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Section 832 (Engine 6.8L): Installation: Engine: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the engine in the vehicle and remove the Modular Engine Lift Bracket and the jack supporting the transmission.
  2. Raise and support the vehicle.
  3. Install and tighten the nuts.
    Fig 1: Tightening Nuts
    G01537540Courtesy of FORD MOTOR CO.
  4. Install the fuel tube line bracket and the remaining transmission to engine bolts.
    Fig 2: Installing Fuel Tube Line Bracket
    G01537541Courtesy of FORD MOTOR CO.
  5. Install and tighten the six new nuts retaining the torque converter.
    Fig 3: Tightening Torque Converter Retaining Nuts
    G01537542Courtesy of FORD MOTOR CO.
  6. Install the starter motor. For additional information, refer to STARTERS - EXCEPT DIESEL .
  7. Position the A/C compressor manifold assembly and install the bolt.
    Fig 4: Installing A/C Compressor Manifold Assembly
    G02764302Courtesy of FORD MOTOR CO.
  8. Install and tighten the nuts.
    Fig 5: Installing And Tighten Nuts
    G01537544Courtesy of FORD MOTOR CO.
  9. Connect the power steering pressure hose.
    Fig 6: Connecting Power Steering Pressure Hose
    G02764304Courtesy of FORD MOTOR CO.
  10. Install the oil cooler to the oil filter adapter and install the oil filter.
    Fig 7: Installing Oil Cooler To Oil Filter Adapter
    G01537546Courtesy of FORD MOTOR CO.
  11. Position the oil cooler hoses and install the hose clamps.
    Fig 8: Positioning Oil Cooler Hoses
    G01537547Courtesy of FORD MOTOR CO.
  12. Connect the lower radiator hose.
    Fig 9: Connecting Lower Radiator Hose
    G02764307Courtesy of FORD MOTOR CO.
  13. Lower the vehicle.
  14. Connect the transmission wiring harness and the LH and RH heated exhaust gas oxygen sensor connectors.
    Fig 10: Connecting Transmission Wiring Harness And LH And RH Heated Exhaust Gas Oxygen Sensor Connectors
    G01537549Courtesy of FORD MOTOR CO.
  15. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD  in this section.
  16. Install the suction line to the accumulator.
    Fig 11: Installing Suction Line To Accumulator
    G01537550Courtesy of FORD MOTOR CO.
  17. Install the power steering reservoir hose at the power steering pump.
    Fig 12: Installing Power Steering Reservoir Hose At Power Steering Pump
    G01537551Courtesy of FORD MOTOR CO.
  18. Connect the 16 and 42-pin connectors.
  19. Install the drive belt. For additional information, refer to SPECIFICATIONS & DRIVE BELT ROUTING .
  20. Install the upper and lower radiator supports, valance panel, radiator grille support and the radiator RH and LH air deflectors. For additional information, refer to FRONT END BODY PANELS .
  21. Install the A/C condenser core. For additional information, refer to AIR CONDITIONING .
  22. Install the radiator. For additional information, refer to ENGINE COOLING .
  23. Install the side marker lamps and headlamps. For additional information, refer to EXTERIOR LIGHTING .
  24. Install the engine air cleaner assembly and tubes.
  25. Fill all fluids to the correct levels.
  26. Connect the battery ground cable.
  27. Start the engine and check for leaks. Stop the engine and recheck the fluid levels.
  28. Evacuate and recharge the A/C system. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
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