and stud bolts in the sequence shown to 15-22 ft. lbs. (20-30 Nm).
11. Connect the Y-pipe to the exhaust manifold, then install and tighten the catalytic converter nuts to 25-34 ft. lbs. (34-46 Nm).
12. Attach the oxygen sensor connector, then lower the vehicle.
13. For the left-hand exhaust manifold, install a new oil level indicator tube O-ring onto the tube. Insert the tube into the engine block and tighten the bracket retaining nut to 15-22 ft. lbs. (20-30 Nm).
14. For the right-hand exhaust manifold, Install the EGR valve-to-exhaust manifold tube. Tighten the upper and lower fittings to 25-34 ft. lbs. (34-47 Nm).
15. Connect the negative battery cable.

#### 4.6L, 5.4L and 6.8L Engines

Remove the catalytic converter-to-exhaust manifold flange bolts

Remove the oil dipstick tube from the engine

Remove the exhaust manifold-to-cylinder head retaining nuts/studs and ...

... remove the manifold from the cylinder head

Remove the exhaust manifold gaskets and ...

... thoroughly clean the cylinder head and exhaust manifold gasket mating surfaces

Tighten the driver's side exhaust manifold bolts in the order shown—4.6L and 5.4L engines

Click to enlarge

Tighten the passenger side exhaust manifold bolts in the order shown—4.6L and 5.4L engines

Click to enlarge

1. Raise and safely support the vehicle.
2. Remove the front fender splash shield.
3. For the left-hand exhaust manifold, remove the EGR valve-to-exhaust manifold tube and disconnect the Differential Pressure Feedback Exhaust (DPFE) gas recirculation transducer hoses.
4. Remove the oil dipstick from the engine.
5. On the 4.6L and 5.4L engines, remove the catalytic converter-to-exhaust manifold bolts. On the 6.8L engine, remove the front exhaust pipe from the manifold.
6. Remove the exhaust manifold mounting nuts, then remove the exhaust manifold itself.
7. Remove and discard the old gasket.
8. Clean and inspect the exhaust manifold for damage.

To install:

9. Position a new gasket and the exhaust manifold onto the engine block.
10. Install the mounting nuts and tighten, in the sequence shown, to 13-16 ft. lbs. (18-22 Nm) on the 4.6L and 5.4L engines. Tighten the nuts to 17-20 ft. lbs. (23-27 Nm) on the 6.8L engine.
11. On the 6.8L engine, tighten the exhaust manifold-to-front pipe fasteners to 27-34 ft. lbs. (34-46 Nm).
12. On the 4.6L and 5.4L engines, attach the catalytic converter to the exhaust manifold, then install the catalytic converter-to-exhaust manifold bolts and tighten to 25-34 ft. lbs. (34-46 Nm).
13. Install the oil dipstick tube.
14. For the left-hand exhaust manifold, install the DPFE transducer hoses if equipped, and the EGR valve-to-exhaust manifold tube. Tighten the upper and lower fittings to 26-33 ft. lbs. (35-45 Nm).
15. Install the front fender splash shield.
16. Lower the vehicle to the ground.

Tighten the exhaust manifold bolts in the sequence shown—right side of 6.8L engine shown

Click to enlarge

#### 5.8L and 7.5L Engines

5.8L and 7.5L engine exhaust manifold mounting

Click to enlarge

1. Raise and safely support the vehicle securely on jackstands.
2. Disconnect the exhaust pipe or catalytic converter from the exhaust manifold. Remove and discard the doughnut gasket.
3. Lower the vehicle.
4. Disconnect any necessary emission components to access the exhaust manifolds.
5. Remove the exhaust manifold attaching screws and remove the manifold from the cylinder head.

To install:

6. Apply a light coat of graphite grease to the mating surface of the manifold. Install and tighten the attaching bolts, starting from the center and working to both ends alternately. Tighten to 25-35 ft. lbs. (34-47 Nm).
7. Connect any necessary emission components removed to access the exhaust manifolds.
8. Raise and safely support the vehicle securely on jackstands.
9. Install the exhaust pipe or catalytic converter to the exhaust manifold using a new doughnut gasket. Tighten the retaining bolts to 25-35 ft. lbs. (34-47 Nm).
10. Lower the vehicle.

#### 7.3L Diesel Engine

1. Disconnect the ground cables from both batteries.
2. If removing the passenger side manifold and the vehicle is equipped with an automatic, remove the transmission fill tube bracket bolt and rotate the bracket to the side.
3. Raise the vehicle and safely support it.
4. Disconnect the turbocharger inlet pipe-to-exhaust manifold retaining bolts.
5. Remove the manifold retaining bolts and remove the manifold.

To install:

6. Before installing, clean all mounting surfaces on the cylinder heads and the manifold. Apply an anti-seize compound on the manifold bolt threads and install the manifold, using a new gasket and new locking tabs.
7. Tighten the bolts to 45 ft. lbs. (61 Nm).
8. Install the turbocharger inlet pipe onto the exhaust manifold and tighten the retaining bolts to 28 ft. lbs. (38 Nm).
9. Lower the vehicle.
10. On the passenger side manifold, install the transmission fill tube bracket if equipped.
11. Connect the negative battery cables.

## Turbocharger

### REMOVAL & INSTALLATION

#### 7.3L Diesel Engine

Turbocharger components—7.3L diesel engine

Click to enlarge

Turbocharger and induction system components—7.3L diesel engine

Click to enlarge

1. Disconnect the negative battery cable.
2. Remove the two air intake tube assembly bolts, clamps at the turbocharger, crankcase breather assembly, engine air cleaner and air intake tube and hoses.
3. Remove the exhaust outlet clamp from the turbocharger.
4. Raise and safely support the vehicle.
5. Remove the engine charge exhaust pipe bolt from the transmission, if so equipped.
6. Remove the bolts and nuts from the catalytic converter-to-engine charge exhaust pipe, if so equipped.
7. Loosen two bolts retaining the turbocharger exhaust inlet pipe to the left exhaust manifold.
8. For automatic transmissions, remove the bolts retaining the left turbocharger exhaust inlet pipe to the turbocharger exhaust inlet adapter.
9. Loosen the two bolts retaining the turbocharger exhaust inlet pipe to the right exhaust manifold.
10. Remove the lower bolt retaining the right turbocharger exhaust inlet pipe to the turbocharger exhaust inlet adapter.
11. Lower the vehicle.
12. For automatic transmissions, remove the upper bolts retaining the right and left turbocharger exhaust inlet pipes to the turbocharger exhaust inlet adapter.
13. Remove the right engine lift hook and bolt.
14. Loosen the air inlet hose clamp at the turbocharger. Disconnect the hose and lay aside.
15. For automatic transmissions, loosen the four intake manifold hose clamps, and one clamp retaining the compressor manifold to the turbocharger. Remove the compressor manifold.
16. Remove the four bolts retaining the turbocharger pedestal assembly to the cylinder block.
17. Remove the turbocharger assembly and detach all electrical connectors from it.

If the turbocharger is not being removed for service, install the Fuel/Oil turbo Protector Cap Set T94T-9395-AH or equivalent.

18. Remove the oil gallery O-rings.

After loosening the clamps, the compressor manifold can be removed—diesel engines

Click to enlarge

To install:

19. Install new oil gallery O-rings.
20. Attach the turbocharger electrical connectors and install the turbocharger assembly.
21. Install the four bolts retaining the turbocharger pedestal assembly to the engine block. Tighten the bolts to 18 ft. lbs. (25 Nm).
22. Loosely install the four bolts retaining the right and left turbocharger exhaust inlet pipes to the turbocharger exhaust inlet adapter.
23. Install the compressor manifold, intake manifold hoses and clamps. Be sure the compressor outlet seal is in position.
24. Install the right engine lift hook and bolt.
25. Raise and safely support the front of the vehicle.
26. Tighten the two right and left lower bolts (retaining the turbocharger exhaust inlet pipes to the turbocharger exhaust inlet adapter) to 36 ft. lbs. (49 Nm).
27. Tighten the four right and left bolts and nuts (retaining the turbocharger exhaust inlet pipes to the exhaust manifolds) to 36 ft. lbs. (49 Nm).
28. Install the catalytic converter to the engine charge exhaust pipe bolts and nuts.
29. Lower the vehicle.
30. Tighten the two right and left upper bolts (retaining the turbocharger exhaust inlet pipes to the turbocharger exhaust inlet adapter) to 36 ft. lbs. (49 Nm).
31. Install the exhaust outlet clamp to the turbocharger.
32. Install the air intake tube and hose assembly.
33. Connect the negative battery cable.

## Radiator

### REMOVAL & INSTALLATION

Remove the retaining clips for the radiator support brace trim cover and ...

... remove the trim panel from the vehicle

Remove the fan shroud-to-radiator retaining bolts

Place the special fan removal tools over the water pump pulley bolts and onto the fan clutch hub and loosen the fan clutch assembly

Remove the fan clutch from the water pump and ...

... remove the fan clutch and the shroud assembly from the vehicle

Slide the hoes clamps back and ...

... remove the upper and ...

... the lower hoses from the radiator

Remove the recovery tank hose from the radiator

Using a back-up wrench to support the radiator fitting, loosen the transmission cooler lines from the radiator and ...

... plug the lines to prevent contamination from entering the transmission

The radiator is retained by two upper support mounts

Remove the radiator upper support mount bolts and ...

... remove the support mount brackets from the radiator

Remove the radiator by lifting it straight out of the engine compartment

All gasoline-engine equipped trucks use a cross-flow radiator. In this type, the coolant flows horizontally from a radiator inlet tank to a radiator outlet tank.

The 7.3L diesel engine is equipped with an aluminum downflow radiator.

1. Drain the cooling system.

CAUTION
When draining the coolant, keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.

2. If applicable, use a suitable prytool (see photo) to remove the push-in fasteners that retain the air intake duct, then remove the duct from its mounting on the radiator support.
3. On 1999-00 Super Duty trucks, remove the expansion tank from the top of the radiator.
4. Remove the radiator support brace trim cover.
5. Remove the fan and fan shroud from the vehicle.
6. Disconnect the upper and lower hoses from the radiator.
7. Disconnect the recovery tank hose from the radiator.
8. On automatic transmission equipped trucks only, disconnect the transmission cooling lines from the bottom of the radiator and plug the lines.
9. Remove the radiator retaining bolts or the upper supports and lift the radiator from the vehicle.

To install:

10. Lower the radiator into the vehicle.
11. Install the radiator retaining bolts or the upper supports.
12. Connect the transmission cooling lines at the bottom of the radiator.
13. Connect the upper and lower hoses at the radiator.
14. Connect the recovery tank hose to the radiator.
15. Install the fan and shroud.
16. If applicable, install the air intake duct.
17. Fill and bleed the cooling system.

## Engine Fan

### REMOVAL & INSTALLATION

#### 4.2L, 4.6L, 5.4L And 6.8L Engines

Remove the fan shroud-to-radiator retaining bolts

Place the special fan removal tools over the water pump pulley bolts and onto the fan clutch hub and loosen the fan clutch assembly

Remove the fan clutch from the water pump and ...

... remove the fan clutch and the shroud assembly from the vehicle

1. Disconnect the negative battery cable.
2. Remove the engine air cleaner outlet tube.
3. Remove the fan shroud-to-radiator retaining bolts

WARNING
The large nut on the fan clutch has a left-hand thread and must be removed by turning the nut clockwise.

4. Remove the fan clutch using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, or equivalents.
5. Lift the fan and the shroud assembly from the engine compartment.
6. If the fan or clutch are to be replaced, remove 4 retaining bolts and separate the fan from the clutch assembly.

To install:

7. Assemble the fan and clutch, if separated. Install 4 retaining bolts and tighten to 12-15 ft. lbs. (16-20 Nm).
8. Place the fan assembly and shroud in place at the same time and thread the fan clutch nut onto the water pump shaft. Tighten the fan clutch nut using Fan Clutch Holding Tool T84T-6312-C and Fan Clutch Wrench T93T-6312-B, or equivalents to 45 ft. lbs. (61 Nm).

WARNING
The large nut on the fan clutch has a left-hand thread and must be tightened by turning the nut counterclockwise.

9. Install the fan shroud and tighten the shroud retaining bolts.
10. Install the engine air cleaner outlet tube.
11. Connect the negative battery cable.
12. Start the engine and check for proper operation.

#### 5.8L And 7.5L Engines

Fan assembly—5.8L and 7.5L engines

Click to enlarge

CAUTION
The large nut on the fan clutch has a right-hand thread and must be removed by turning the nut counterclockwise.

1. Remove the clutch by turning the large nut on the back of the clutch assembly. (The nut is part of the clutch assembly). Use fan clutch holding tool T84T-6312-C and fan clutch wrench T93T-6312-B or equivalents.
2. Remove the 2 fan shroud retaining screws.
3. Remove the fan and clutch along with the shroud.
4. If the fan and clutch need to be separated, remove the 4 retaining bolts.

To install:

5. Assemble the fan and clutch. Tighten to bolts to 12-18 ft. lbs. (16-24 Nm).
6. Position the fan assembly and shroud in place. Tighten the fan clutch nut to the water pump shaft with fan clutch holding tool T84T-6312-C and fan clutch wrench T93T-6312-B or equivalents.

CAUTION
The large nut on the fan clutch has a right-hand thread and must be tightened by turning the nut clockwise.

7. Tighten the 2 fan shroud retaining screws.

#### 7.3L Diesel Engine

Fan assembly—7.3L diesel engine

Click to enlarge

1. Disconnect the negative battery cable.
2. Remove the engine air cleaner outlet tube.
3. Remove the fan shroud-to-radiator retaining bolts

WARNING
The large nut on the fan clutch has a right-hand thread and must be removed by turning the nut counter-clockwise.

4. Remove the fan clutch using Fan Clutch Holding Tool T94T-6312-AH and Fan Clutch Wrench T93T-6312-B, or equivalents.
5. Lift the fan and the shroud assembly from the engine compartment.
6. If the fan or clutch are to be replaced, remove 4 retaining bolts and separate the fan from the clutch assembly.

To install:

7. Assemble the fan and clutch, if separated. Install 4 retaining bolts and tighten to 12-18 ft. lbs. (16-24 Nm).
8. Place the fan assembly and shroud in place at the same time and thread the fan clutch nut onto the water pump shaft. Tighten the fan clutch nut using Fan Clutch Holding Tool T94T-6312-AH and Fan Clutch Wrench T93T-6312-B, or equivalents to 84-112 ft. lbs. (113-153 Nm).

WARNING
The large nut on the fan clutch has a left-hand thread and must be tightened by turning the nut counterclockwise.

9. Install the fan shroud and tighten the shroud retaining bolts.
10. Install the engine air cleaner outlet tube.
11. Connect the negative battery cable.
12. Start the engine and check for proper operation.

## Water Pump

### REMOVAL & INSTALLATION

#### 4.2L, 4.6L, 5.4L And 6.8L Engines

Remove the fan shroud-to-radiator retaining bolts

Place the special fan removal tools over the water pump pulley bolts and onto the fan clutch hub and loosen the fan clutch assembly

Remove the fan clutch from the water pump and ...

... remove the fan clutch and the shroud assembly from the vehicle

Remove the four water pump retaining bolts and ...

... remove the water pump from the engine

Remove the water pump O-ring using a pick or other suitable tool

Always replace the water pump O-ring with a quality replacement such as a Fel-Pro®

1. Disconnect the negative battery cable.
2. Drain the engine cooling system.
3. Remove the engine cooling fan and fan shroud.
4. Release the belt tensioner and remove the accessory drive belt.
5. Remove 4 bolts retaining the water pump pulley to the water pump and remove the pulley.
6. Remove 4 bolts retaining the water pump to the cylinder block and remove the water pump.

To install:

7. Clean the sealing surfaces of the water pump and cylinder block.
8. Lubricate a new O-ring seal with clean antifreeze and install on the water pump.
9. Install the water pump and 4 retaining bolts. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm).
10. Install the water pump pulley and 4 retaining bolts. Tighten the retaining bolts to 15-22 ft. lbs. (20-30 Nm).
11. Release the belt tensioner and install the accessory drive belt.
12. Install the engine cooling fan and fan shroud.
13. Fill the engine cooling system.
14. Connect the negative battery cable.
15. Start the engine and allow to reach normal operating temperature while checking for coolant leaks.
16. Road test the vehicle and check for proper operation.

#### 5.8L And 7.5L Engines

1. Drain the cooling system.
2. Remove the engine fan and fan shroud.
3. Disconnect the lower radiator hose, heater hose and by-pass hose at the water pump.
4. Remove the water pump pulley.
5. Loosen the alternator pivot bolt and the bolt attaching the alternator adjusting arm to the water pump. Remove the power steering pump, and air conditioning compressor bracket from the water pump and position it out of the way.
6. Remove the bolts securing the water pump to the timing chain cover and remove the water pump.

To install:

7. Coat a new gasket with sealer and install the water pump. Tighten the bolts to 18 ft. lbs. (25 Nm).
8. Install the power steering pump bracket.
9. Connect the lower radiator hose, heater hose and by-pass hose at the water pump.
10. Install the water pump pulley, fan, fan shroud and drive belt.
11. Fill the cooling system.

#### 7.3L Diesel Engine

1. Disconnect both battery ground cables.
2. Drain the cooling system.
3. Remove the radiator shroud and the fan clutch and fan.

The fan clutch bolts are right-hand thread. Remove them by turning counter-clockwise.

4. Loosen, but do not remove, the water pump pulley bolts.
5. Remove the drive belt.
6. Remove the water pump pulley bolts and remove the pulley from the pump.
7. Detach the ECT sensor connector.
8. Remove the heater hose from the water pump.
9. Remove the bolts attaching the water pump to the front cover and lift off the pump.

To install:

10. Thoroughly clean the mating surfaces of the pump and front cover.
11. Using a new gasket, position the water pump over the dowel pins and into place on the front cover.
12. Install the attaching bolts. Tighten the bolts to 15 ft. lbs. (20 Nm).
13. Connect the heater hose to the pump.
14. Attach the ECT sensor connector.
15. Install the water pump pulley and start the water pump pulley bolts.
16. Install the drive belt.
17. Install and tighten the pulley retaining bolts to 12-18 ft. lbs. (16-24 Nm).
18. Install the fan and fan shroud assembly.
19. Fill and bleed the cooling system.
20. Connect the battery ground cables.
21. Start the engine and check for leaks.

Water pump mounting—7.3L diesel engine

Click to enlarge

Apply aviation grade RTV sealant to the bolts indicated—7.3L diesel engine

Click to enlarge

## Cylinder Head

### REMOVAL & INSTALLATION

#### 4.2L Engine

Relieve the fuel system pressure before starting any work that involves disconnecting the fuel lines. Refer to Fuel System .

1. The A/C system, should be discharged by a qualified mechanic using an approved refrigerant recovery/recycling machine.
2. Disconnect the negative battery cable.
3. Drain the cooling system.
4. Remove the upper and lower intake manifolds and related components.
5. Remove the valve covers.
6. Remove the exhaust manifold (s).
7. If removing the left-hand cylinder head, perform the following:
   1. Position the power steering pump reservoir aside and remove the A/C compressor.
   2. Remove and support the A/C compressor bracket and power steering pump aside.
8. If removing the right-hand cylinder head, perform the following:
   1. Remove the alternator.
   2. Remove the idler pulley.
   3. Remove the alternator bracket.

If the cylinder head components, such as rocker arms, valve springs, etc., are to be reinstalled, they must be installed in the same position. Mark the components for original location.

9. Remove the six rocker arms by removing the retaining bolts.
10. Pull the pushrods out of the engine. Once again, be sure to label or mark the components removed for reinstallation in their original location.
11. Remove and discard the eight cylinder head mounting bolts. New bolts are a must for installation.
12. Lift the cylinder head off of the engine block. Remove the cylinder head gasket and discard.

To install:

13. Clean and inspect the cylinder head for flatness.
14. Install a new cylinder head gasket on the cylinder block with the small hole to the front of the engine, then install the cylinder head.

WARNING
Always use new cylinder head bolts for installation.

15. Lubricate the cylinder head bolts with clean engine oil prior to installation.

Be sure to tighten the cylinder head bolts in three (3) steps.

16. Install the new cylinder head bolts. Tighten the cylinder head bolts in the sequence shown and in three steps to the following values:

- Step 1—14 ft. lbs. (20 Nm)
- Step 2—29 ft. lbs. (40 Nm)
- Step 3—36 ft. lbs. (50 Nm)

Cylinder head torque sequence—4.2L engines

Click to enlarge

WARNING
Do not loosen all of the cylinder head bolts at one time. Each cylinder head bolt must be loosened and the final tightening performed prior to loosening the next bolt in the sequence.

17. In the same sequence as used previously, loosen the cylinder head bolt three turns, then tighten the cylinder head bolt to the specific value according to its length. The short bolts (A) should be tightened to 15-32 ft. lbs. (20-30 Nm) and the long bolts (B) to 30-36 ft. lbs. (40-50 Nm). Finally, tighten each cylinder head bolt, in sequence, an additional 175-185 degrees (C). It would be very helpful to utilize a degree socket wrench for this last step.
18. Lubricate the pushrods with clean engine oil prior to installation, then install them into their original positions.
19. Install the rocker arms. Tighten the rocker arm mounting bolts to 23-29 ft. lbs. (30-40 Nm).
20. If the valvetrain components were replaced with new components, inspect the valve clearance.
21. If installing the right-hand cylinder head, perform the following:
    1. Position the alternator bracket in place, then install the two long bolts to 31-39 ft. lbs. (41-54 Nm). Install the short bolt and tighten to 18-22 ft. lbs. (24-31 Nm).
    2. Install the idler pulley. Tighten the center retaining bolt to 35-46 ft. lbs. (47-63 Nm).
    3. Install the alternator.
22. If installing the left-hand cylinder head, complete the following steps:
    1. Position the A/C compressor bracket and power steering pump in place, then start the A/C compressor bracket bolt. Install the three compressor bracket bolts to 30-40 ft. lbs. (40-55 Nm). Then, install the two compressor bracket nuts to 16-21 ft. lbs. (21-29 Nm).
    2. Install the A/C compressor.
    3. Install the power steering pump reservoir. Tighten the hold-down bolts to 80-107 inch lbs. (9-12 Nm).
23. Install the exhaust manifold.
24. Install the two rocker arm covers. Inspect the rocker arm cover gaskets for damage prior to installation; replace them if necessary.
25. Install the lower intake manifold and related components.
26. Install the upper intake manifold and related components.
27. Fill the cooling system and connect the negative battery cable.
28. Change the engine oil.
29. Start the engine and check for any fuel, coolant and vacuum leaks.

#### 4.6L, 5.4L and 6.8L Engines

Remove the cylinder head bolts and ...

... carefully lift the cylinder head off of the engine block and place it in a safe location

Remove the head gasket from the engine block

Thoroughly clean the cylinder head and ...

... engine block of any gasket material left

After the gasket material has been removed, wipe the head and ...

... engine block clean using a suitable solvent

Relieve the fuel system pressure before starting any work that involves disconnecting the fuel lines. Refer to Fuel System .

1. The A/C system, should be discharged by an EPA certified mechanic utilizing the appropriate refrigerant recovery/recycling machine.
2. Disconnect the negative battery cable.
3. Remove the valve covers.
4. Remove the intake manifold(s).
5. Remove the timing chains from the engine.
6. Remove the exhaust manifolds.
7. Remove the two heater hose retaining bolts, then compress and slide the hose clamp back to remove the heater water hose.
8. Remove the cylinder head bolts, then lift the cylinder head from the engine block.
9. Discard the cylinder head gasket and clean the engine block surface.

To install:

WARNING
Cylinder head bolts must be replaced with new ones. They are torque-to-yield designed and cannot be reused.

10. Turn the crankshaft to position the key-way at the 12 o'clock position.
11. Clean and inspect the cylinder head for damage or warpage. Install the cylinder head gasket over the dowel pins. Then, install the cylinder head onto the engine block. Loosely install NEW cylinder head bolts.

Be sure to tighten the head bolts in three steps.

12. Tighten the cylinder head bolts in the sequence shown in three steps, as follows:
    1. Step 1—27-31 ft. lbs. (37-43 Nm).
    2. Step 2—tighten an additional 85-95 degrees.
    3. Step 3—tighten another 85-95 degrees.

Tighten the cylinder head bolts in three steps using the sequence shown—4.6L and 5.4L engines

Click to enlarge

Be sure to tighten the cylinder head bolts in three steps using the sequence shown—6.8L engine

Click to enlarge

13. Install the heater water hose and slide the hose clamp back into position. Install the two heater water hose bolts.
14. Install the exhaust manifolds.
15. Install the timing chains.
16. Install the intake manifold.
17. Install the valve covers.
18. Connect the negative battery cable, then start the engine and check for leaks.
19. If the vehicle is equipped with A/C, have the system evacuated and recharged by an EPA certified mechanic utilizing the appropriate refrigerant recovery/recycling machine.
20. Change the engine oil.
21. Connect the negative battery cable.

#### 5.8L Engine

Relieve the fuel system pressure before starting any work that involves disconnecting the fuel lines. Refer to Fuel System .

1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Remove the intake manifolds.
4. Remove the valve cover(s).
5. If the right cylinder head is to be removed:

- Lift the tensioner and remove the drive belt
- Loosen the alternator adjusting arm bolt and remove the alternator mounting bracket bolt and spacer
- Swing the alternator down and out of the way.

6. Remove the air cleaner inlet duct.
7. If the left cylinder head is being removed:
   - Remove the air conditioning compressor
   - Remove the oil dipstick and tube
   - Remove the cruise control bracket
8. Disconnect the exhaust manifold(s) from the muffler inlet pipe(s).
9. Loosen the rocker arm stud nuts so the rocker arms can be rotated to the side. Remove the pushrods and identify them so they can be reinstalled in their original positions.
10. Remove the cylinder head bolts and lift the cylinder head from the block. Remove the discard the gasket.

To install:

11. Clean the cylinder head, intake manifold, the valve cover and the head gasket surfaces.

WARNING
A specially treated composition head gasket is used. Do not apply sealer to a composition gasket.

12. Position the new gasket over the locating dowels on the cylinder block.
13. Position the cylinder head on the block and install the attaching bolts.
14. The cylinder head bolts are tightened in progressive steps. Tighten all the bolts in the proper sequence to:

- Step 1—85 ft. lbs.(115 Nm)
- Step 2—95 ft. lbs. (129 Nm)
- Step 3—105-112 ft. lbs. (143-152 Nm)

15. Clean the pushrods. Blow out the oil passage in the rods with compressed air. Check the pushrods for straightness by rolling them on a piece of glass. Never try to straighten a pushrod; always replace it.
16. Apply Lubriplate® to the ends of the pushrods and install them in their original positions.
17. Apply Lubriplate® to the rocker arms and their fulcrum seats and install the rocker arms. Adjust the valves.
18. Position a new gasket(s) on the muffler inlet pipe(s) as necessary. Connect the exhaust manifold(s) at the muffler inlet pipe(s).
19. If the right cylinder head was removed, install the alternator, air cleaner duct, and the drive belt. If the left cylinder head was removed, install the compressor, the dipstick and cruise control bracket.
20. Clean the valve rocker arm cover and the cylinder head gasket surfaces. Place the new gaskets in the covers, making sure the tabs of the gasket engage the notches provided in the cover. Evacuate, charge and leak test the air conditioning system.
21. Install the intake manifold and related parts.
22. Fill and bleed the cooling system.
23. Change the engine oil.
24. Connect the negative battery cable.

Cylinder head bolt torque sequence—5.8L and 7.5L engines

Click to enlarge

#### 7.5L Engine

Relieve the fuel system pressure before starting any work that involves disconnecting the fuel lines. Refer to Fuel System .

1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Remove the upper and lower intake manifolds..
4. Disconnect the exhaust pipe from the exhaust manifold.
5. Remove the drive belts.
6. Loosen the alternator attaching bolts and remove the bolt attaching the alternator bracket to the right cylinder head.
7. Disconnect the air conditioning compressor from the engine and move it aside, out of the way. Do not discharge the air conditioning system.
8. Remove the bolts securing the power steering reservoir bracket to the left cylinder head. Position the reservoir and bracket out of the way. On motor home chassis, remove the oil filler tube.
9. Remove the valve covers.
10. Remove the rocker arm bolts, rocker arms, oil deflectors, fulcrums and pushrods in sequence so they can be reinstalled in their original positions.
11. Remove the cylinder head bolts and lift the head and exhaust manifold off the engine. If necessary, pry at the forward corners of the cylinder head against the casting bosses provided on the cylinder block. Do not damage the gasket mating surfaces of the cylinder head and block by prying against them.

To install:

12. Remove all gasket material from the cylinder head and block. Clean all gasket material from the mating surfaces of the intake manifold. If the exhaust manifold was removed, clean the mating surfaces of the cylinder head and exhaust manifold. Apply a thin coat of graphite grease to the cylinder head exhaust port areas and install the exhaust manifold.
13. Position the two long cylinder head bolts in the two rear lower bolt holes of the left cylinder head. Place a long cylinder head bolt in the rear lower bolt hole of the right cylinder head. Use rubber bands to keep the bolts in position until the cylinder heads are installed on the cylinder block.
14. Position new cylinder head gaskets on the cylinder block dowels. Do not apply sealer to the gaskets, heads, or block.
15. Place the cylinder heads on the block, guiding the exhaust manifold studs into the exhaust pipe connections. Install the remaining cylinder head bolts. The longer bolts go in the lower row of holes.
16. Tighten all the cylinder head attaching bolts in the proper sequence in three stages: 80-90 ft. lbs. (109-122 Nm), 100-110 ft. lbs. (136-149 Nm), and finally to 130-140 ft. lbs. (176-190 Nm). When this procedure is used, it is not necessary to retighten the heads after extended use.
17. Be sure the oil holes in the pushrods are open and install the pushrods in their original positions. Place a dab of Lubriplate® to the ends of the pushrods before installing them.
18. Lubricate and install the valve rockers. Be sure the pushrods remain seated in their lifters.
19. Connect the exhaust pipes to the exhaust manifolds.
20. Install the upper and lower intake manifolds.
21. Install the air conditioning compressor.
22. Install the power steering reservoir.
23. Install the valve covers.
24. Install the alternator and adjust the drive belts.
25. On motor home chassis, install the oil filler tube.
26. Fill and bleed the cooling system.
27. Change the engine oil.
28. Connect the negative battery cable.
29. Start the engine and check for leaks.

#### 7.3L Diesel Engine

##### RIGHT CYLINDER HEAD

Remove the oil rail drain plug as shown—7.3L DI turbo diesel engine

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Remove the injector using special tools as shown—7.3L DI turbo diesel engine

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Special fuel injector protection sleeve and holding rack—7.3L DI turbo diesel engine

Click to enlarge

Install a lifting eye as shown

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Use a suitable bore brush to clean out the injector bores

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Cylinder head bolt tightening sequence—7.3L DI turbo diesel engine

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Install the injectors using the special tool as shown—7.3L DI turbo diesel engine

Click to enlarge

1. Disconnect both negative battery cables.
2. Drain the cooling system.
3. Remove the radiator.
4. Remove the turbocharger assembly.
5. Disconnect the fuel lines by disconnecting them from the rear of both cylinder heads and the fuel pump.
6. Label and disconnect the wiring from the alternator.
7. Remove the adjusting bolts and pivot bolts from the alternator and the vacuum pump and remove both units.
8. Remove the alternator and its bracket.
9. Remove the engine oil dipstick tube.
10. Remove the MAP sensor and position it aside.
11. Remove the valve cover
12. Remove the connectors from the injectors and glow plugs.
13. Remove the valve cover gasket.
14. Remove the high pressure oil pump supply line to the right cylinder head.
15. Remove the exhaust back pressure line.
16. Remove the three glow plug relay bracket nuts and the ground wire.
17. Disconnect the heater hose from the cylinder head.
18. Remove the outer half of the heater distribution box.
19. Remove the four outboard fuel injector hold-down bolts, retaining screws and four oil deflectors.

WARNING
Remove the oil drain plugs prior to removing the injectors or oil could enter the combustion chamber which could result in hydrostatic lock and severe engine damage.

20. Remove the oil rail drain plugs.
21. Remove the fuel injectors using Injector Remover No. T94T-9000-AH1, or equivalent. Position the tool's fulcrum beneath the fuel injector hold-down plate and over the edge of the cylinder head. Install the remover screw in the threaded hole of the fuel injector plate (see illustration). Tighten the screw to lift out the injector from its bore. Place the injector in a suitable protective sleeve such as Rotunda Injector Protective Sleeve, No. 014-00933-2, and set the injector in a suitable holding rack.
22. Use a suitable vacuum tool, such as Rotunda Vacuum Pump, No. 021-00037, or equivalent to remove the oil and fuel left over in the injector bores.
23. Remove the rocker arms and pushrods, KEEP EVERYTHING IN ORDER.
24. Remove the four glow plugs.
25. Remove the right turbo exhaust inlet pipe.
26. Remove the ground strap from the rear of the cylinder head.
27. Disconnect the fuel return line at the front of the cylinder head.
28. Remove the four inboard fuel injector shoulder bolts.
29. Remove the cylinder head bolts and attach a Rotunda Cylinder Head Lifting Bracket, 014-00932-2, or equivalent.
30. Carefully lift the cylinder head out of the engine compartment and remove the head gaskets.

To install:

To prepare a good seat for the fuel injector O-rings, use a suitable injector sleeve brush to clean any debris from the bore.

31. Carefully clean the cylinder block and head mating surfaces.
32. Position the cylinder head gasket on the engine block and carefully lower the cylinder head in place.
33. Install the cylinder head bolt and torque in 3 steps using the sequence shown in the illustration.

Lubricate the threads and the mating surfaces of the bolt heads and washers with engine oil.

34. Connect the fuel return line to the cylinder head.
35. Install the four inboard injector shoulder bolts. Tighten them to 9 ft. lbs. (12 Nm).
36. Install the fuel injectors using special tools as follows:
    1. Lubricate the injectors with clean engine oil. Using new copper washers, carefully push the injectors square into the bore using hand pressure only to seat the O-rings.
    2. Position the open end of Injector Replacer, No. T94T-9000-AH2, or equivalent between the fuel injector body and injector hold-down plate, while positioning the opposite end of the tool over the edge of the cylinder head.
    3. Align the hole in the tool with the threaded hole in the cylinder head and install the bolt from the tool kit. Tighten the bolt to fully seat the injector, then remove the bolt and tool.
37. Install the four outboard fuel injector hold-down bolts, the four oil deflectors and retaining screws. Tighten them to 9 ft. lbs. (12 Nm).
38. Dip the pushrod ends in clean engine oil and install the pushrods with the copper colored ends toward the rocker arms, making sure the pushrods are fully seated in the tappet pushrod seats.
39. Install the rocker arms and posts in their original positions. Apply Lubriplate® grease to the valve stem tips. Turn the engine over by hand until the timing mark is at the 11 o'clock position as viewed from the front. Install the rocker arm posts, bolts and tighten to 27 ft. lbs. (37 Nm). Install the valve covers.
40. Install the fuel rail drain plugs, tightening them to 8 ft. lbs. (11 Nm).
41. Install the oil rail drain plugs, tightening them to 53 inch lbs. (6 Nm).
42. Install the heater distribution box.
43. Install the heater hose to the cylinder head.
44. Install the glow plug relay bracket and ground wire.
45. Install the exhaust back pressure line.
46. Install the oil supply line to the cylinder head, tightening it to 19 ft. lbs. (26 Nm).
47. Install the dipstick tube.
48. Install the MAP sensor and screws.
49. Install the valve cover gasket.
50. Connect the wiring to the fuel injectors and glow plugs.
51. Install the valve cover, tightening the bolts to 8 ft. lbs. (11 Nm).
52. Connect the injector wiring harness to the valve cover gasket.
53. Install the alternator, tightening the bracket bolts to 40-55 ft. lbs. (54-75 Nm).
54. Connect the alternator wiring and install the drive belt.
55. The remainder of the installation is the reverse of the removal. Tighten the fuel pump-to-fuel line banjo bolt to 40 ft. lbs. (54 Nm).
56. Connect both negative battery cables.
57. Refill and bleed the cooling system.
58. Run the engine and check for fuel, coolant and exhaust leaks.

##### LEFT CYLINDER HEAD

Remove the oil rail drain plug as shown—7.3L DI turbo diesel engine

Click to enlarge

Remove the injector using special tools as shown—7.3L DI turbo diesel engine

Click to enlarge

Special fuel injector protection sleeve and holding rack—7.3L DI turbo diesel engine

Click to enlarge

Install a lifting eye as shown

Click to enlarge

Use a suitable bore brush to clean out the injector bores

Click to enlarge

Cylinder head bolt tightening sequence—7.3L DI turbo diesel engine

Click to enlarge

Install the injectors using the special tool as shown—7.3L DI turbo diesel engine

Click to enlarge

1. Disconnect both negative battery cables.
2. Drain the cooling system.
3. Remove the radiator.
4. Remove the turbocharger assembly.
5. Remove the two crankcase breather screws and the breather.
6. Disconnect the wiring from the air conditioning compressor.
7. Remove the four left accessory bracket bolts.
8. Disconnect the vacuum hose at the brake vacuum pump.
9. Disconnect the A/C lines from the compressor.
10. Remove the power steering lines from the pump.
11. Remove the left accessory bracket and accessories as an assembly.
12. Remove the valve cover
13. Disconnect the fuel line assembly between the cylinder heads and fuel pump.
14. Remove the fuel line nut from the intake manifold stud.
15. Disconnect the fuel return line from the cylinder head.
16. Remove the high pressure oil pump supply line from the cylinder head.
17. Raise the vehicle and support it safely on jackstands.
18. Remove the left turbo exhaust pipe from the manifold.
19. Lower the vehicle.
20. Remove the oil rail drain plugs.
21. Remove the four outboard fuel injector hold-down bolts, retaining screws and four oil deflectors.

WARNING
Remove the oil drain plugs prior to removing the injectors or oil could enter the combustion chamber which could result in hydrostatic lock and severe engine damage.

22. Remove the oil rail drain plugs.
23. Remove the fuel injectors using Injector Remover No. T94T-9000-AH1, or equivalent. Position the tool's fulcrum beneath the fuel injector hold-down plate and over the edge of the cylinder head. Install the remover screw in the threaded hole of the fuel injector plate (see illustration). Tighten the screw to lift out the injector from its bore. Place the injector in a suitable protective sleeve such as Rotunda Injector Protective Sleeve, No. 014-00933-2, and set the injector in a suitable holding rack.
24. Use a suitable vacuum tool, such as Rotunda Vacuum Pump, No. 021-00037, or equivalent to remove the oil and fuel left over in the injector bores.
25. Remove the rocker arms and pushrods, KEEP EVERYTHING IN ORDER.
26. Remove the four glow plugs.
27. Remove the left turbo exhaust inlet pipe.
28. Remove the main engine harness connectors in the left fender well and position the harness aside.
29. Remove the four inboard fuel injector shoulder bolts.
30. Remove the cylinder head bolts and attach a Rotunda Cylinder Head Lifting Bracket, 014-00932-2, or equivalent.
31. Carefully lift the cylinder head out of the engine compartment and remove the head gaskets.

To install:

To prepare a good seat for the fuel injector O-rings, use a suitable injector sleeve brush to clean any debris from the bore.

32. Carefully clean the cylinder block and head mating surfaces.
33. Position the cylinder head gasket on the engine block and carefully lower the cylinder head in place.
34. Install the cylinder head bolt and torque in 3 steps using the sequence shown in the illustration.

Lubricate the threads and the mating surfaces of the bolt heads and washers with engine oil.

35. Apply anti-seize paste and install the glow plugs, tightening them to 14 ft. lbs. (19 Nm).
36. Install the four outboard fuel injector hold-down bolts, the four oil deflectors and retaining screws. Tighten them to 9 ft. lbs. (12 Nm).
37. Dip the pushrod ends in clean engine oil and install the pushrods with the copper colored ends toward the rocker arms, making sure the pushrods are fully seated in the tappet pushrod seats.
38. Install the rocker arms and posts in their original positions. Apply Lubriplate® grease to the valve stem tips. Turn the engine over by hand until the timing mark is at the 11 o'clock position as viewed from the front. Install the rocker arm posts, bolts and tighten to 27 ft. lbs. (37 Nm). Install the valve covers.
39. Install the four inboard injector shoulder bolts. Tighten them to 9 ft. lbs. (12 Nm).
40. Install the fuel injectors using special tools as follows:
    1. Lubricate the injectors with clean engine oil. Using new copper washers, carefully push the injectors square into the bore using hand pressure only to seat the O-rings.
    2. Position the open end of Injector Replacer, No. T94T-9000-AH2, or equivalent between the fuel injector body and injector hold-down plate, while positioning the opposite end of the tool over the edge of the cylinder head.
    3. Align the hole in the tool with the threaded hole in the cylinder head and install the bolt from the tool kit. Tighten the bolt to fully seat the injector, then remove the bolt and tool.
41. Install the fuel rail drain plugs, tightening them to 8 ft. lbs. (11 Nm).
42. Install the oil rail drain plugs, tightening them to 53 inch lbs. (6 Nm).
43. Install the heater distribution box.
44. Install the valve cover gasket.
45. Connect the wiring to the fuel injectors and glow plugs.
46. Install the valve cover, tightening the bolts to 8 ft. lbs. (11 Nm).
47. Connect the engine wiring harness.
48. Raise and safely support the vehicle on jackstands.
49. Loosely install the turbo exhaust pipe to the manifold.
50. Lower the vehicle.
51. The remainder of the installation is the reverse of the removal. Tighten the fuel pump-to-fuel line banjo bolt to 40 ft. lbs. (54 Nm).
52. Connect both negative battery cables.
53. Refill and bleed the cooling system.
54. Run the engine and check for fuel, coolant and exhaust leaks.

## Oil Pan

### REMOVAL & INSTALLATION

#### 4.2L Engine

Remove the three oil pan-to-transmission bolts

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Remove the 15 oil pan-to-cylinder block mounting bolts, then lower the oil pan

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Temporarily install two locator dowels in two of the oil pan-to-engine block corner mounting bolt holes

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Clean and apply sealant to the rear main bearing cap, the oil pan mating surface, the front cover mounting area, the front cover-to-engine block joints

Click to enlarge

1. Raise and safely support the front of the vehicle.
2. Remove the oil pan plug and drain the engine oil.
3. If equipped with 4 wheel drive:
   1. Remove the two front wheel driveshafts and joints, if so equipped.
   2. Remove the front differential from the vehicle.
   3. Remove the front differential support.
4. Remove the three oil pan-to-transmission bolts.
5. Remove the 15 oil pan-to-cylinder block mounting bolts, then lower the oil pan.

To install:

If the oil pan is not installed within 15 minutes, remove the sealer and reapply.

6. Temporarily install two locator dowels in two of the oil pan-to-engine block corner mounting bolt holes.
7. Clean and apply sealant to the rear main bearing cap, the oil pan mating surface, the front cover mounting area, the front cover-to-engine block joints, then install the oil pan rear seal. Make certain to use Silicone Gasket and Sealant F6AZ-19562-A or equivalent for the sealant.
8. Position the oil pan, then install 13 of the oil pan mounting bolts loosely.
9. Remove the two locator dowels and install the remaining two oil pan-to-engine block bolts.
10. Starting from the rear and alternating from the right to left, tighten the 15 oil pan mounting bolts to 36-44 inch lbs. (4-5 Nm), then retighten the bolts to 80-106 inch lbs. (9-12 Nm).
11. Install the oil pan-to-transmission bolts to 28-38 ft. lbs. (38-51 Nm).
12. Install the oil pan drain plug to 16-22 ft. lbs. (22-30 Nm).
13. Install the front differential and front differential support.
14. Install the front driveshafts and joints.
15. Lower the vehicle to the ground.
16. Fill the engine with the correct type and amount of engine oil.

#### 4.6L and 5.4L Engines

Tighten the oil pan-to-engine block bolts in three steps following the sequence shown—4.6L and 5.4L engines

Click to enlarge

1. Raise and safely support the vehicle.
2. On 4 X 4 equipped models, remove the front axle housing from the vehicle.
3. Drain the engine oil.
4. Remove the 16 oil pan-to-engine block bolts.
5. Remove the oil pan and the oil pan gasket.

To install:

6. Clean the oil pan and engine block mating surfaces of oil and old gasket material.
7. Install the new oil pan gasket and the oil pan, then install the 16 oil pan-to-engine block bolts loosely.

Be sure to tighten the oil pan bolts in three steps.

8. Tighten the oil pan-to-engine bolts in the sequence shown, in the following three steps:
   1. Step 1—18 inch lbs. (2 Nm).
   2. Step 2—15 ft. lbs. (20 Nm).
   3. Step 3—tighten an additional 60 degrees (one hex head flat of a bolt).
9. Install the oil drain plug.
10. If removed, install the front axle housing.
11. Lower the vehicle.
12. Fill the engine with the correct amount and type of engine oil.

#### 5.8L Engine

1. Drain the cooling system.
2. Remove the bolts attaching the fan shroud to the radiator and position the shroud over the fan.
3. Remove the upper intake manifold and throttle body.
4. Remove the nuts and lockwashers attaching the engine support insulators to the chassis bracket.
5. If equipped with an automatic transmission, disconnect the oil cooler line at the left side of the radiator.
6. Remove the exhaust system.
7. Raise the engine and place wood blocks under the engine supports.
8. Drain the engine oil.
9. Support the transmission with a floor jack and remove the transmission crossmember.
10. Remove the oil pan attaching bolts and lower the oil pan onto the crossmember.
11. Remove the two bolts attaching the oil pump pick-up tube to the oil pump. Remove the nut attaching the oil pump pick-up tube to the No. 3 main bearing cap stud. Lower the pick-up tube and screen into the oil pan.
12. Remove the oil pan from the vehicle.

Exploded view of the oil pan mounting. apply RTV sealant to the areas marked "A"—5.8L engine

Click to enlarge

To install:

13. Clean the oil pan, inlet tube and gasket surfaces. Inspect the gasket sealing surface for damages and distortion due to over tightening of the bolts. Repair and straighten as required.
14. Position a new oil pan gasket and seal to the cylinder block.
15. Position the oil pick-up tube and screen to the oil pump, and install the lower attaching bolt and gasket loosely. Install the nut on the No. 3 main bearing cap stud.
16. Place the oil pan on the crossmember. Install the upper pick-up tube bolt. Tighten the pick-up tube bolts.
17. Position the oil pan to the cylinder block and install the attaching bolts. Tighten to 10-12 ft. lbs. (14-16 Nm).
18. Install the transmission crossmember.
19. Raise the engine and remove the blocks under the engine supports. Bolt the engine to the supports.
20. Install the exhaust system.
21. If equipped with an automatic transmission, connect the oil cooler line at the left side of the radiator.
22. Install the nuts and lockwashers attaching the engine support insulators to the chassis bracket.
23. Install the upper intake manifold and throttle body.
24. Install the fan shroud.
25. Fill the engine with the proper type and amount of oil.
26. Fill and bleed the cooling system.

#### 6.8L Engine

1. Disconnect the negative battery cable.
2. Relieve the fuel system pressure.
3. Drain the cooling system.
4. Disconnect the upper radiator hose from the intake manifold.
5. Remove the engine air cleaner outlet tube.
6. Disconnect the accelerator cable from the bracket and the throttle body cam.
7. If equipped, remove the speed control actuator cable from the throttle body.
8. Disconnect all vacuum hoses, fuel lines and electrical wires from the throttle body and intake manifold.
9. Remove the brake booster vacuum hose bracket.
10. Remove the EGR valve-to-exhaust manifold tube and disconnect the vacuum line.
11. Remove the connector and vacuum line from the Engine Vacuum Regulator (EVR) solenoid.
12. Remove the four bolts and the throttle body adapter.
13. Remove the upper fan shroud mounting screws and position the shroud toward the engine.
14. Remove the generator and install the Modular Engine Support Bracket on the engine using the generator mounting holes.
15. Raise and safely support the vehicle.
16. Remove the lower engine mount-to-frame nuts.
17. Clean the area around the Turbine Shaft Speed (TSS) and Output Shaft Speed (OSS) sensors and remove them from the transmission. Plug the openings.
18. Lower the vehicle to the floor and raise the engine using a hoist attached to the support bracket.
19. Install an engine support fixture with a J hook to keep the engine raised, then remove the hoist.
20. Raise and safely support the vehicle.
21. Drain the engine oil and remove the bypass filter.
22. Remove the dual converter Y-pipe and the flywheel inspection cover.
23. Remove the driveshaft and the two transmission mounting nuts.
24. Raise the transmission assembly with a transmission jack. Be sure to support the transmission along the rails of the pan to avoid damage.
25. Remove the oil pan mounting bolts and partially lower the pan.
26. Remove the oil pump pick-up tube and screen assembly and allow it to drop into the pan.
27. Remove the oil pan towards the rear of the vehicle.

Oil pump pick-up tube and screen assembly—6.8L engine

Click to enlarge

To install:

WARNING
To prevent possible oil leaks, use only a plastic scraper to clean the oil pan mounting surface.

28. Clean the oil pan-to-engine mounting surface.
29. Place the oil pump pick-up tube and screen assembly in the oil pan, then position the pan and gasket near the engine.
30. Install the oil pump pick-up tube and screen assembly. Tighten the nut to 15-22 ft. lbs. (20-30 Nm) and the two bolts to 71-106 in lbs. (8-12 Nm).
31. Apply a bead of silicone sealant to the areas where the front cover and rear bearing cap meet the engine block.

To prevent leaks, tighten the oil pan bolts in the order shown—6.8L engine

Click to enlarge

32. Install the oil pan. Tighten the bolts in sequence using three steps as follows:
    - Step one—18 inch lbs. (2 Nm)
    - Step two—15 ft. lbs. (20 Nm)
    - Step three—tighten an additional 60°
33. Lower the transmission and install the two mounting nuts. Tighten the nuts to 60-80 ft. lbs. (81-108 Nm).
34. Install the driveshaft and the TSS and OSS sensors.
35. Install the flywheel cover and dual converter Y-pipe.
36. Install the oil bypass filter.
37. Lower the vehicle and remove the engine support fixture.
38. Install the engine mounting nuts. Tighten the nuts to 66 ft. lbs. (90 Nm).
39. Remove the modular engine support bracket and install the generator.
40. Install the fan shroud.
41. Use a new gasket and install the throttle body adapter. Tighten the bolts in two steps first to 71-88 in lbs. (8-10 Nm), then tighten them an additional 85-95°.
42. Connect the EVR solenoid harness and vacuum line.
43. Attach the vacuum line to the EGR valve.
44. Install the EGR valve-to-exhaust manifold tube. Tighten the fittings to 55 ft. lbs. (41 Nm).
45. Install the EGR transducer.
46. Install all remaining components in the reverse of the removal.

WARNING
Operating the engine without the proper amount and type of engine oil will result in severe engine damage.

47. Fill the engine with the proper amount and type of engine oil
48. Fill and bleed the cooling system.

#### 7.5L Engine

Relieve the fuel system pressure before starting any work that involves disconnecting the fuel lines. Refer to Fuel System .

1. Remove the hood.
2. Disconnect the battery ground cable.
3. Drain the cooling system.
4. Remove the air intake tube and air cleaner assembly.
5. Disconnect the throttle linkage at the throttle body.
6. Disconnect the power brake vacuum line at the manifold.
7. Disconnect the fuel lines at the fuel rail.
8. Disconnect the air tubes at the throttle body.
9. Remove the radiator.
10. Remove the power steering pump and position it out of the way without disconnecting the lines.
11. Remove the oil dipstick tube. On motor home chassis, remove the oil filler tube.
12. Remove the front engine mount through-bolts.
13. Position the air conditioner refrigerant hoses so they are clear of the firewall. If necessary, discharge the system and remove the compressor.
14. Remove the upper intake manifold and throttle body.
15. Drain the crankcase. Remove the oil filter.
16. Disconnect the exhaust pipe at the manifolds.
17. Disconnect the transmission linkage at the transmission.
18. Remove the driveshaft(s).
19. Remove the transmission fill tube.
20. Raise the engine with a jack placed under the crankshaft damper and a block of wood to act as a cushion. Raise the engine until the transmission contacts the underside of the floor. Place wood blocks under the engine supports. The engine must remain centralized at a point at least 4 in. (102mm) above the mounts, to remove the oil pan!
21. Remove the oil pan attaching screws and lower the oil pan onto the crossmember. Remove the two bolts attaching the oil pump pick-up tube to the oil pump. Lower the assembly from the oil pump. Leave it on the bottom of the oil pan. Remove the oil pan and gaskets. Remove the inlet tube and screen from the oil pan.

To install:

22. Clean the gasket surfaces of the oil pan and cylinder block.
23. Apply a coating of gasket adhesive on the block mating surface and stick the one-piece silicone gasket on the block.
24. Clean the inlet tube and screen assembly and place on the pump.
25. Position the oil pan against the cylinder block and install the retaining bolts. Tighten all bolts to 10 ft. lbs. (14 Nm).

Exploded view of the oil pan mounting—7.5L engine

Click to enlarge

26. Lower the engine and bolt it in place.
27. Install the transmission fill tube.
28. Install the driveshaft(s).
29. Attach the transmission linkage at the transmission.
30. Connect the exhaust pipe at the manifolds.
31. Install the oil filter.
32. Install the upper intake manifold and throttle body.
33. Install the compressor or reposition the hoses.
34. Install the oil dipstick tube. On motor home chassis, install the oil filler tube.
35. Install the power steering pump.
36. Install the radiator.
37. Connect the air tubes at the throttle body.
38. Connect the fuel lines at the fuel rail.
39. Connect the power brake vacuum line at the manifold.
40. Connect the throttle linkage at the throttle body.
41. Install the air intake tube and air cleaner assembly.
42. Fill and bleed the cooling system.
43. Fill the crankcase.
44. Connect the battery ground cable.
45. Install the hood.

#### 7.3L Diesel Engine

Remove the twelve oil pan retaining bolts and remove the oil pan from the engine

Click to enlarge

Apply a 1/8 in. (3mm) bead of RTV silicone sealant to the pan mating surfaces, and a 1/4 in. (6mm) bead on the front and rear covers and in the corners

Click to enlarge

1. Remove the engine.
2. Remove the oil pan bolts.
3. Lower the oil pan.

The oil pan is sealed to the crankcase with RTV silicone sealant in place of a gasket. It may be necessary to separate the pan from the crankcase with a utility knife. Also, the crankshaft may have to be turned to allow the pan to clear the crankshaft throws.

4. Clean the pan and crankcase mating surfaces thoroughly.

To install:

5. Apply a 1/8 in. (3mm) bead of RTV silicone sealant to the pan mating surfaces, and a 1/4 in. (6mm) bead on the front and rear covers and in the corners; you have 15 minutes within which to install the pan!
6. Install the locating dowels into position.
7. Position the pan on the engine and install the pan bolts loosely.
8. Remove the dowels.
9. Tighten the pan bolts to 7 ft. lbs. (10 Nm) for 1/4 in.-20 bolts; 14 ft. lbs. (19 Nm) for 5/16 in.-18 bolts; 24 ft. lbs. (33 Nm) for 3/8 in.-16 bolts.
10. Install the engine.

## Oil Pump

### REMOVAL & INSTALLATION

#### 4.2L Engine

1. Raise and support the front of the vehicle.
2. Drain the engine oil and dispose.
3. Remove the oil filter.
4. Remove the six oil pump bolts, then remove the oil pump drive gear, the oil pump driven gear, the oil pump O-ring and the oil pump itself. Discard the used oil pump O-ring.
5. Inspect the oil pump components for damage or excessive wear.
6. Check the oil pump face for warpage with a flat edge ruler. The face cannot exhibit more than 0.00157 in. (0.04mm) of distortion.
7. Remove the plug over the oil pressure relief; valve.
8. Remove the oil pressure relief valve ball and spring, then clean the parts.

To install:

Lubricate the parts with clean engine oil before assembly.

9. Assemble the oil pressure relief valve ball and spring with a new plug.

Tighten the oil pump mounting bolts to the specifications shown—4.2L engines

Click to enlarge

10. Install the oil pump, along with a new O-ring, the oil pump driven gear and the drive gear. Install and tighten the six oil pump mounting bolts to the torque value specifications indicated in the illustration.
11. Apply a film of clean engine oil to the rubber O-ring on the new filter, then install the filter onto the filter mount.
12. Install the oil pan drain plug.
13. Lower the vehicle.
14. Fill the engine with the correct amount and type of new engine oil.
15. Start the engine and make certain that the oil light on the instrument panel extinguishes within 6-8 seconds after the engine starts.

#### 4.6L and 5.4L Engines

1. Remove the timing chain.
2. Remove the oil pan.
3. Remove the three oil pump screen and cover bolts, then remove the screen and cover.
4. Remove the oil pump screen and cover spacer.
5. Remove the four oil pump mounting bolts, then remove the oil pump from the engine.

To install:

6. Clean and inspect the mating surfaces.
7. Install the oil pump and loosely install the four oil pump mounting bolts. Tighten the four oil pump bolts in the sequence shown to 71-106 inch lbs. (8-12 Nm).

Tighten the oil pump mounting bolts to 71-106 inch lbs. (8-12 Nm) in the sequence shown—4.6L and 5.4L engines

Click to enlarge

8. Install the oil pump screen and cover spacer to 15-22 ft. lbs. (20-30 Nm).
9. Install the oil pump screen and cover, then install the three oil pump screen and cover bolts. Tighten the bolts near the oil pick-up screen to 15-22 ft. lbs. (20-30 Nm) and the bolts at the opposite end of the pick-up to 70-106 inch lbs. (8-12 Nm).
10. Install the timing chains, then install the oil pan.

#### 5.8L and 7.5L Engines

1. Remove the oil pan.
2. Remove the oil pump inlet tube and screen assembly.
3. Remove the oil pump attaching bolts and remove the oil pump gasket and intermediate driveshaft.

To install:

4. Before installing the oil pump, prime it by filling the inlet and outlet port with oil and rotating the shaft of the pump to distribute it.
5. Position the intermediate driveshaft into the distributor socket.
6. Position the new gasket on the pump body and insert the intermediate driveshaft into the pump body.
7. Install the pump and intermediate driveshaft as an assembly. Do not force the pump if it does not seal readily. The driveshaft may be misaligned with the distributor shaft. To align it, rotate the intermediate driveshaft into a new position.
8. Install the oil pump attaching bolts and tighten them to 12-15 ft. lbs. (16-20 Nm) on the 4.9L engine and to 20-25 ft. lbs. (27-34 Nm) on the 5.8L and 7.5L engines.

Exploded view of the oil pump mounting—5.8L and 7.5L engines

Click to enlarge

#### 6.8L Engine

1. Disconnect the negative battery cable.
2. Remove the engine front cover and crankshaft sprocket.
3. Remove the oil pan.
4. Remove the three oil pump mounting bolts, then remove the oil pump from the engine.

To install:

5. Clean and inspect the mating surfaces.
6. Install the oil pump and loosely install the oil pump mounting bolts. Tighten the bolts in the sequence shown to 71-106 inch lbs. (8-12 Nm).

Be sure to tighten the oil pump mounting bolts in the sequence shown—6.8L engine

Click to enlarge

7. Install the oil pan.
8. Install the crankshaft sprocket and timing chains.
9. Install the front cover.

#### 7.3L Diesel Engine

The oil pump is mounted on the cylinder block with four bolts—diesel engine

Click to enlarge

1. Disconnect the negative battery cable.
2. Remove the radiator.
3. Remove the drive belt.
4. Remove the crankshaft damper.
5. Remove the oil pump retaining bolts.
6. Remove the oil pump housing and square cut O-ring.

To install:

7. Install the oil pump housing and tighten the bolts to 14 ft. lbs. (19 Nm).
8. Install the crankshaft damper.
9. Install the drive belt.
10. Install the radiator.
11. Connect the negative battery cable.

## Crankshaft Damper

### REMOVAL & INSTALLATION

#### Gasoline Engines Except Lightning

Remove the crankshaft damper retaining bolt and ...

... install a suitable puller onto the damper assembly

Tighten the puller forcing screw until the damper assembly releases from the crankshaft

1. Disconnect the negative battery cable.
2. Remove the fan shroud and engine fan.
3. Remove the drive belt(s).
4. On the 4.2L, 5.8L and 7.5L engines, the crankshaft pulley is removable from the damper. Remove the crankshaft pulley retaining bolts.
5. Remove the vibration damper/pulley retaining bolt from the center of the damper/pulley.
6. Using a suitable puller, remove the damper/pulley from the crankshaft.

To install:

7. Align the key slot of the pulley hub to the crankshaft key, then install the damper, tightening the retaining hardware to the following torque:

- On the 4.2L engine tighten to 103-117 ft. lbs. (140-160 Nm)
- On the 4.6L, 5.4L and 6.8L engines tighten to 66 ft. lbs. (90 Nm), then back off the bolt 90°, tighten to 35-39 ft. lbs. (47-53 Nm), then tighten an additional 85-95°.
- On the 5.8L and 7.5L engines tighten to 70-90 ft. lbs. (95-122 Nm)

8. If the pulley is separate, install the pulley and tighten the pulley retaining bolts to the following torque:

- On the 4.2L engine tighten to 20-28 ft. lbs. (26-38 Nm)
- On the 5.8L and 7.5L engines tighten to 40-52 ft. lbs. (54-71 Nm)

9. Install the drive belt.
10. Install the fan and fan shroud.
11. Connect the negative battery cable.

#### 5.4L Lightning

Remove the supercharger pulley and brace assembly

Click to enlarge

Remove the supercharger pulley adapter

Click to enlarge

1. Disconnect the negative battery cable.
2. Remove the drive belt.
3. Raise and safely support the vehicle securely on jackstands.
4. Remove the nuts and position the under vehicle shield aside.
5. Remove the two nuts and one bolt.
6. Remove the starter motor.
7. Install Crankshaft Damper Remover T58P-6316-D or equivalent onto the crankshaft pulley.

The auxiliary supercharger pulley has left-hand threads.

8. Remove the pulley and brace assembly.
9. Remove the supercharger pulley adapter.
10. Remove the bolt.
11. Using the special tool, remove the crankshaft pulley.

To install:

The crankshaft pulley must be installed within four minutes after applying the silicone.

12. Apply silicone sealant to the woodruff key slot on the crankshaft pulley.
13. Using the special tool, install the crankshaft pulley.
14. Install the bolt and washer. Tighten the bolt in four stages.
    1. Stage 1: tighten to 66 ft. lbs. (90 Nm).
    2. Stage 2: loosen the bolt.
    3. Stage 3: tighten to 34-39 ft. lbs. (47-53 Nm).
    4. Stage 4: tighten an additional 85-90 degrees.
15. Install the supercharger pulley adapter.

Coat the threads of the supercharger pulley with High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A.

The auxiliary supercharger pulley has left-hand threads.

16. Install the pulley and brace assembly.
17. Remove the special tool.
18. Install the starter motor.
19. Position the transmission cooler line clip and install the two nuts and one bolt.
20. Position the shield and install the nut.
21. Lower the vehicle.
22. Install the drive belt.
23. Connect the negative battery cable.

#### 7.3L Diesel Engine

Remove the diesel engine vibration damper as illustrated (Ford Special tools shown)

Click to enlarge

Special tools used in the removal of the crankshaft damper wear ring—7.3L diesel engine

Click to enlarge

Special tools used in the installation of the crankshaft damper wear ring—7.3L diesel engine

Click to enlarge

1. Disconnect the negative battery cable.
2. Drain the cooling system.
3. Remove the radiator as outlined in this Section.
4. Raise the vehicle and safely support it with jackstands.
5. Remove the flywheel housing cover.
6. Install a suitable flywheel holding tool onto the flywheel.
7. Remove the crankshaft pulley bolt and washer.
8. Remove the crankshaft vibration damper using a suitable puller.
9. Remove the crankshaft damper wear ring by assembling Step Plate Adapter D80L-630-A, Damper Wear Ring Remover T94T-6379-AH1, Bearing Collet Sleeve T77F-7025-C, Remover Tube T77J-7025-B and Forcing Screw T84T-7025-B, or their equivalents to the crankshaft damper. Tighten the forcing screw until the damper wear ring is pulled free from the hub (see illustration).

To install:

10. Assemble Driver Handle T80T-4000-W to Damper Wear Ring Replacer T94T-6379-AH2. Insert the crankshaft damper wear ring into the Damper Wear Ring Replacer T94T-6379-AH2 and position the tool assembly onto the vibration damper.
11. Use a ball peen hammer to seat the wear ring into the hub. Use Loctite® 271, or equivalent to the inside diameter of the wear sleeve to prevent oil from travelling through.
12. Install a new crankshaft front seal.
13. Apply RTV sealant to the damper key-way, then drive on the damper using a suitable installation tool set.
14. Install the crankshaft pulley bolt and washer.
15. tighten the crankshaft pulley bolt to 212 ft. lbs. (287 Nm).
16. Remove the flywheel holding tool and install the flywheel housing cover.
17. Lower the vehicle.
18. Install the radiator, the fan and clutch and fan shroud assembly.
19. Refill and bleed the cooling system.
20. Connect the negative battery cable.

## Front Cover Seal

### REMOVAL AND INSTALLATION

#### 4.2L Engine

Install the seal into the engine using the necessary tools

Click to enlarge

1. Disconnect the negative battery cable.
2. Remove the accessory drive belt.
3. Remove the fan blade assembly.

Match mark the crankshaft pulley to damper positioning for installation reference.

4. Remove 4 crankshaft pulley retaining bolts from the crankshaft damper and remove the pulley.
5. Remove the crankshaft damper retaining bolt and washer and remove the damper with Damper Remover T58P-6316-D and Adapter T82L-6316-B, or equivalents.
6. Remove the front cover oil seal using special tool T92C-6700-CH or equivalent.

To install:

7. Clean and inspect the front cover seal recess and damper.
8. Apply clean engine oil to the front cover oil seal lip.
9. Install the front cover oil seal using Seal Replacer T94P-6701-AH, Aligner T88T-6701-A (aligner) and Adapter T82L-6316-B or equivalents.
10. Apply a bead of silicone sealer to the crankshaft key-way. Line up the damper key-way with the key on the crankshaft and push the damper onto the crankshaft. Install the bolt and washer and tighten to 103-117 ft. lbs. (140-160 Nm).
11. Install the crankshaft pulley, aligning the match marks made during removal. Install 4 retaining bolts and tighten to 20-28 ft. lbs. (26-38 Nm).
12. Install the fan blade assembly.
13. Install the accessory drive belt.
14. Connect the negative battery cable.
15. Start the engine and check for oil leaks.
16. Road test the vehicle and check for proper engine operation.

#### 4.6L, 5.4L and 6.8L Engines Except 5.4L Lightning

The front crankshaft seal is located in the cover—4.6L, 5.4L and 6.8L engines

Remove the seal from the cover using a suitable seal puller by carefully prying on the seal to ...

... remove the seal from the cover

1. Disconnect the negative battery cable.
2. Remove the engine cooling fan and fan shroud.
3. Release the drive belt tensioner and remove the accessory drive belt.
4. Remove the crankshaft pulley retaining bolt.
5. Remove the crankshaft pulley using Crankshaft Damper Remover T58P-6316-D, or equivalent.
6. Remove the front cover oil seal using a suitable seal remover.

To install:

7. Clean the engine front cover seal bore, then lubricate the seal bore and the seal lip with clean engine oil.
8. Install the new front cover oil seal using Seal Installer T88T-6701-A, or equivalent. Make sure the seal is installed evenly and straight.
9. Install the crankshaft pulley using Crankshaft Damper Replacer T74P-6316-B, or equivalent.
10. Apply a suitable silicone sealer to the outer end of the crankshaft damper key-way.
11. Install the crankshaft pulley retaining bolt.
12. Tighten the bolt in 4 steps as follows:

- Tighten the bolt to 88 ft. lbs. (120 Nm)
- Loosen the bolt 1 full turn
- Tighten the bolt to 34-39 ft. lbs. (47-53 Nm)
- Rotate the bolt an additional 85-95 degrees

13. Release the drive belt tensioner and install the accessory drive belt.
14. Install the engine cooling fan and shroud assembly.
15. Check the engine oil level.
16. Connect the negative battery cable.
17. Start the engine and check for leaks.
18. Road test the vehicle and check for proper engine operation.

#### 5.4L Lightning

1. Disconnect the negative battery cable.
2. Remove the drive belt.
3. Raise and safely support the vehicle securely on jackstands.
4. Remove the nuts and position the under vehicle shield aside.
5. Remove the two nuts and one bolt.
6. Remove the starter motor.
7. Install Crankshaft Damper Remover T58P-6316-D or equivalent onto the crankshaft pulley.

The auxiliary supercharger pulley has left-hand threads.

8. Remove the pulley and brace assembly.
9. Remove the supercharger pulley adapter.
10. Remove the bolt.
11. Using the special tool, remove the crankshaft pulley.
12. Remove the front cover oil seal using Front Cover Seal Remover T74P-6700-A, or equivalent.

To install:

13. Clean the engine front cover seal bore, then lubricate the seal bore and the seal lip with clean engine oil.
14. Install the new front cover oil seal using Seal Installer T88T-6701-A, or equivalent. Make sure the seal is installed evenly and straight.

The crankshaft pulley must be installed within four minutes after applying the silicone.

15. Apply silicone sealant to the woodruff key slot on the crankshaft pulley.
16. Using the special tool, install the crankshaft pulley.
17. Install the bolt and washer. Tighten the bolt in four stages.
    1. Stage 1: tighten to 66 ft. lbs. (90 Nm).
    2. Stage 2: loosen the bolt.
    3. Stage 3: tighten to 34-39 ft. lbs. (47-53 Nm).
    4. Stage 4: tighten an additional 85-90 degrees.
18. Install the supercharger pulley adapter.

Coat the threads of the supercharger pulley with High Temperature Nickel Anti-Seize Lubricant F6AZ-9L494-AA or equivalent meeting Ford specification ESE-M12A4-A.

The auxiliary supercharger pulley has left-hand threads.

19. Install the pulley and brace assembly.
20. Remove the special tool.
21. Install the starter motor.
22. Position the transmission cooler line clip and install the two nuts and one bolt.
23. Position the shield and install the nut.
24. Lower the vehicle.
25. Install the drive belt.
26. Connect the negative battery cable.

#### 5.8L and 7.5L Engines

Installing the oil seal into the 7.5L engine front cover. The tool makes it easier to drive in the seal evenly

Click to enlarge

Aligning the front cover on the 7.5L engine

Click to enlarge

1. Remove the fan shroud, radiator fan, spacer, pulley and drive belts.
2. Remove the crankshaft pulley from the crankshaft damper. Remove the damper attaching bolt and washer and remove the damper with a puller.
3. Remove the front cover seal using special tool T70P-6B070-B or equivalent. Tighten the two long bolts to force the tool under the seal flange, then tighten the four corner bolts to force the tool away from the cover.

To install:

4. Apply Lubriplate® or equivalent to the oil seal lip and fit the seal into place. Install special tool T70P-6B070-A or an equivalent seal installation tool and carefully press the new seal into place.
5. Apply Lubriplate® or equivalent to the crankshaft vibration damper to the to prevent damage to the seal. Coat the front of the crankshaft with engine oil for damper installation.
6. Line up the damper key-way with the key on the crankshaft and push the damper onto the crankshaft. Install the bolt and washer and tighten to 80 ft. lbs. Install the crankshaft pulley.
7. Install the fan, spacer, pulley and drive belts.
8. Install the fan shroud to the radiator.

## Timing Chain, Sprockets and Front Cover

### REMOVAL & INSTALLATION

#### 4.2L Engine

1. Disconnect the negative battery cable.
2. Remove the accessory drive belt.
3. Drain the coolant into a suitable clean container.
4. Remove the radiator, fan blade assembly and fan shroud.
5. Remove the water pump.
6. Remove the EGR valve vacuum hose.
7. Remove the EGR tube upper fitting.
8. Remove the EGR valve and adapter assembly.
9. Detach the wiring harness from the heater water outlet tube.
10. Remove the heater water outlet bolt and position the outlet tube aside.
11. Remove the Camshaft Position (CMP) sensor electrical harness connector and mark the position of the connector for proper installation.

After removing the CMP drive gear, be sure the timing marks (A) and key-ways (B) are aligned—4.2L engine

Click to enlarge

Compress the tensioner assembly and install a pin into the hole in the tensioner body

Click to enlarge

Turn the balance shaft so that the timing mark (B) on the gear(A) is in alignment

Click to enlarge

After the timing chains are installed, remove the retaining pin from the tensioner

Click to enlarge

12. Rotate the crankshaft until the TDC timing mark lines up with the timing mark.
13. Remove the two bolts retaining the CMP and remove the CMP from the camshaft synchronizer.
14. Remove the camshaft synchronizer adjustment bolt and remove the camshaft synchronizer.

The oil pump drive shaft may come out with the camshaft synchronizer.

15. Raise and safely support the vehicle.
16. Remove the oil pan drain plug and drain the engine oil in a suitable container.
17. Remove the crankshaft pulley and damper using appropriate tools.
18. Remove the engine oil pan.
19. Remove the two engine front cover stud bolts, front cover bolt and cap screw.
20. Slide the engine front cover and gasket off the dowels and discard the gasket.
21. Remove the CMP sensor drive gear bolt and remove the drive gear.
22. Be sure the timing marks and key-ways align.
23. Compress and install a retaining pin to hold the timing chain tensioner.
24. Slide both sprockets and timing chain forward and remove as an assembly.
25. Remove the three bolts retaining the timing chain tensioner and remove the tensioner.
26. Check the timing chain and sprockets for excessive wear. Replace if necessary.

To install:

27. Before installation, clean and inspect all parts. Clean the gasket material from the engine oil pan, cylinder block and engine front cover.
28. Place the timing chain tensioner in position and install the three retaining bolts. Tighten the bolts to 6-10 ft. lbs. (8-14 Nm).
29. Verify that the balance shaft timing gears are in correct alignment.
30. Slide both sprockets and the timing chain onto the camshaft and crankshaft with the timing marks aligned. Install the CMP sensor drive gear and bolt. Tighten the bolt to 30-36 ft. lbs. (40-50 Nm).
31. Remove the retaining pin.

Install the camshaft synchronizer (A) in the orientation shown (white arrow points to front of engine)—4.2L engines

Click to enlarge

32. Inspect the engine front cover seal for wear or damage and replace if necessary.
33. Install the engine front cover gasket and front cover onto the guide studs.
34. Install the two engine front cover stud bolts, front cover bolt and cap screw. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
35. Install the engine oil pan.
36. Install the crankshaft damper and pulley.

WARNING
A Synchro Positioning Tool must be used prior to installation. Failure to using this procedure will result in the fuel system being out of time, possibly causing engine damage.

37. Install Synchro Positioning Tool T89P-12200-A or equivalent, on the camshaft synchronizer by rotating the tool until it engages the notch in the housing.
38. Install the camshaft synchronizer housing assembly so that the arrow on the tool is 54 degrees from the centerline of the engine.
39. Install the adjustment bolt and tighten to 15-22 ft. lbs. (21-30 Nm).
40. Remove the tool and position the CMP sensor. Install the 2 bolts and 40-70 inch lbs. (5-8 Nm) and install the CMP electrical harness connector.
41. Install the water pump.
42. Install the fan shroud, fan blade assembly and radiator.
43. Install the accessory drive belt.
44. Fill the crankcase with the correct amount and type of engine oil.
45. Fill and bleed the engine cooling system.
46. Connect the negative battery cable.
47. Start the engine and check for coolant and oil leaks.
48. Road test the vehicle and check for proper engine operation.

#### 4.6L Engine

Remove the driver's side ignition coil bracket bolts

Remove the passenger side ignition coil bracket bolts along with the belt tensioner retaining bolts and the idler pulley retaining bolt

Click to enlarge

Remove the power steering pump mounting bolts and position the pump to the side

Remove the four front oil pan-to-timing cover retaining bolts

Once the necessary components are removed, the timing cover bolts are accessible, remove the bolts and ...

... remove the cover from the engine

Install the camshaft holding tool

Click to enlarge

Remove the crankshaft position sensor trigger wheel from the crankshaft

Remove the timing chain tensioner retaining bolts and ...

... remove the tensioner from the engine

Remove the tensioner arm from the engine

Remove the timing chain from around the camshaft pulley

When removing the timing chains, rotate the crankshaft so that the camshaft key-ways are positioned as shown—4.6L engines

Click to enlarge

Remove the timing chain guide retaining bolts and remove the guides from the engine

Place the tensioner into a bench vise or other suitable device and retract the plunger

Using a small screwdriver or other suitable tool, push back and hold the ratchet mechanism

While holding the ratchet mechanism, push the ratchet arm back into the tensioner assembly

After the ratchet mechanism is retracted, place a paper clip or other suitable tool into the hole in the tensioner body to hold the ratchet arm and plunger during installation

Place the tensioner assembly onto the engine and tighten the retaining bolts

Remove the paper clip from the tensioner assembly

1. Disconnect the negative battery cable.
2. Remove the radiator, fan blade and fan shroud assembly.
3. Remove the accessory drive belt.
4. Remove the water pump pulley.
5. Detach the electrical harness connectors from both ignition coils.
6. Remove both ignition coils with their brackets attached.
7. Remove the left-hand and right-hand cylinder head covers.
8. Raise and safely support the vehicle.
9. Remove the two upper power steering pump retaining bolts.
10. Remove the two lower power steering pump retaining bolts and move the pump aside.
11. Detach the Crankshaft Position (CKP) sensor electrical harness connector. Remove the retaining bolt and remove the CKP sensor.
12. Drain the engine oil into a suitable container.
13. Remove the four oil pan-to-engine front cover retaining bolts.
14. Lower the vehicle.
15. Remove the crankshaft damper retaining bolt and washer from the crankshaft.
16. Install Crankshaft Damper Remover T58P-6316-D or equivalent and pull the damper from the crankshaft.
17. Remove the Camshaft Position (CMP) sensor retaining bolt and remove the CMP sensor.
18. Remove the idler pulley bolt and remove the pulley.
19. Remove the three belt tensioner retaining bolts and remove the tensioner.
20. Remove the eight engine front cover retaining bolts and the seven nuts. Swing the top of the cover out off the dowel pins and remove the cover.
21. Remove the sensor ring from the crankshaft.
22. Use Camshaft Positioning Tool T91P-6256-A and Camshaft Positioning Adapters T92P-6256-A or equivalents, to position the camshaft.
23. Rotate the crankshaft until both camshaft key-ways are 90 degrees from the cam cover surface. Be sure the copper links line up with the dots on the camshaft sprockets.

WARNING
At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or the camshaft be rotated. Severe piston and valve damage will occur.

24. Remove the two left-hand and right-hand tensioner bolts and remove the timing chain tensioners.
25. Slide the left-hand and right-hand tensioner guides off the dowel pins.
26. Remove the right-hand timing chain from the camshaft sprocket.
27. Remove the left-hand timing chain from the camshaft sprocket.
28. Remove the left-hand and right-hand timing chain guide bolts and remove the timing chain guides.
29. If necessary, remove the camshaft gear bolt and remove the camshaft gear.

To install:

When installing the timing chains, make certain that the copper colored links (A) are aligned with the timing marks—4.6L engine

Click to enlarge

Tighten the first five front cover fasteners in the sequence shown—4.6L engine

Click to enlarge

Continue tightening the remaining fasteners in the sequence shown here—4.6L engine

Click to enlarge

30. Examine the timing chains, looking for the copper links. If the copper links are not visible, lay the chain on a flat surface and pull the chain taught until the opposite sides of the chain contact one another. Mark the links at each end of the chain and use these marks in place of the copper links.

If the engine jumped time, damage has been done to valves and possibly pistons and/or connecting rods. Any damage must be corrected before installing the timing chains.

31. If removed, install the camshaft gears and tighten the retaining bolt to 81-95 ft. lbs. (110-130 Nm).
32. Install the left-hand and right-hand timing chain guides and retaining bolts. Tighten the retaining bolts to 71-106 inch lbs. (8-12 Nm).
33. If removed, install the left-hand crankshaft sprocket with the tapered part of the sprocket facing away from the engine block.

The crankshaft sprockets are identical. They may only be installed one way, with the tapered part of the sprockets facing each other. Ensure that the key-way and timing marks on the crankshaft sprockets are aligned.

34. Install the left-hand timing chain on the camshaft and crankshaft sprockets. Be sure the copper links of the timing chain line up with the timing marks on both sprockets.
35. If removed, install the right-hand crankshaft sprocket with the tapered part of the sprocket facing the left-hand crankshaft sprocket.
36. Install the right-hand timing chain on the camshaft and crankshaft sprockets. Be sure the copper links of the timing chain line up with the timing marks on both sprockets.
37. It is necessary to bleed the timing chain tensioners before installation. Proceed as follows:
    1. Place the timing chain tensioner in a soft-jawed vise.
    2. Using a small pick or similar tool, hold the ratchet lock mechanism away from the ratchet stem and slowly compress the tensioner plunger by rotating the vise handle.

WARNING
The tensioner must be compressed slowly or damage to the internal seals will result.

3. Once the tensioner plunger bottoms in the tensioner bore, continue to hold the ratchet lock mechanism and push down on the ratchet stem until flush with the tensioner face.
4. While holding the ratchet stem flush to the tensioner face, release the ratchet lock mechanism and install a paper clip or similar tool in the tensioner body to lock the tensioner in the collapsed position.
5. The paper clip must not be removed until the timing chain, tensioner, tensioner arm and timing chain guide are completely installed on the engine.

38. Install the left-hand and right-hand timing chain tensioner guides on the dowel pins.
39. Place the left-hand and right-hand timing chain tensioners in position and install the retaining bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
40. Remove the retaining pins from the timing chain tensioners.
41. Remove Camshaft Positioning Tool T91P-6256-A and Camshaft Positioning Adapters T92P-6256-A or equivalents. from the camshaft.
42. Install the crankshaft sensor ring on the crankshaft.
43. Apply a bead of silicone sealer along the cylinder head-to-cylinder block and the oil pan-to-cylinder block sealing surfaces.
44. Install the engine front cover carefully onto the dowel pins.
45. Tighten the engine front cover bolts, in sequence, to 15-22 ft. lbs. (20-30 Nm).
46. Place the idler pulley in position and install the retaining bolt. Tighten the bolt to 15-22 ft. lbs. (20-30 Nm).
47. Install the drive belt tensioner and the three retaining bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
48. Install the CMP sensor and the retaining bolt. Tighten the bolt to 106 inch lbs. (12 Nm).
49. Place the damper on the crankshaft. Ensure the crankshaft key and key-way are aligned.
50. Using Crankshaft Damper Replacer T74P-6316-B or equivalent, install the crankshaft damper.
51. Raise and safely support the vehicle.
52. Install the four oil pan-to-engine front cover bolts and tighten, in sequence, in 2 steps:
    1. Tighten the bolts to 15 ft. lbs. (20 Nm).
    2. Rotate the bolts an additional 60 degrees.
53. Install the CKP sensor and the retaining bolt. Tighten the bolt to 106 inch lbs. (12 Nm). Connect the CKP sensor electrical harness connector.
54. Install the power steering pump and the two upper and two lower retaining bolts. Tighten the bolts to 15-20 ft. lbs. (20-30 Nm).
55. Lower the vehicle.
56. Place the ignition coil and brackets on the engine front cover and install the bracket bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
57. Connect the ignition coil and capacitor electrical harness connectors.
58. Connect the CMP electrical harness connector.
59. Install the water pump pulley and tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
60. Install the radiator, fan blade and fan shroud assembly.
61. Install the accessory drive belt.
62. Connect the negative battery cable.
63. Start the engine and check for leaks.
64. Road test the vehicle and check for proper engine operation.

#### 5.4L and 6.8L Engines

1. Disconnect the negative battery cable.
2. Remove the radiator, fan blade and fan shroud assembly.
3. Remove the accessory drive belt.
4. Remove the water pump pulley.
5. Detach the electrical harness connectors from both ignition coils.
6. Remove both ignition coils with their brackets attached.
7. Raise and safely support the vehicle.
8. Remove the two upper power steering pump retaining bolts.
9. Remove the two lower power steering pump retaining bolts and move the pump aside.
10. Detach the Crankshaft Position (CKP) sensor electrical harness connector. Remove the retaining bolt and remove the CKP sensor.

Timing chains and related components—5.4L and 6.8L engines

Click to enlarge

11. Drain the engine oil into a suitable container.
12. Remove the four oil pan-to-engine front cover retaining bolts.
13. Lower the vehicle.
14. Remove the crankshaft damper retaining bolt and washer from the crankshaft.
15. Install Crankshaft Damper Remover T58P-6316-D or equivalent and pull the damper from the crankshaft.
16. Remove the Camshaft Position (CMP) sensor retaining bolt and remove the CMP sensor.
17. Remove the idler pulley bolt and remove the pulley.
18. Remove the three belt tensioner bolts and remove the tensioner.
19. Remove the eight engine front cover retaining bolts and the seven nuts. Swing the top of the cover out off the dowel pins and remove the cover.
20. Remove the sensor ring from the crankshaft.
21. Use Camshaft Positioning Tool T96T-6256-A or equivalent, to position the camshaft.
22. Rotate the crankshaft until both camshaft key-ways are 90 degrees from the cam cover surface. Be sure the copper links line up with the dots on the camshaft sprockets.

WARNING
At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or the camshaft be rotated. Severe piston and valve damage will occur.

23. Install Camshaft Holding Tool T96T-6256-B or equivalent, on the camshaft.
24. Remove 2 left-hand and right-hand tensioner bolts and remove the timing chain tensioners.
25. Slide the left-hand and right-hand tensioner guides off the dowel pins.
26. Remove the right-hand timing chain from the camshaft sprocket.
27. Remove the left-hand timing chain from the camshaft sprocket.
28. Remove the left-hand and right-hand timing chain guide bolts and remove the timing chain guides.

To install:

29. Examine the timing chains, looking for the copper links. If the copper links are not visible, lay the chain on a flat surface and pull the chain taught until the opposite sides of the chain contact one another. Mark the links at each end of the chain and use these marks in place of the copper links.

If the copper links are not visible, mark one link on one end of the chain and two links on the opposite end of the chain—5.4L and 6.8L engines

Click to enlarge

If the engine jumped time, damage has been done to valves and possibly pistons and/or connecting rods. Any damage must be corrected before installing the timing chains.

30. Install the left-hand and right-hand timing chain guides and retaining bolts. Tighten the retaining bolts to 71-106 inch lbs. (8-12 Nm).
31. If removed, install the left-hand crankshaft sprocket with the tapered part of the sprocket facing away from the engine block.

The crankshaft sprockets are identical. They may only be installed one way, with the tapered part of the sprockets facing each other. Ensure that the key-way and timing marks on the crankshaft sprockets are aligned.

32. Install the left-hand timing chain on the camshaft and crankshaft sprockets. Be sure the one copper link aligns with the mark on the crankshaft sprocket and the two copper links align with the mark on the camshaft sprocket.
33. Install the right-hand crankshaft sprocket with the tapered part of the sprocket facing the left-hand crankshaft sprocket.
34. Install the right-hand timing chain on the camshaft and crankshaft sprockets. Be sure the copper links of the timing chain line up with the timing marks on both sprockets.
35. It is necessary to bleed the timing chain tensioners before installation. Proceed as follows:
    1. Place the timing chain tensioner in a soft-jawed vise.
    2. Using a small pick or similar tool, hold the ratchet lock mechanism away from the ratchet stem and slowly compress the tensioner plunger by rotating the vise handle.

WARNING
The tensioner must be compressed slowly or damage to the internal seals will result.

3. Once the tensioner plunger bottoms in the tensioner bore, continue to hold the ratchet lock mechanism and push down on the ratchet stem until flush with the tensioner face.
4. While holding the ratchet stem flush to the tensioner face, release the ratchet lock mechanism and install a paper clip or similar tool in the tensioner body to lock the tensioner in the collapsed position.
5. The paper clip must not be removed until the timing chain, tensioner, tensioner arm and timing chain guide are completely installed on the engine.

36. Install the left-hand and right-hand timing chain tensioner guides on the dowel pins.
37. Place the left-hand and right-hand timing chain tensioners in position and install the retaining bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
38. Remove the retaining pins from the timing chain tensioners.
39. Remove Cam Holding Tool T96T-6256-B or equivalent, from the camshaft.
40. Install the crankshaft sensor ring on the crankshaft.
41. Apply silicone gasket along the cylinder head-to-cylinder block and engine oil pan-to-cylinder block sealing surfaces.
42. Install the engine front cover carefully onto the dowel pins.
43. Tighten the engine front cover bolts, in sequence, in the following manner:
    1. Tighten bolts 1 through 5 to 15-22 ft. lbs. (20-30 Nm).
    2. Tighten bolts 6 through 15 to 29-40 ft. lbs. (40-55 Nm).
44. Place the idler pulley in position and install the retaining bolt. Tighten the bolt to 15-22 ft. lbs. (20-30 Nm).
45. Place the drive belt tensioner in position and install 3 retaining bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
46. Place the CMP sensor in position and install the retaining bolt. Tighten the bolt to 106 inch lbs. (12 Nm).
47. Install the damper on the crankshaft. Ensure the crankshaft key and key-way are aligned.
48. Using Crankshaft Damper Replacer T74P-6316-B or equivalent, install the crankshaft damper.
49. Raise and safely support the vehicle.
50. Install 4 front oil pan-to-engine front cover retaining bolts and tighten in sequence in 2 steps:
    1. Tighten the bolts to 15 ft. lbs. (20 Nm).
    2. Rotate the bolts an additional 60 degrees.
51. Place the CKP sensor in position and install the retaining bolt. Tighten the bolt to 106 inch lbs. (12 Nm).
52. Connect the CKP sensor electrical harness connector.
53. Install the power steering pump with 2 upper and 2 lower retaining bolts. Tighten the bolts to 15-20 ft. lbs. (20-30 Nm).
54. Lower the vehicle.
55. Place the ignition coil and brackets on the engine front cover and install the bracket bolts. Tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
56. Connect the ignition coil and capacitor electrical harness connectors.
57. Connect the CMP electrical harness connector.
58. Install the water pump pulley and tighten the bolts to 15-22 ft. lbs. (20-30 Nm).
59. Install the radiator.
60. Connect the negative battery cable.
61. Start the engine and check for leaks.
62. Road test the vehicle and check for proper engine operation.

#### 5.8L Engine

1. Drain the cooling system and the crankcase.
2. Disconnect the upper and lower radiator hoses and the transmission oil cooler lines and remove the radiator.
3. Disconnect the heater hose from the water pump. Slide the water pump bypass hose clamp toward the water pump.
4. Loosen the alternator pivot bolt and the bolt which secures the alternator adjusting arm to the water pump. Position the alternator out of the way.
5. Remove the power steering pump and air conditioning compressor from their mounting brackets, if so equipped.
6. Remove the fan, spacer, pulley and drive belts.
7. Remove the crankshaft pulley from the crankshaft damper. Remove the damper attaching bolt and washer and remove the damper with a puller.
8. If equipped with a manual fuel pump, disconnect the fuel pump outlet line at the fuel pump. Disconnect the vacuum inlet and outlet lines from the fuel pump. Remove the fuel pump attaching bolts and lay the pump to one side with the fuel inlet line still attached.
9. If necessary, remove the oil level dipstick and the bolt holding the dipstick tube to the exhaust manifold.
10. Remove the oil pan-to-cylinder front cover attaching bolts. Use a sharp, thin cutting blade to cut the oil pan gasket flush with the cylinder block. Remove the front cover and water pump as an assembly.
11. Discard the front cover gasket. If necessary, properly support the cover and carefully drive the oil seal out towards the front of the cover.
12. Rotate the crankshaft counterclockwise to take up the slack on the left side of the chain.
13. Establish a reference point on the cylinder block and measure from this point to the chain.
14. Rotate the crankshaft in the opposite direction to take up the slack on the right side of the chain.
15. Force the left side of the chain out with your fingers and measure the distance between the reference point and the chain. The timing chain deflection is the difference between the two measurements. If the deflection exceeds 1/2 in. (13mm), replace the timing chain and sprockets.
16. Turn the crankshaft until the timing marks on the sprockets are aligned vertically.
17. Remove the camshaft sprocket retaining screw, if equipped, remove the fuel pump eccentric and washers.
18. Alternately slide both of the sprockets and timing chain off the crankshaft and camshaft until free of the engine.

To install:

19. Clean the front cover mating surfaces of all gasket material and/or sealer. If the front cover seal is being replaced, support the cover to prevent damage and drive out the seal. Coat the new seal with heavy SJ engine oil and install it in the cover, making sure it is not cocked.
20. Position the timing chain on the sprockets so that the timing marks on the sprockets are aligned vertically. Alternately slide the sprockets and chain onto the crankshaft and camshaft sprockets.
21. If equipped with a manual fuel pump, install the fuel pump eccentric washers and attaching bolt on the camshaft sprocket. Tighten to 40-45 ft. lbs.
22. Cut the new oil pan gasket as needed for a correct fit. Apply sealing compound to the oil pan and fit the gasket into place.
23. Apply sealing compound to the gasket surfaces on the cylinder block and back side of the front cover. Position the gasket onto the cylinder block and fit the front cover onto the engine.
24. Coat the screw threads with sealing compound and start all the screws. Center the cover by inserting an alignment tool (T74P-6019-a or equivalent) in the oil seal.
25. Tighten the oil pan screws first to 12-18 ft. lbs. (17-24 Nm), then tighten the front cover screws to the same torque.
26. Apply Lubriplate® or equivalent to the oil seal lip and to the vibration damper to prevent damage to the seal. Coat the front of the crankshaft with engine oil for damper installation.
27. Line up the damper key-way with the key on the crankshaft and push the damper onto the crankshaft. Install the bolt and washer and tighten to 80 ft. lbs. Install the crankshaft pulley.
28. Install the fan, spacer, pulley and drive belts.
29. Install the bolts holding the fan shroud to the radiator, if so equipped.
30. Install the power steering pump and air conditioning compressor.
31. Install the alternator and adjust the belt tension.
32. Connect the heater hose at the water pump.
33. Install the radiator.
34. Connect the upper and lower radiator hoses, and transmission oil cooler lines.
35. Fill the cooling system and the crankcase.

Align the marks when installing the timing chain—5.8L and 7.5L engines

Click to enlarge

#### 7.5L Engine

Align the timing marks on the pulleys

Click to enlarge

Alternately slide both of the sprockets and timing chain off the crankshaft and camshaft until free of the engine

Click to enlarge

1. Drain the cooling system and crankcase.
2. Remove the radiator shroud and fan.
3. Disconnect the upper and lower radiator hoses and the automatic transmission oil cooler lines from the radiator.
4. Remove the radiator upper support and remove the radiator.
5. Loosen the alternator attaching bolts and air conditioning compressor idler pulley and remove the drive belts with the water pump pulley. Remove the bolts attaching the compressor support to the water pump and remove the bracket (support), if equipped.
6. Remove the crankshaft pulley from the vibration damper. Remove the bolt and washer attaching the crankshaft damper and remove the damper with a puller. Remove the woodruff key from the crankshaft.
7. Loosen the bypass hose at the water pump and disconnect the heater return tube at the water pump.
8. Disconnect and plug the fuel inlet and outlet lines at the fuel pump and remove the fuel pump.
9. Remove the bolts attaching the front cover to the cylinder block. Cut the oil pan seal flush with the cylinder block face with a thin knife blade prior to separating the cover from the cylinder block. Remove the cover and water pump as an assembly. Discard the front cover gasket and oil pan seal.
10. Rotate the crankshaft counterclockwise to take up the slack on the left side of the chain.
11. Establish a reference point on the cylinder block and measure from this point to the chain.
12. Rotate the crankshaft in the opposite direction to take up the slack on the right side of the chain.
13. Force the left side of the chain out and measure the distance between the reference point and the chain. The timing chain deflection is the difference between the two measurements. If the deflection exceeds 1/2 in. (13mm), replace the timing chain and sprockets.
14. Turn the crankshaft until the timing marks on the sprockets are aligned vertically.
15. Remove the camshaft sprocket retaining screw and remove the fuel pump eccentric and washers.
16. Alternately slide both of the sprockets and timing chain off the crankshaft and camshaft until free of the engine.

To install:

17. Position the timing chain on the sprockets so the timing marks on the sprockets are aligned vertically. Alternately slide the sprockets and chain onto the crankshaft and camshaft sprockets.
18. Install the fuel pump eccentric washers and attaching bolt on the camshaft sprocket. Tighten to 40-45 ft. lbs. (54-61 Nm).
19. Transfer the water pump if a new cover is going to be installed. Clean all of the gasket sealing surfaces on both the front cover and the cylinder block.
20. Coat the gasket surface of the oil pan with sealer. Cut and position the required sections of a new seal on the oil pan. Apply sealer to the corners.
21. Drive out the old front cover oil seal with a pin punch. Clean out the seal recess in the cover. coat a new seal with Lubriplate® or equivalent grease. Install the seal, making sure the seal spring remains in the proper position. A front cover seal tool, Ford part no. T72J-117 or equivalent, makes installation easier.
22. Coat the gasket surfaces of the cylinder block and cover with sealer and position the new gasket on the block.
23. Position the front cover on the cylinder block. Use care not to damage the seal and gasket or misplace them.
24. Coat the front cover attaching screws with sealer and install them.

It may be necessary to force the front cover downward to compress the oil pan seal in order to install the front cover attaching bolts. Use a prybar or drift to engage the cover screw holes through the cover and pry downward.

25. Install the fuel pump.
26. Connect the fuel inlet and outlet lines at the fuel pump.
27. Tighten the bypass hose at the water pump.
28. Connect the heater return tube at the water pump.
29. Install the woodruff key from the crankshaft.
30. Install the damper.
31. Install the crankshaft pulley on the vibration damper.
32. Install the compressor support on the water pump and install the bracket (support), if equipped.
33. Install the drive belts with the water pump pulley.
34. Install the radiator and upper support.
35. Connect the upper and lower radiator hoses and the automatic transmission oil cooler lines.
36. Install the radiator shroud and fan.
37. Fill the cooling system and crankcase.

Tighten the fasteners to the following specifications:

- Front cover bolts: 15-20 ft. lbs. (20-27 Nm)
- Water pump attaching screws: 12-15 ft. lbs. (16-20 Nm)
- Crankshaft damper: 70-90 ft. lbs. (95-122 Nm)
- Crankshaft pulley: 35-50 ft. lbs. (47-68 Nm)
- Fuel pump: 19-27 ft. lbs. (26-37 Nm)
- Oil pan bolts: 9-11 ft. lbs. (12.2-15.0 Nm) for the 5/16 in. (7.9mm) screws and to 7-9 ft. lbs. (9.5-12.2 Nm) for the 1/4 in. (6.3mm) screws
- Alternator pivot bolt: 45-57 ft. lbs. (61-77 Nm)

## Timing Gears and Front Cover

### REMOVAL & INSTALLATION

#### 7.3L Diesel Engine

1. Disconnect the negative battery cable.
2. Remove the engine.
3. Remove the water pump.
4. Remove the crankshaft damper.
5. Remove the oil pan.
6. Remove the four front cover retaining bolts.
7. Remove the front cover from the engine.

The crankshaft gear sprocket is not serviced separately from the crankshaft. Do not try to remove the sprocket or you will damage the crankshaft. To replace the crankshaft sprocket crankshaft replacement is necessary.

Remove the camshaft sprocket as follows:

8. Remove the camshaft.
9. Use a press to remove the sprocket from the camshaft.

The camshaft gear is removed with the camshaft, then pressed off—7.3L diesel engine

Click to enlarge

10. Remove the thrust plate and sprocket key.
11. Inspect the camshaft and related parts for wear and damage.

To install:

12. Clean the nose of the camshaft and install the thrust plate.
13. Place the key in the key-way on the camshaft.
14. Heat the sprocket in an oven to 500° F (260° C).
15. Remove the sprocket from the oven, align the sprocket key-way with the camshaft key and install the sprocket on the camshaft until it is fully seated. Allow the camshaft assembly to cool before installation
16. Install the camshaft in the engine and align the timing marks on the gears.

Be sure the timing marks are aligned as illustrated—Diesel engines

Click to enlarge

17. Install new gaskets onto the engine front cover and apply silicone sealant into the sealing grooves on the front cover.
18. Install the front cover onto the engine.
19. Install the four front cover retaining bolts and tighten the bolts to 15 ft. lbs. (20 Nm).
20. Install the oil pan.
21. Install the crankshaft damper.
22. Install the water pump.
23. Install the engine.
24. Connect the negative battery cable.

## Camshaft and Lifters

### REMOVAL & INSTALLATION

#### 4.2L Engine

1. Disconnect the negative battery cable.
2. Remove the lower intake manifold.
3. Remove the rocker arm cover.
4. Remove the rocker arm hold-down bolt, then remove the rocker arm from the cylinder head.
5. Remove the pushrods.
6. Remove the valve lifters by pulling them up out of their bores.
7. Remove the timing chain and sprockets.
8. Remove the camshaft key from the end of the camshaft, then slide the engine dynamic balance shaft drive gear off of the camshaft.
9. Remove the two camshaft thrust plate retaining bolts (1), then remove the thrust plate (2). Remove the camshaft spacer (3), then slide the camshaft (4) out of the front of the engine block. Be cautious not to gouge or scratch the camshaft bearing journals.

Exploded view of the camshaft retaining hardware—4.2L engine

Click to enlarge

To install:

10. Lubricate the camshaft with engine oil prior to installation.
11. Carefully slide the camshaft into the camshaft bore. Do not scratch the bearing surfaces.
12. Install the camshaft thrust plat with the spacer. Tighten the thrust plate mounting bolts to 6-10 ft. lbs. (8-14 Nm).
13. Slide the engine dynamic balance shaft drive gear onto the camshaft. Install the camshaft key to the camshaft groove.
14. Install the timing chain and sprockets.
15. Install the valve lifters, pushrods, intake manifolds and rocker arm covers.

#### 4.6L, 5.4L, and 6.8L Engines

1. Remove the cylinder head covers from the engine.
2. Remove the timing chain.

CAUTION
At no time, when the timing chains are removed and the cylinder heads are installed may the crankshaft or camshaft be rotated. Severe piston and valve damage will occur.

3. On the 6.8L engine, remove the six bolts securing the balance shaft to the cylinder head and remove the shaft.
4. Remove the camshaft roller lifters.
5. On VIN W engines, remove the timing chain camshaft gear by removing the gear retaining bolt.

Keep the bearing caps in order so they can be installed in the same position.

6. Remove the camshaft bearing cap bolts, then lift the camshaft bearing caps off of the cylinder head.
7. Lift the camshaft from the cylinder head.
8. Remove the rocker arms and pull the lash adjusters out of their bores. Keep all the parts in order. They must be installed in their original positions.

To install:

9. Install the lash adjusters and rocker arms in their original positions.
10. Lubricate the camshaft journals and bearing caps with super premium SAE 5W30 engine oil which meets Ford specifications WSS-M2C153-G. On the 6.8L engine, lubricate the balance shaft journals and bearing caps with the same lubricant.
11. Lower the camshaft onto the camshaft bearing journals.
12. Install the camshaft bearing caps, then loosely install the bearing cap bolts.

Tighten the bearing caps in the sequence shown—4.6L and 5.4L engines

Click to enlarge

Camshaft bearing cap bolt tightening sequence—6.8L engine

Click to enlarge

13. Tighten the camshaft bearing cap mounting bolts, in the sequence shown for the particular engine, to 71-107 inch lbs. (8-12 Nm).
14. On the 6.8L engine, align the timing marks and position the balance shaft on the journals, then install the bearing caps. Tighten the bolts in sequence to 71-106 in lbs. (8-12 Nm).

Be sure to align the balance shaft timing mark with the mark on the camshaft gear—6.8L engine

Click to enlarge

Tighten the balance shaft bearing cap bolts in the sequence shown—6.8L engine

Click to enlarge

15. On VIN W engines, install the camshaft timing chain gear by tightening the retaining bolt to 81-95 ft. lbs. (110-130 Nm).
16. Install the valve lifters.
17. Install the timing chain and sprockets, if applicable.
18. Install the cylinder head covers.

#### 5.8L and 7.5L Engines

1. Remove the intake manifold and valley pan, if equipped.
2. Remove the rocker covers, and loosen the rockers on their pivots and remove the pushrods. The pushrods must be reinstalled in their original positions.
3. Remove the valve lifters in sequence with a magnet. They must be replaced in their original positions.
4. Remove the timing gear cover, timing chain and sprockets.
5. In addition to the radiator and air conditioning condenser, if equipped, it may be necessary to remove the front grille assembly and the hook lock assembly to gain the necessary clearance to code the camshaft out of the front of the engine.

A camshaft removal tool, Ford part no. T65L-6250-a and adapter 14-0314 are needed to remove the Diesel camshaft.

Camshaft and related components—5.8L and 7.5L engines

Click to enlarge

To install:

6. Coat the camshaft liberally with clean engine oil before installing it. Slide the camshaft into the engine very carefully so as not to scratch the bearing bores with the camshaft lobes. Install the camshaft thrust plate and tighten the attaching screws to 9-12 ft. lbs. (12-16 Nm). Measure the camshaft end-play. If the end-play is more than 0.009 in. (0.228mm), replace the thrust plate. Assemble the remaining components in the reverse order of removal.
7. Install the radiator, front grille, hood lock assembly and air conditioning condenser, if removed.
8. Install the timing chain and front cover.
9. Install the valve lifters. They must be replaced in their original positions.
10. Install the pushrods, the rocker arms and the rocker arm covers.
11. Install the intake manifold and valley pan, if equipped.

#### 7.3L Diesel Engine

The camshaft gear is removed with the camshaft, then pressed off—7.3L diesel engine

Click to enlarge

Be sure the timing marks are aligned as illustrated—Diesel engines

Click to enlarge

Ford recommends removing the Diesel engine from the vehicle for camshaft removal.

1. Remove the valve covers, and either remove the rocker arm shafts or loosen the rockers on their pivots and remove the pushrods. The pushrods must be reinstalled in their original positions.
2. Remove the timing gear cover.
3. Remove the valve lifters in sequence with a magnet. They must be replaced in their original positions.
4. Rotate the crankshaft to align the camshaft sprocket timing marks.
5. Remove the camshaft thrust plate retaining bolts.
6. Remove the camshaft sprocket, thrust plate and camshaft as an assembly from the engine.

To install:

7. Inspect the camshaft as described in this section.
8. liberally coat the camshaft with oil before installing it. Slide the camshaft with the thrust plate and sprocket attached into the engine very carefully so as not to scratch the bearing bores with the camshaft lobes.
9. Tighten the camshaft thrust plate retaining bolts to 9-12 ft. lbs. (12-16 Nm). Measure the camshaft end-play. If the end-play is more than 0.009 in. (0.228mm), replace the thrust plate.
10. Install the valve lifters. They must be replaced in their original positions.
11. Install the timing gear cover.
12. Install the pushrods, the rocker arms and the rocker arm covers.
13. Install the engine.

### INSPECTION

Measuring camshaft lobe lift

Click to enlarge

Measuring camshaft run-out

Click to enlarge

Measuring camshaft straightness

Click to enlarge

Using solvent, degrease the camshaft and clean out all of the oil holes. Visually inspect the cam lobes and bearing journals for excessive wear. If a lobe is questionable, check all of the lobes as indicated. If a journal or lobe is worn, the camshaft MUST BE or replaced.

If a journal is worn, there is a good chance that the bearings or journals are worn and need replacement.

If the lobes and journals appear intact, place the front and rear journals in V-blocks and rest a dial indicator on the center journal. Rotate the camshaft to check the straightness. If deviation exceeds 0.001 in. (0.0254mm), replace the camshaft.

Check the camshaft lobes with a micrometer, by measuring the lobes from the nose to the base and again at 90° (see illustration). The lobe lift is determined by subtracting the second measurement from the first. If all of the exhaust and intake lobes are not identical, the camshaft must be reground or replace.

## Balance Shaft

### REMOVAL AND INSTALLATION

#### 4.2L Engine

Remove the balance shaft drive gear and spacer

Click to enlarge

Align the balance shaft timing marks

Click to enlarge

1. Disconnect the negative battery cable.
2. Drain and recycle the engine coolant.
3. Drain and recycle the engine oil.
4. Remove the engine oil pan.
5. Remove the engine front cover.
6. Remove the timing chain and sprockets.
7. Remove 2 bolts retaining the balance shaft thrust plate.

Use care not to damage the balance shaft bearing surfaces.

8. Carefully slide the balance shaft, driven gear and thrust plate out the front of the cylinder block.

To install:

9. Inspect the balance shaft rear bearing cover. If damaged or leaking, replace the balance shaft rear bearing cover. Inspect the balance shaft and bearings for signs of wear or damage and replace as necessary.
10. Lubricate the balance shaft journals with engine assembly lubricant.
11. Install the balance shaft, driven gear and thrust plate, being careful not to damage the bearing surfaces while sliding it into position. Install 2 thrust plate retaining bolts and tighten to 70-124 inch lbs. (8-14 Nm).
12. Install the balance shaft drive gear and spacer.
13. Align the balance shaft timing marks.
14. Install the timing chain and sprockets.
15. Install the engine front cover.
16. Install the engine oil pan.
17. Fill the crankcase with the proper grade and quantity of engine oil.
18. Fill and bleed the engine cooling system.
19. Connect the negative battery cable.
20. Start the engine and check for leaks.
21. Road test the vehicle and check for proper engine operation.

#### 6.8L Engine

Remove the bolts and the balance shaft bearing caps

Click to enlarge

Remove the balance shafts from the cylinder head

Click to enlarge

Align the balance shaft timing marks as shown

Click to enlarge

Tighten the balance shaft bearing caps in the sequence shown

Click to enlarge

1. Disconnect the negative battery cable.
2. Remove the engine air cleaner assembly.
3. Remove the radiator.
4. Remove the engine front cover.
5. Remove the crankshaft sensor ring from the crankshaft.
6. Remove the 6 bolts retaining the balance shaft bearing caps. Remove the bearing caps.
7. Remove the balance shaft.

To install

8. Lubricate the balance shaft journals with clean engine oil.
9. Install the balance shaft onto the journals. Align the balance shaft timing marks.
10. Install the bearing caps and tighten the bolts in the proper sequence. Torque the bolts to 71-106 inch lbs. (8-12 Nm).
11. Clean the front engine cover sealant off the engine. Allow to dry and apply a bead of silicone along the head-to-block surface. Apply a bead of silicone along the oil pan-to-block surface.
12. Install a new gasket and install the engine front cover.
13. Install the radiator.
14. Fill and bleed the cooling system.
15. Install the engine air cleaner.
16. Connect the negative battery cable.

## Rear Main Seal

### REMOVAL & INSTALLATION

#### 7.5L Engine

1. Raise and safely support the vehicle.
2. Remove the oil pan.
3. Loosen all the crankshaft main bearing cap bolts and lower the crankshaft no more than 1/32 in. (0.7938mm).

CAUTION
Be careful that the crankshaft sealing surfaces are not damaged in this process

4. Remove the rear main bearing cap and remove the seal. On the cylinder block half of the seal, use a seal removal tool, or install a small metal screw in one end of the seal and pull on the screw to remove the seal.

To install:

5. Clean the seal groove in the crankshaft main bearing cap and the block using a brush and a solvent such as metal surface cleaner F4AZ-19A536-RA or its equivalent.
6. Clean the areas where the sealer is to be applied later and dry the area thoroughly so that no solvent contacts the rear main seal.
7. Dip the seal halves in engine oil.

Rear main seal and related components—7.5L engines

Click to enlarge

CAUTION
Be sure no rubber has been removed from the outside diameter of the seal by the bottom edge of the groove. Do not allow oil to get on the sealer.

8. Install the upper half of the seal (cylinder block side) into its groove with the undercut side of the seal towards the front of the engine (with the tab side of the seal towards the rear face of the block), by rotating it on the seal journal until approximately 3/8 in. (9.525mm) protrudes below the parting surface.
9. Tighten all the crankshaft main bearing cap bolts, EXCEPT THE REAR MAIN BEARING, to 95-105 ft. lbs. (129-142 Nm).
10. Install the lower half of the seal in the rear crankshaft main bearing cap with the undercut side of the seal towards the front of the engine (with the tab side of the seal towards the rear face of the block), Allow the seal to protrude 3/8 in. (9.525mm) above the parting surface to mate with the upper half of the seal.
11. Apply a 1/16 in. (1.588mm) bead of gasket maker E2AZ-19562-B or its equivalent to the rear oil seal area of the block starting from the forward face of the return groove and overlaying the end of the wire seal retainer.

Do not allow the sealer to contact the inside diameter of the seal.

12. Install the rear main cap and tighten the bolts to 95-105 ft. lbs. (129-142 Nm).
13. Install the oil pan.

#### Gasoline Engines Except 7.5L Engine

If the crankshaft rear oil seal replacement is the only operation being performed, it can be done in the vehicle as detailed in the following procedure. If the oil seal is being replaced in conjunction with a rear main bearing replacement, the engine must be removed from the vehicle and installed on a work stand.

1. Remove the transmission from the vehicle. Refer to Section 7.
2. Remove the flywheel/flexplate. If equipped, remove the crankshaft oil slinger from the crankshaft.
3. Use an awl to punch two holes in the crankshaft rear oil seal. Punch the holes on opposite sides of the crankshaft and just above the bearing cap-to-cylinder block split line.
4. Install a sheet metal screw in each hole. Use two small prybars to pry against both screws at the same time to remove the crankshaft rear oil seal. It may be necessary to place small blocks of wood against the cylinder block to provide a fulcrum point for the prybars. Use caution throughout this procedure to avoid scratching or otherwise damaging the crankshaft oil seal surface.
5. Clean the oil seal recess in the cylinder block and main bearing cap.

To install:

6. Clean, inspect and polish the rear oil seal rubbing surface on the crankshaft.
7. Coat the new oil seal and the crankshaft with a light film of engine oil.

Rear main oil seal installation— 5.8L engine

Click to enlarge

8. Start the seal in the recess with the seal lip facing forward and install it with a seal driver. Keep the tool straight with the centerline of the crankshaft and install the seal until the tool contacts the cylinder block surface. Remove the tool and inspect the seal to be sure it was not damaged during installation.
9. If equipped, install the crankshaft oil slinger.
10. Position the flywheel on the crankshaft flange. Coat the threads of the flywheel attaching bolts with Locktite® and install the bolts. Tighten the bolts in sequence across from each other to 75-85 ft. lbs. (102-115 Nm).
11. Install the transmission. Refer to Section 7.

#### 7.3L Diesel Engine

1. Remove the transmission. Refer to Section 7.
2. Remove the flywheel.
3. Loosen the crankshaft rear oil seal bolts and remove the seal.
4. Clean the seal mating surfaces.
5. If installing the old seal, inspect it for damage.
6. Using crankshaft wear ring removal tool T94T-6701-AH1, forcing screw T84T-7025-B, remover tube T77J-7025-B and wear ring remover sleeve T94T-6701-AH2 (refer to the illustration), or their equivalents, remove the wear ring.

Assemble the seal and wear ring removal tools, then remove the wear ring—7.3L diesel engine

Click to enlarge

To install:

7. Apply silicone sealant D6AZ-19562-BA, or equivalent, to the seal retaining ring and the seal retaining bolts.
8. using seal replacers T94T-6701-AH3 and T94T-AH4, driver sleeve T79T-6316-A4 (part of T79T-6316-A) and guide pins T94P-7000-P or their equivalents, install the wear ring and oil seal.
9. Install and tighten the seal retaining bolts.
10. Remove the installation tools and install the flywheel.
11. Install the transmission. Refer to Section 7.

## Flywheel/Flexplate

### REMOVAL & INSTALLATION

#### All Engines

Check the flywheel run-out

Click to enlarge

The ring gear is replaceable only on engines mated with a manual transmission. Engines with automatic transmissions have ring gears which are welded to the flexplate.

1. Remove the transmission assembly. Refer to Section 7.
2. If equipped with a manual transmission, remove the clutch and pressure plate assembly. Refer to Section 7.
3. Loosen the flywheel bolts a little at a time in a cross pattern to avoid warping the flywheel.
4. Remove the flywheel from the engine.
5. On trucks with manual transmissions, replace the pilot bearing in the end of the crankshaft.
6. The flywheel should be checked for cracks and glazing. It can be resurfaced by a machine shop.
7. If the ring gear is to be replaced, drill a hole in the gear between two teeth, being careful not to contact the flywheel surface. Using a cold chisel at this point, crack the ring gear and remove it.
8. Polish the inner surface of the new ring gear and heat it in an oven to about 600°F (316°C). Quickly place the ring gear on the flywheel and tap it into place, making sure that it is fully seated.

WARNING
Never heat the ring gear past 800°F (426°C), or the tempering will be destroyed.

To install:

9. Position the flywheel on the end of the crankshaft. Tighten the bolts a little at a time, in a cross pattern, to the following torque:

- 4.2L Engine 54-64 ft. lbs. (73-87 Nm)
- 4.6L Engine 54-64 ft. lbs. (73-87 Nm)
- 5.4L Engine 54-64 ft. lbs. (73-87 Nm)
- 5.8L Engine 75-85 ft. lbs. (103-115 Nm)
- 6.8L Engine 54-64 ft. lbs. (73-87 Nm)
- 7.3L Engine 89 ft. lbs. (121 Nm)
- 7.5L Engine 75-85 ft. lbs. (103-115 Nm)

10. Install the clutch and pressure plate assembly. Refer to Section 7.
11. Install the transmission assembly. Refer to Section 7.