How to Install a Powerstroke Diesel Engine in Your Truck – A Beginner’s Guide

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Changing out your engine can require a lot of work, but it can also be very rewarding. Doing the job yourself means that you can save money and prevent complications down the road. This article will list out the the tools you’ll need and step by step instructions on how to install a Ford Powerstroke Diesel Engine in your truck.

To get started, you’ll need to gather the following tools and materials: a catch pan, WD-40, four to eight bolts, 7/16 or ½, tensioner jack chain, and footage of wiring and hoses.

Step 1: Disconnect and remove the batteries. Take pictures of all removed parts, this way you’ll know where to put them back.

Step 2: Place the catch pan under the radiator petcock and drain the radiator.

Step 3: Remove the starter. On a Ford, this usually means a thick wire from the solenoid to the starter.

How to Install a Powerstroke Diesel Engine in Your Truck - A Beginner's Guide

Step 4: Remove the two or three bolts that connect the exhaust manifold to the exhaust pipes. You may need to use WD-40 or other lubricant to help loosen it up. Also, remove the Y-pipe from the manifolds and from the rear pipe(s).

Step 5: Remove the four bolts, usually 7/16 or ½, that hold the driveshaft to the differential input. Slide the drive shaft out and place something over the tail piece of the transmission or it will leak fluid all over. Then, remove the two bolts holding both sides of the transmission crossmember. After that, remove the two or three bolts holding the crossmember to the transmission.

Step 6: Remove the clamps holding the radiator hoses and then pull the hoses off the engine block. If the power steering reservoir mounts on the side, remove it. Remove the four to eight bolts holding the radiator and pull it out. Take more pictures as you go. finally, remove the fuel lines, heater hoses, electrical wires and vacuum lines from the engine, noting where everything went.

How to Install a Powerstroke Diesel Engine in Your Truck - A Beginner's Guide

Step 7: Wheel the cherry picker in at the front. Connect the hoist chain to two head or block bolts and tighten. Put tension on the jack chain. Remove the motor mount bolts from both sides. Carefully lift the engine and transmission out and over the front end.

Step 8: Remove the hoist chain from the old engine and attach it to the new one. Carefully lift the engine into place and attach the motor mount bolts.

Step 9: Reattach the starter to the motor. Place the exhaust pipe components back in place and properly secure. Reattach the transmission crossmember. Slide the driveshaft into the transmission and connect the differential.

Step 10: Reconnect all the wiring and hoses that you disconnected in step 6.

How to Install a Powerstroke Diesel Engine in Your Truck - A Beginner's Guide

Step 11: Place and secure the radiator. Resecure the radiator hoses. Refill the cooling system to capacity.

Step 12: Put the batteries in and reconnect them. Fill the engine with oil, make sure it has an oil filter and prime the fuel system. Double check all connections and fittings to make sure they are tight. Start the engine and check for any leaks.

Congratulations! You have just completed the installation of a Ford Powerstroke diesel engine. If you’ve followed this step-by-step tutorial, you should have no problem getting your engine to run like new. The next time you’re in the market for a new engine, know that you’re more than capable of replacing it with the help of this article. Happy driving!

  • February 17, 2022