1. Install the Heavy Duty Floor Crane (014-00071) and the Diesel Engine Lifting Bracket (303-D043, D83T-6000-B) on the engine. See Fig. 37. Raise the engine high enough to clear the No. 1 crossmember, then position the engine into the vehicle.
2. On vehicles equipped with an automatic transmission, align the torque converter studs with the holes in the engine flexplate, making sure the stud and hole marked during removal are aligned.
3. On all vehicles, lower the engine onto the engine mount crossmember and remove the heavy duty floor crane and the lifting fixture from the engine.
4. On vehicles equipped with an automatic transmission, remove the jack and wood block supporting the transmission. See Fig. 35. Position the transmission fill tube into the transmission. See Fig. 36.
5. On all vehicles, raise and support the vehicle. Install the left and right side engine mount retaining nuts. See Fig. 34. Tighten left and right side engine mount retaining nuts to specification. See TORQUE SPECIFICATIONS.
6. On vehicles equipped with an automatic transmission, install the transmission-to-engine mounting bolts. Tighten transmission-to-engine mounting bolts to specification. See TORQUE SPECIFICATIONS. Install the torque converter-to-flywheel retaining nuts and tighten to specification.
7. Install the flywheel housing cover retaining bolts and tighten to specification. See TORQUE SPECIFICATIONS. Position the starter and install the 3 bolts. See Fig. 32. Tighten starter bolts to specification. Connect the starter electrical connectors. Position and install the “B” terminal. See Fig. 31. Position the and install the “S” terminal. Install the “B” and “S” terminal nuts and tighten to specification.
8. On all vehicles, connect the block heater harness connector. See Fig. 33. Install the oil filter. Lower the vehicle.
9. Remove the Lifting Eye (303-D099, D94T-6000-C) from the right side cylinder head. See Fig. 30. Remove the 2 engine lift adapters. See Fig. 29. Position the lower water outlet tube and install the bolts. See Fig. 28. Tighten lower water outlet tube bolts to specification. See TORQUE SPECIFICATIONS.
10. Position the glow plug and intake air heater relays and install the nuts. See Fig. 27. Position the idler pulley and install the accessory drive belt idler pulley. Install the idler pulley bolt and tighten to specification. See Fig. 26. See TORQUE SPECIFICATIONS.
11. Position the fuel tube and install the fuel tube retaining bolt. See Fig. 25. Connect the 2 fuel tubes. Install the turbocharger. See TURBOCHARGER.
12. Connect the heater supply hose. See Fig. 23. Connect the heater return hose. See Fig. 22.
Connect the ground strap. See Fig. 21.
13. Position the cables and connect the fusible link. See Fig. 20. Install the fusible link nuts and tighten to specification. See TORQUE SPECIFICATIONS.
14. Connect the engine control sensor harness connector. See Fig. 19. Connect the negative battery cable to the left side of the engine block and install the bolt. See Fig. 18. Tighten negative battery cable bolt to specification. See TORQUE SPECIFICATIONS.
15. Position the generator mounting bracket and install the bolts. See Fig. 17. Tighten generator mounting bracket bolts to specification. See TORQUE SPECIFICATIONS.
16. On vehicles equipped with dual generators, connect the lower generator electrical connectors. See Fig. 19.
17. On all vehicles, connect the generator electrical connectors. Connect the power steering hoses to the power steering pump.
18. On vehicles equipped with A/C, connect the air conditioning manifold lines to the A/C compressor. Connect the electrical connector to the A/C compressor.
19. On all vehicles, install the engine ground cable onto the right side of the engine block. See Fig. 16. Position the starter wires and bracket. Install the nut and tighten to specification.
See TORQUE SPECIFICATIONS. Install the Manifold Absolute Pressure (MAP) sensor hose. See Fig. 15.
20. Install the accessory drive belt. Using the Fan Pulley Holding Wrench (303-478, T94T- 6312-AH) and Fan Clutch Nut Wrench (303-214, T83T-6312-B) install the fan and fan clutch on the water pump pulley.
21. Position the fan shroud on the fan. Position the radiator. Raise and support the vehicle.
Connect the degas supply and the lower radiator hoses to the radiator. Lower the vehicle.
22. Position the fan shroud and install the bolts. See Fig. 14. Tighten fan shroud bolts to specification. See TORQUE SPECIFICATIONS. Connect the upper radiator hose to the radiator.
23. Position the air charge cooler and install the inlet and outlet ducts to the air charge cooler.
See Fig. 13. Position the ducts on the air charge cooler and tighten the clamps.
24. On vehicles equipped with A/C, install the A/C condenser assembly. Connect the A/C condenser core inlet and outlet hoses. See Fig. 12. Tighten inlet and outlet hose bolt to specification. See TORQUE SPECIFICATIONS. Install the radiator sight shield. See Fig. 11.
25. Position the radiator core support and install the 8 bolts. See Fig. 10. Tighten radiator core support bolts to specification. See TORQUE SPECIFICATIONS.
26. Position the battery cable and connect the retainers. See Fig. 9. Position the radiator support brackets and install the bolts. Tighten radiator support bracket bolts to specification. See TORQUE SPECIFICATIONS.
27. Install the charge air cooler retainers. See Fig. 8. Install the 3 right side air deflector pushpins. See Fig. 7. Position the hood latch and install the bolts. Tighten hood latch bolts to specification. See TORQUE SPECIFICATIONS.
28. Install the radiator grille opening panel and the radiator grille. See RADIATOR GRILLE (EXCURSION & “F” SERIES).
29. Install the degas bottle. Squeeze the clamp and install the degas bottle supply hose. Install degas bottle retaining bolts. See Fig. 6. Squeeze the clamp and install the overflow hose.
Install the lug wrench and wing bolt.
30. Install the air intake tube and adapter. Install the air intake tube bolts. See Fig. 5. Tighten the air intake tube clamp. Install the air cleaner outlet tube and tighten the clamps.
31. On vehicles equipped with a manual transmission, install the manual transmission. See CLUTCHES article for 2002 models or MANUAL TRANSMISSION for 2003 models.
32. On all vehicles, fill the engine with clean Super Duty SAE 15W-40 Motor Oil (XO-15W40-QSD). Connect both battery ground cables. Fill the power steering reservoir.
33. Fill and bleed the cooling system. See COOLING SYSTEM BLEEDING.
34. On vehicles equipped with an automatic transmission, fill automatic transmission to proper level with appropriate fluid. Charge the A/C system. See RECOVERY, EVACUATION & RECHARGING in GENERAL SERVICING PROCEDURES article in GENERAL SERVICING.