Cylinder Head: Installation

Both cylinder heads 

NOTE: Install new D-ring seals on the crankcase-to-head tube. It requires several hours after installation for the D-ring seals to relax back to their original size. If the tube assembly is installed before the D-ring seals have relaxed, damage to the D-ring seals can occur.
1. Install new D-ring seals on each end of the crankcase-to-head tube assemblies.
Fig 1: Identifying D-Ring Seals
Courtesy of FORD MOTOR CO.
NOTE: Use care to avoid scratching the blue compound on the cylinder head gasket. Install a new cylinder head gasket with the part number facing upward and verify the top 5 holes and the head gasket push rod holes line up.
2. Install new dowels and the cylinder head gaskets.
3. Using the Cylinder Head Lifting Bracket, install the cylinder heads on the engine.
Fig 2: Identifying Cylinder Head Lifting Bracket On Cylinder Head
Courtesy of FORD MOTOR CO.
4. Install the 10 outer cylinder head bolts finger-tight.
Fig 3: Identifying Outer Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
5. Apply clean engine oil to each end of the push rods and insert them into their respective positions.
Fig 4: Identifying Push Rods
Courtesy of FORD MOTOR CO.
NOTE: Coat the end of each valve stem with clean engine oil.
6. Install the 16 valve bridges.
Fig 5: Identifying Valve Bridges
Courtesy of FORD MOTOR CO.
NOTE: LH cylinder head shown, RH cylinder head similar.
7. Install the new press-in-place gaskets, the rocker arm carriers and 4 bolts.
   • Tighten to 62 Nm (46 lb-ft).
Fig 6: Rocker Arm Carrier Bolts
Courtesy of FORD MOTOR CO.
NOTE: Rotate the crankshaft until the damper locating dowel notch is in the 6 o'clock position or engine damage can occur.
NOTE: Apply clean engine oil to the top center of each valve bridge.
8. Install the rocker arm assemblies and the 16 bolts.
   • Tighten to 31 Nm (23 lb-ft).
Fig 7: Identifying Rocker Arm Assembly Bolts
Courtesy of FORD MOTOR CO.
NOTE: Using too much engine oil on the threads of the cylinder head bolts can cause damage to the threads and poor sealing. Using anti-seize compounds, grease or any other lubricants other than engine oil on the cylinder head bolt threads can affect the true torque value of the bolts.
NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
NOTE: LH cylinder head shown, RH cylinder head similar.
9. Install the 20 new inner cylinder head retaining bolts finger-tight.
Fig 8: Identifying Cylinder Head Retaining Bolts
Courtesy of FORD MOTOR CO.
10. Tighten the head bolts in sequence in 7 stages:
    • Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
    • Stage 2: Tighten bolts 1 through 10 to 115 Nm (85 lb-ft).
    • Stage 3: Tighten bolts 1 through 10 an additional 90 degrees.
    • Stage 4: Tighten bolts 1 through 10, a second time, 90 degrees.
    • Stage 5: Tighten bolts 1 through 10, a third time, 90 degrees.
    • Stage 6: Tighten bolts 11 through 15 to 24 Nm (18 lb-ft).
    • Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
Fig 9: Cylinder Head Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
NOTE: If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.
NOTE: Lubricate the fuel injector and O-ring seals liberally with clean engine oil.
11. Install new O-ring seals and a copper washer on the fuel injectors.
Fig 10: Identifying O-Ring Seals, Copper Washer And Fuel Injector
Courtesy of FORD MOTOR CO.
NOTE: Failure to tighten the injector correctly can lead to engine failure.
NOTE: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.
12. Install the fuel injectors, the fuel injector hold down and bolt.
    • Tighten to 35 Nm (26 lb-ft).
Fig 11: Identifying Fuel Injector Hold-Down Bolt
Courtesy of FORD MOTOR CO.
NOTE: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
13. Install the fuel injector electrical connector into the rocker carrier.
Fig 12: Identifying Fuel Injector Electrical Connector
Courtesy of FORD MOTOR CO.
14. Apply clean engine oil to the top fuel injector O-ring seals.
Fig 13: Identifying Top Fuel Injector O-Ring Seals
Courtesy of FORD MOTOR CO.
NOTE: Using the bolts to push the high pressure oil rail into the fuel injectors can damage the fuel injectors and high pressure oil rail.
NOTE: LH cylinder head shown, RH cylinder head similar.
NOTE: Apply clean engine oil to the top fuel injector O-ring seals before installing the high-pressure oil rail.
15. Position the high-pressure oil rail on the injectors.
    • Place the high-pressure oil rail on top of the carrier so that the 4 single ball tubes are engaging the fuel injector lead angle.
    • Insert 3 guide bolts, 2 on the ends of the straight side of the high-pressure oil rail and 1 in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 turns.
    • Manually press the high-pressure oil rail into the fuel injectors.
    • Inspect that the high-pressure oil rail mounting feet are flat against the mounting surface.
    • Loosely install the 6 bolts.
Fig 14: Identifying Bolts And High-Pressure Oil Rail
Courtesy of FORD MOTOR CO.
NOTE: LH cylinder head shown, RH cylinder head similar.
16. Remove the 3 guide bolts, install the remaining bolts and tighten the 9 bolts in the sequence shown.
    • Tighten to 13 Nm (115 lb-in).
Fig 15: High-Pressure Oil Rail Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
17. Apply clean engine oil and reassemble the crankcase-to-head tube. Install the crankcase-to-head tubes.
    • Tighten to 82 Nm (60 lb-ft).
Fig 16: Locating D-Ring Seals
Courtesy of FORD MOTOR CO.
18. Connect the fuel injector electrical connectors.
Fig 17: Identifying Fuel Injector Electrical Connector & Retainer Clip
Courtesy of FORD MOTOR CO.

RH cylinder head 

19. Install the high-pressure oil rail-to-valve cover gasket.
Fig 18: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
Courtesy of FORD MOTOR CO.
NOTE: To prevent engine damage, do not use air-powered tools when installing the valve cover.
20. Position the RH valve cover gasket, RH valve cover, 6 stud bolts and 5 bolts.
    • Tighten to 9 Nm (80 lb-in).
Fig 19: Identifying RH Stud Bolts, Bolts & Valve Cover
Courtesy of FORD MOTOR CO.
NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.
NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.
NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.
21. Install the RH exhaust manifold, 8 spacers and the 8 new bolts.
    • Tighten to 38 Nm (28 lb-ft).
Fig 20: Exhaust Manifold Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.

LH cylinder head 

22. Cover the LH cylinder head with an appropriate covering.
23. Position the turbocharger heat shield and install the 3 bolts.
    1. Tighten to 49 Nm (36 lb-ft).
    2. Tighten to 11 Nm (97 lb-in).
Fig 21: Turbocharger Heat Shield Bolts
Courtesy of FORD MOTOR CO.
NOTE: Install new sealing washers.
24. Install the LH cylinder head fuel line.
    • Tighten to 38 Nm (28 lb-ft).
Fig 22: Identifying Fuel Line Banjo Bolt
Courtesy of FORD MOTOR CO.
NOTE: Start installing the bolts with the second bolt from the rear on the top. The hole diameter is smaller, thus allowing alignment of the remaining bolts.
NOTE: When installing the exhaust manifolds, use only prevailing torque hex flange bolts with an interference fit.
NOTE: Apply anti-seize lubricant to the bolt threads prior to installing.
25. Install the LH exhaust manifold, 8 spacers and the 8 new bolts.
    • Tighten to 38 Nm (28 lb-ft).
Fig 23: Exhaust Manifold Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.

Both cylinder heads 

26. Install the 8 glow plugs.
    • Tighten to 19 Nm (168 lb-in).
Fig 24: Identifying Glow Plug
Courtesy of FORD MOTOR CO.
NOTE: Clean and apply clean engine oil to the O-ring seals.
27. Using the Glow Plug Connector Remover/Installer, install the glow plug harness.
Fig 25: Identifying Glow Plug Harness Special Tool (303-1114)
Courtesy of FORD MOTOR CO.
28. Install the Adapter for 303-D043.
Fig 26: Locating Engine Lift Adapters (303-D043-01)
Courtesy of FORD MOTOR CO.
29. Install the Adapter for 303-D043.
Fig 27: Identifying Special Tool (303-D043-02)
Courtesy of FORD MOTOR CO.
30. Remove the engine from the engine stand.
31. Install the flexplate and 10 new bolts. Tighten the bolts in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 94 Nm (69 lb-ft).
Fig 28: Identifying Flexplate/Flywheel Bolt Tightening Sequence
Courtesy of FORD MOTOR CO.
32. Install the engine. For additional information, refer to Engine .