Machinists are hard to come by around here, especially ones who are willing to work on a diesel engine. So I only took the heads to be resurfaced. The connecting rod bearings were over sized (90% this engine has been rebuilt before) and I replaced them with the same sized bearings. There was no unusual wear on the components when I disassembled the engine.

 

DOH!

I responded and didn't update the thread, anyways...

I'd use your second source for torque specs. Here's a good thread that agrees with what you just posted.

https://www.ford-trucks.com/forums/1...cs-needed.html
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Good news is that the bolts are not part of the pistons. I was able to easily pound the broken one out with a punch. I ended up spending about 2 hours lifting a spare engine I had to remove four bolts from the other pistons. Then I replaced the bolts I over torqued with those.

Finally got the last part I was waiting on, a camshaft from Russ Repair. So I’m going to try to find the time to put the rest of the engine together this weekend. Does anyone have any advice on installing those giant oil seals for the front cover and rear main seal?

 

Kept forgetting to take photos of it, but the new camshaft came without the mounting flange that connects it to the motor or the lobe for the fuel pump. The machinists looked at me like I was crazy when I asked if they could press some lobes off my camshaft for me. I can’t blame them though, I’ve never heard of that before.
I took some photos of the old one (without the lobes) and the new one installed on the vehicle.

 

I made some great progress this weekend. Got the heads installed, new camshaft, set the timing (still need to do the IP), and installed lifters. I soaked the lifters in a bag of 15W-40 for about a week. Not sure if that really makes a difference but it was easy to do so why not. I also did the rear main seal and the oil pan. But I keep dropping things so I’ve taken the pan off 3 times so far. It’s going to be the last thing I install now just in case I drop more bolts.

Not sure if I mentioned this earlier but I’m installing some performance lifters, valve springs, and camshaft. Most of the parts are from Classic Diesel Design. I have some nice fuel components from IDI Performance that I’ll be installing later, though. So far everything looks nice and I’m optimistic that they’ll run well too.


Starting to look like an actual engine again.

The workshop manual doesn’t mention this at all… these retainer clips for the lifters… what direction do they go? It’s been well over a year since I tore down the engine so I can’t remember. I assume they go with the nub pointed up so it contacts the retaining plate. Am I correct?

 

Same question about the nubs on the retainers!
Assume they are to face up so "intake gasket" pushes down on them?
I never could find any info on this on line and need to know as well.

 

If no one knows the answer, I’ll try to find the time, this weekend, to take the intake off another engine and report back.

 

The nubs go UP and connect to the plate. Finally had time and took the valley pan off another truck.

 

Does anyone have any experience with the R&D injector common rail kit? I used it briefly on my old engine but ended up swapping it back to stock after I kept ripping o-rings. I wanted to use it on this engine but I’m having fitment issues. The rail will not sit on the fuel filter side as it’s hitting the bracket. Am I missing something obvious?

 

Useful info! I am going to start in on (my first) a factory turbo IDI rebuild pretty soon. I am curious how yours well yours runs and so on when all said and done.

 

After comparing the bracket to a couple others I had lying around I found that there are apparently ones with different dimensions. The one I have on there now is shorter on the “arms” and is allowing the railing to sit properly. Not sure why Ford/International would decide to make fuel filter brackets of varying sizes across different model years.

 

It’s all finished and I just got started on the engine removal process so I have a truck to put this in. Hopefully I’ll have a video for you in a couple weeks!

 

My buddy came over today and I finally swapped the motors. Going to spend all day tomorrow reconnecting everything, hopefully all goes according to plan.

 

I have everything almost back together but I’m having fitment issues with the fan shroud that are leaving me perplexed. The fan, shroud, and radiator are all from the same truck that I’m putting back together. But the fan keeps getting caught on the edge of the shroud. There’s no adjustment in where the mounting bolts go. Has anyone dealt with this before? Do I need spacers? Are there differences between the 6.9L and 7.3L water pump pullies?

 

what is the spacing on bottom of the shroud?
if it is also touching you could have either wrong fan, or wrong shroud.