LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 729 (Engine - 6.0L Diesel - F250-F550 Super Duty) >> In-Vehicle Repair >> Cylinder Head RH >> Installation

Cylinder Head RH: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    One-piece head tube 

    CAUTION: 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.
    Fig 1: Installing New D-Ring Seals
    G03899307Courtesy of FORD MOTOR CO.
  1. Install new D-ring seals on each end of the crankcase to head tube assemblies.

    2. Two-piece head tube 

    CAUTION: 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-rings have relaxed, damage to the D-ring seals can occur.
    Fig 2: Identifying D-Ring Seals
    G03899308Courtesy of FORD MOTOR CO.
  2. Install new D-ring seals on the crankcase-to-head tube.

    3. All vehicles 

    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 up and verify the top five holes and the head gasket push rod holes line up.
  3. Install the dowels and the cylinder head gasket.
  4. Using the special tools and with the help of an assistant, install the cylinder head on the engine. Remove the special tools.
    Fig 3: Installing Cylinder Head On Engine
    G03899309Courtesy of FORD MOTOR CO.
  5. Install the outer cylinder head bolts finger-tight.
    Fig 4: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
    6. CAUTION: 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.
    NOTE: Higher mileage engines require push rods to be cleaned so the copper colored end of the push rod can be identified.
    NOTE: If a push rod has been replaced, it may not have a copper-colored end and can be installed with either end up.
    Fig 5: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
  6. Apply clean engine oil to each end of the push rods. Insert them into their respective positions with the copper colored end up.
    7. NOTE: Coat the end of each valve stem with clean engine oil.
    Fig 6: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
  7. Install the eight valve bridges.
    8. CAUTION: Rotate the crankshaft until the damper locating dowel notch is in the six o'clock position or engine damage can occur.
    NOTE: Apply clean engine oil to the top center of each valve bridge.
    Fig 7: Locating Rocker Arm Assembly Bolts - With Torque Specification
    G03887670Courtesy of FORD MOTOR CO.
  8. Install the rocker arm assemblies and eight bolts.
    9. CAUTION: 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.
    Fig 8: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
  9. Install the 10 new inner cylinder head retaining bolts finger-tight.
  10. Tighten the head bolts in the following sequence.
    1. Tighten bolts 1 through 10 to 88 N.m (65 lb-ft).
    2. Tighten bolts 1 through 10 to 115 N.m (85 lb-ft).
    3. Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
    4. Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees.
    5. Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees.
    6. Tighten bolts 11 through 15 to 24 N.m (18 lb-ft).
    7. Tighten bolts 11 through 15 to 31 N.m (23 lb-ft).
    Fig 9: Cylinder Head Bolt Tightening Sequence
    G03887672Courtesy of FORD MOTOR CO.
  11. Install the four glow plugs.
    Fig 10: Glow Plugs - With Torque Specification
    G03887699Courtesy of FORD MOTOR CO.

    12. Late build 

    NOTE: Clean and apply clean engine oil to the O-rings.
    Fig 11: View Of Glow Plug Harness And Special Tool
    G03887483Courtesy of FORD MOTOR CO.
  12. Using the special tool, install the glow plug harness.

    13. One-piece head tube 

    CAUTION: To prevent engine damage, check that the crankcase-to-head tube assemblies bottom out in the branch tube assembly. The oil rail, crankcase-to-head tube and the fuel injectors will not function correctly if the tube is not bottomed out.
    Fig 12: Installing Crankcase-To-Head Tube Assembly
    G03899318Courtesy of FORD MOTOR CO.
  13. Apply clean engine oil and install the crankcase-to-head tube assembly.

    14. Early build 

    NOTE: Clean and inspect the glow plug buss bar O-rings and install new as necessary.
    NOTE: Apply clean engine oil to the O-rings before installing.
    Fig 13: Installing Glow Plug Buss Bar
    G03899319Courtesy of FORD MOTOR CO.
  14. Install the glow plug buss bar.
    15. NOTE: Install a new lower O-ring.
    Fig 14: Installing New Crankcase To Head Tube Assembly
    G03899320Courtesy of FORD MOTOR CO.
  15. Install a new crankcase to head tube assembly.

    16. All vehicles 

  16. Position the turbocharger adapter pipe.
    Fig 15: Positioning Turbocharger Adapter Pipe
    G03899321Courtesy of FORD MOTOR CO.
    17. NOTE: Apply anti-seize lubricants to the bolt threads prior to installing the bolts.
    NOTE: Do not tighten until after the turbocharger is installed.
    Fig 16: Installing Nuts And Bolts Adapter Pipe
    G03899322Courtesy of FORD MOTOR CO.
  17. Install the nuts and bolts in the adapter pipe.
    18. NOTE: Apply clean engine oil to the O-ring prior to installing.
    Fig 17: Installing Cylinder Block Drain Plug
    G03899323Courtesy of FORD MOTOR CO.
  18. Install the cylinder block drain plug.
  19. Install the starter. For additional information, refer to STARTERS .
    20. CAUTION: If the fuel injector oil inlet D-shaped O-ring seal is damaged, a new fuel injector must be installed.
    Fig 18: Identifying O-Ring Seals, Copper Washer And Fuel Injector
    G03887397Courtesy of FORD MOTOR CO.
  20. Install new O-rings seals and copper washer on the fuel injector. Lubricate the fuel injector and O-ring seals liberally with clean engine oil.
    21. CAUTION: Failure to tighten the injector properly can lead to engine failure.
    CAUTION: To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
    Fig 19: View Of Fuel Injector Hold-Down Clamp Bolt - With Torque Specification
    G03887398Courtesy of FORD MOTOR CO.
  21. Install the fuel injector, fuel injector hold-down clamp and bolt.
    22. CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
    Fig 20: Identifying Fuel Injector Electrical Connector
    G03887399Courtesy of FORD MOTOR CO.
  22. Install the fuel injector electrical connector into the rocker arm carrier.
  23. Apply engine oil to the top fuel injector O-ring seals.
    Fig 21: Identifying Top Fuel Injector O-Ring Seals
    G03888010Courtesy of FORD MOTOR CO.

    24. Late build 

    NOTE: Apply clean engine oil to the top fuel injector D-ring before installing the high pressure oil rail.
    Fig 22: Locating High-Pressure Oil Rail On Injector Bolts
    G03887401Courtesy of FORD MOTOR CO.
  24. Position the oil rail on the fuel injectors.
    • Place the oil rail on top of the carrier so that the four single ball tubes are engaging the injector lead angle.
    • Insert three guide bolts, two on the ends of the straight side of the oil rail and one in the middle of the wavy side of the oil rail. Install the guide studs six to seven turns.
    • Press the oil rail into the fuel injectors.
    • Inspect that the oil rail mounting feet are flat against the mounting surface.
    • Loosely install the six bolts.
  25. Install the oil rail retaining bolts.
    • Remove the three guide bolts.
    • Loosely install the three remaining bolts.
    • Tighten the bolts in the sequence shown.
    Fig 23: Tightening Bolts In Sequence
    G03899329Courtesy of FORD MOTOR CO.

    26. Two-piece head tube 

    NOTE: Apply clean engine oil to the crankcase-to-head tube prior to installation.
    Fig 24: Crankcase-To-Head Tube Bolt With Torque Specification
    G03887403Courtesy of FORD MOTOR CO.
  26. If equipped with an updated crankcase-to-head tube, install the crankcase-to-head tube assembly.

    27. Late build 

  27. Install the high-pressure oil rail-to-valve cover gasket.
    Fig 25: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    G03887197Courtesy of FORD MOTOR CO.

    28. Early build 

  28. Install the high-pressure oil rail and bolts.
    • Install the high-pressure oil rail.
    • Install the bolts finger tight.
    Fig 26: Installing High-Pressure Oil Rail Bolts
    G03899332Courtesy of FORD MOTOR CO.
  29. Tighten the bolts in the sequence shown.
    Fig 27: Tightening Bolts In Sequence
    G03899333Courtesy of FORD MOTOR CO.
  30. Install the high-pressure oil line.
    Fig 28: Installing High-Pressure Oil Line
    G03899334Courtesy of FORD MOTOR CO.

    31. All vehicles 

    NOTE: Late build shown, early build similar.
    CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.
    Fig 29: View Of Valve Cover Mounting Bolts/Studs With Torque Specification
    G03887405Courtesy of FORD MOTOR CO.
  31. Position the valve cover gasket. Install the valve cover and 11 bolts.
  32. If equipped, position back the transmission fluid indicator and tube. Install the retaining nut.
    Fig 30: Identifying Transmission Fluid Indicator Retaining Nut
    G03899172Courtesy of FORD MOTOR CO.

    33. Late build 

  33. Install the ICP sensor.
    Fig 31: Installing ICP Sensor
    G03899337Courtesy of FORD MOTOR CO.

    34. All vehicles 

    NOTE: Only one retainer shown.
    Fig 32: Connecting Wiring Retainers To Studs
    G03899338Courtesy of FORD MOTOR CO.
  34. Connect the wiring retainers to the studs.
  35. Install the evaporator core housing. For additional information, refer to HEATING & VENTILATION .
  36. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
    37. NOTE: Install a new oil filter.
  37. Fill the crankcase with clean engine oil.
scientia non olet · About LEMON Manuals