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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 799 (Engine - 6.0L Diesel -- E350 & E450) >> In-Vehicle Repair >> Rocker Arm >> Installation

Rocker Arm: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

    CAUTION: Install new O-ring seals on the crankcase-to-head tube. It requires several hours after installation for the O-ring seals to relax back to their original size. If the tube assembly is installed before the O-rings seals have relaxed, damage to the O-ring seals can occur.
    NOTE: Late build shown, early build similar.
    Fig 1: Installing New D-Ring Seals
    G03899308Courtesy of FORD MOTOR CO.
  1. Install new O-ring seals on the crankcase-to-head tube assemblies.
    2. NOTE: Apply clean engine oil on the valve stems prior to installing the valve bridges.
    Fig 2: Installing New Valve Bridges
    G03887388Courtesy of FORD MOTOR CO.
  2. Install the new valve bridges.
  3. Install the special tool plate and bolt. Tighten the bolt until the plate contacts the top of the tool base.
    Fig 3: Tightening Bolt
    G03887387Courtesy of FORD MOTOR CO.
    4. 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 that 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 4: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
  4. Apply clean engine oil to each end of the push rods. Insert them into their respective positions with the copper-colored end up.
  5. Place a dab of multi-purpose grease in the fulcrum socket to hold the ball in place while installing the rocker arms.
    Fig 5: Installing Rocker Arms
    G03887393Courtesy of FORD MOTOR CO.
    6. NOTE: Apply clean engine oil to the top center of the valve bridges prior to installing the rocker arms.
    NOTE: Always replace the rocker arm retaining clip with the same color clip.
  6. Insert the rocker arm under the fulcrum and ball, rotate the rocker arm into place and position onto the push rod. Install a new rocker arm retaining clip.
    • Repeat the step for the other rocker arm.
      Fig 6: Inserting Rocker Arm Under Fulcrum Ball
      G03887385Courtesy of FORD MOTOR CO.
  7. Remove the special tool bolt and plate.
    • Make sure the rocker arms remain in place and the fulcrum ball has not fallen out.
      Fig 7: Removing Special Tool Bolt And Plate
      G03887384Courtesy of FORD MOTOR CO.
    8. NOTE: If a snap ring or piece of a snap ring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.
  8. Remove the shop towels.
  9. Remove the injector hold-down and special tool base.
    Fig 8: Removing Shop Towels
    G03887383Courtesy of FORD MOTOR CO.
    10. CAUTION: 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.
    Fig 9: Identifying Fuel Injector O Rings And Electrical Connector
    G03887397Courtesy of FORD MOTOR CO.
  10. Install new O-ring seals and copper washer on the fuel injector.
    11. CAUTION: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.
    Fig 10: View Of Fuel Injector Hold-Down Clamp Bolt - With Torque Specification
    G03887398Courtesy of FORD MOTOR CO.
  11. Install the fuel injector, the fuel injector hold-down and bolt.
    12. CAUTION: Be sure the injector wiring is clear of all moving parts or engine damage can occur.
    Fig 11: Identifying Fuel Injector Electrical Connector At Rocker Carrier
    G03887399Courtesy of FORD MOTOR CO.
  12. Install the fuel injector electrical connector into the rocker arm carrier.

    13. Early build 

    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 these tubes are not bottomed out.
    Fig 12: Identifying Crankcase-To-Head Tube
    G03887400Courtesy of FORD MOTOR CO.
  13. Apply clean engine oil and install the crankcase-to-head tube assembly.

    14. All vehicles 

    NOTE: Apply clean engine oil to the top fuel injector O-ring seals before installing the high-pressure oil rail.
  14. Position the high-pressure oil rail on the injectors.
    • Place the high-pressure oil rail on top of the carrier so that the four single ball tubes are engaging the fuel injector lead angle.
    • Insert three guide bolts, two on the ends of the straight side of the high-pressure oil rail and one in the middle of the wavy side of the high pressure oil rail. Install the guide studs six to seven turns.
    • 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 six bolts.
      Fig 13: Locating High-Pressure Oil Rail On Injector Bolts
      G03887401Courtesy of FORD MOTOR CO.
  15. Install the remaining bolts and tighten.
    • Remove the three guide bolts.
    • Loosely install the three remaining bolts.
    • Tighten the nine bolts in the sequence shown in Fig 14.
      Fig 14: Oil Rail Retaining Bolt Tightening Sequence - With Torque Specifications
      G03887402Courtesy of FORD MOTOR CO.

    16. Late build 

  16. Apply clean engine oil and install the crankcase-to-head tube.
    Fig 15: Crankcase-To-Head Tube Bolt With Torque Specification
    G03887403Courtesy of FORD MOTOR CO.

    17. All vehicles 

  17. If removed, cover the LH cylinder head with an appropriate covering.
  18. Install the RH high-pressure oil rail-to-valve cover gasket.
    Fig 16: Identifying High-Pressure Oil Rail
    G03887197Courtesy of FORD MOTOR CO.
    19. CAUTION: Top prevent engine damage, do not use air-powered tools when installing the valve cover.
    Fig 17: View Of Valve Cover Mounting Bolts/Studs With Torque Specification
    G03887405Courtesy of FORD MOTOR CO.
  19. Position the RH valve cover gasket. Install the RH valve cover, stud bolts and bolts.
  20. Install the engine in the vehicle. For additional information, refer to Engine .
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