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Home >> Ford >> 2003 >> Excursion 5.4 L, 4WD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 15 (Engine - 6.0L Diesel) >> Installation >> Engine >> Installation
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Section 15 (Engine - 6.0L Diesel): Installation: Engine: Installation

WARNING: This page is about a different variant/trim than selected.

All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist.
  2. Raise the engine high enough to clear the No. 1 crossmember, then position the engine into the vehicle.
    Fig 1: Lifting Engine Into Vehicle
    G01549872Courtesy of FORD MOTOR CO.

    Vehicles with automatic transmission 

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

    Vehicles with manual transmission 

  4. Lower the engine onto the engine mount towers.

    All vehicles 

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

    Vehicles with automatic transmission 

  6. Remove the transmission jack.
  7. Install the transmission-to-engine mounting bolts.
    Fig 2: Installing Transmission-To-Engine Mounting Bolts
    G01549873Courtesy of FORD MOTOR CO.
  8. Install the torque converter-to-flywheel retaining nuts.
    Fig 3: Installing Torque Converter Nuts
    G01549874Courtesy of FORD MOTOR CO.
  9. Install the flywheel housing cover.
    Fig 4: Installing Flywheel Housing Cover
    G01549875Courtesy of FORD MOTOR CO.

    All vehicles 

  10. Install the LH and RH side engine mount retaining nuts.
    NOTE: LH shown, RH similar.
    Fig 5: Installing LH & RH Side Engine Mount Retaining Nuts
    G01549876Courtesy of FORD MOTOR CO.
  11. Remove the engine lifting eye from the right side cylinder head.
    Fig 6: Removing Engine Lifting Eye
    G01549877Courtesy of FORD MOTOR CO.
  12. Install the manufacturer's lifting bracket.
    Fig 7: Installing Manufacturer's Lifting Bracket
    G01549878Courtesy of FORD MOTOR CO.
  13. Remove the two engine lift adapters.
    Fig 8: Removing Engine Lift Adapters
    G01549879Courtesy of FORD MOTOR CO.
  14. Position the turbocharger outlet pipe.
    Fig 9: Positioning Turbocharger Outlet Pipe
    G01549880Courtesy of FORD MOTOR CO.
  15. Install the transmission cooler tube bracket and nut.
    Fig 10: Installing Transmission Cooler Tube Bracket & Nut
    G01549881Courtesy of FORD MOTOR CO.
  16. Install the left rear valve cover stud.
    Fig 11: Installing Left Rear Valve Cover Stud
    G01549882Courtesy of FORD MOTOR CO.
  17. Install the fuel injection control module bracket and nuts.
    Fig 12: Installing Fuel Injection Control Module Bracket
    G01549883Courtesy of FORD MOTOR CO.
  18. Connect the fuel injection control module electrical connectors and position the module on the bracket.
    Fig 13: Installing Fuel Injection Control Module
    G01549884Courtesy of FORD MOTOR CO.
  19. Install the fuel injection control module bolts and nuts.
    Fig 14: Installing Fuel Injection Control Module Bolts & Nuts
    G01549885Courtesy of FORD MOTOR CO.
  20. Position the turbocharger adapter pipe.
    Fig 15: Installing Turbocharger Adapter Pipe
    G01549886Courtesy of FORD MOTOR CO.
  21. Install the bolts for the turbocharger adapter pipe.
    NOTE: Left side shown, right side similar.
    NOTE: Do not tighten bolts at this time.
    Fig 16: Installing Turbocharger Adapter Pipe Bolts
    G01549887Courtesy of FORD MOTOR CO.
  22. Position back the block heater and starter wiring.
  23. Connect the block heater electrical connector.
    Fig 17: Connecting Block Heater Electrical Connector
    G01549888Courtesy of FORD MOTOR CO.
  24. Connect the starter wiring and install the solenoid cap.
    Fig 18: Connecting Starter Wiring
    G01549889Courtesy of FORD MOTOR CO.
  25. Connect the ground strap on the right head and install the bolt.
    Fig 19: Connecting Ground Strap
    G01549890Courtesy of FORD MOTOR CO.

    Vehicles with automatic transmission 

  26. Install the automatic transmission fluid indicator and tube.
    Fig 20: Installing Automatic Transmission Fluid Indicator Tube
    G01549891Courtesy of FORD MOTOR CO.

    All vehicles 

  27. Connect the crankshaft position (CKP) sensor electrical connector.
    Fig 21: Connecting Crankshaft Position Sensor Electrical Connector
    G01549892Courtesy of FORD MOTOR CO.

    Vehicles with A/C 

  28. Install the A/C compressor.
    Fig 22: Installing A/C Compressor
    G01549893Courtesy of FORD MOTOR CO.
  29. Position the A/C compressor manifold and install the bolt.
    Fig 23: Installing A/C Compressor Manifold & Bolt
    G01549894Courtesy of FORD MOTOR CO.
  30. Connect the A/C high pressure switch and the clutch electrical connectors.
    Fig 24: Connecting A/C High Pressure Switch & Clutch Electrical Connectors
    G01549895Courtesy of FORD MOTOR CO.

    All vehicles 

  31. Connect the glow plug module electrical connectors.
    Fig 25: Connecting Glow Plug Module Electrical Connectors
    G01549896Courtesy of FORD MOTOR CO.
  32. Connect the ground cable and the ground stud.
    Fig 26: Connecting Ground Cable & Ground Stud
    G01549897Courtesy of FORD MOTOR CO.
  33. Install the battery cable bracket and the nut.
    Fig 27: Installing Battery Cable Bracket & Nut
    G01549898Courtesy of FORD MOTOR CO.
  34. Install the ground cable and bolt onto the left side of the engine block.
    Fig 28: Installing Ground Cable
    G01549899Courtesy of FORD MOTOR CO.
  35. Position the power steering pump and install the lower bolts.
    NOTE: The lower bolts need to be installed evenly.
    Fig 29: Installing Power Steering Pump Lower Bolts
    G01549900Courtesy of FORD MOTOR CO.
  36. Install the power steering pump upper bolts.
    Fig 30: Installing Power Steering Pump Upper Bolts
    G01549901Courtesy of FORD MOTOR CO.
  37. Install the lower radiator hose and clamp.
    Fig 31: Installing Lower Radiator Hose
    G01549902Courtesy of FORD MOTOR CO.
  38. Connect the fuel lines and install the clips.
    Fig 32: Connecting Fuel Lines
    G01549903Courtesy of FORD MOTOR CO.
  39. Connect the battery crossover cable.
    Fig 33: Connecting Battery Crossover Cable
    G01549904Courtesy of FORD MOTOR CO.
  40. Install the battery cable cover.
  41. Connect the heater hose at the coolant pump.
    Fig 34: Connecting Heater Hose At Coolant Pump
    G01549906Courtesy of FORD MOTOR CO.
  42. Install the intake manifold. Refer to INTAKE MANIFOLD .
  43. Tighten the turbocharger adapter pipe at the flanges.
    NOTE: LH shown; RH similar.
    Fig 35: Tightening Turbocharger Adapter Pipe At Flange
    G01549907Courtesy of FORD MOTOR CO.
  44. Position and install the power steering cooler and bolts.
    Fig 36: Installing Power Steering Cooler & Bolts
    G01549908Courtesy of FORD MOTOR CO.
  45. Install the transmission oil cooler.
    Fig 37: Installing Transmission Oil Cooler
    G01549909Courtesy of FORD MOTOR CO.
  46. Connect the transmission cooler hoses.
    Fig 38: Connecting Transmission Cooler Hoses
    G01549910Courtesy of FORD MOTOR CO.
  47. Install the bumper.
  48. Install the upper radiator core support, radiator grill opening panel and the radiator grill. .
  49. Install the headlamp and the parking lamp assemblies. Refer to LAMP ASSEMBLY .

    Vehicles with A/C 

  50. Install the A/C condenser assembly. Refer to CONDENSER CORE .

    All vehicles 

  51. Install the charge air cooler.
  52. Install the radiator.
  53. Install the air cleaner assembly. Refer to AIR CLEANER .

    Vehicles with manual transmission 

  54. Install the clutch assembly. Refer to CLUTCH .
  55. Install the transmission. Refer to REMOVAL & INSTALLATION .

    All vehicles 

  56. Fill the cooling system.
  57. Fill the motor with clean engine oil.
  58. Connect The LH and RH battery cables. Refer to DUAL BATTERIES .

    Vehicles with automatic transmission 

  59. Check and fill the automatic transmission.
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