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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2246 (Engine - 6.0L (99P E-Series) Diesel) >> In-Vehicle Servicing >> Rocker Arm >> Installation

Rocker Arm: Installation

WARNING: This page is about a different car, the 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: 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-ring seals have relaxed, damage to the O-ring seals can occur.
  1. Install new O-ring seals on the crankcase-to-head tube assemblies.
    2. Fig 1: Identifying D-Ring Seals
    G03899308Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine oil on the valve stems prior to installing the valve bridges.
  2. Install the valve bridges.
    3. Fig 2: Identifying Valve Bridges
    G03887388Courtesy of FORD MOTOR CO.
  3. Install the Rocker Arm Service Tool plate and bolt. Tighten the bolt until the plate contacts the top of the tool base.
    4. Fig 3: Special Tool Plate Installed On Top Of The Bridges
    GF0005737Courtesy 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.
  4. Apply clean engine oil to each end of the push rods and insert them into their respective positions.
    5. Fig 4: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
  5. Place a dab of multi-purpose grease in the fulcrum socket to hold the ball in place while installing the rocker arms.
    6. Fig 5: Fulcrum Socket
    GF0005738Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine oil to the top center of the valve bridges prior to installing the rocker arms.
  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.
    7. Fig 6: Locating Rocker Arm Retaining Clip
    G03887385Courtesy of FORD MOTOR CO.
  7. Remove the Rocker Arm Service Tool bolt and plate.
    • Make sure the rocker arms remain in place and the fulcrum ball has not fallen out.
    8. Fig 7: Compressing Valve Spring
    GF0005735Courtesy of FORD MOTOR CO.
  8. Remove the shop towels.
  9. Remove the injector hold down and Rocker Arm Service Tool base.
    10. Fig 8: Injector Hold Down And Special Tool Base
    GF0005733Courtesy 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.
  10. Install new O-ring seals and copper washer on the fuel injector.
    11. Fig 9: Identifying O-Ring Seals, Copper Washer And Fuel Injector
    G03887397Courtesy of FORD MOTOR CO.
    NOTE: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.
  11. Install the fuel injector, the fuel injector hold down and bolt.
    • Tighten to 35 Nm (26 lb-ft).
    12. Fig 10: Identifying Fuel Injector Hold-Down Bolt
    G03887381Courtesy of FORD MOTOR CO.
    NOTE: Be sure the injector wiring is clear of all moving parts or engine damage can occur.
  12. Install the fuel injector electrical connector into the rocker arm carrier.
    13. Fig 11: Identifying Fuel Injector Electrical Connector
    G03887399Courtesy 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: Apply clean engine oil to the top fuel injector O-ring seals before installing the high-pressure oil rail.
  13. 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 one in the middle of the wavy side of the high pressure oil 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.
    14. Fig 12: Locating High-Pressure Oil Rail On Injector Bolts
    G03887401Courtesy of FORD MOTOR CO.
  14. Install the remaining bolts and tighten.
    • Remove the 3 guide bolts.
    • Loosely install the 3 remaining bolts.
    • Tighten the 9 bolts in the sequence shown to 13 Nm (115 lb-in).
    15. Fig 13: High-Pressure Oil Rail Retaining Bolt Tightening Sequence
    GF0005913Courtesy of FORD MOTOR CO.
  15. Apply clean engine oil and install the crankcase-to-head tube(s).
    • Tighten to 82 Nm (60 lb-ft).
    16. Fig 14: Crankcase-To-Head Tube
    GF0005912Courtesy of FORD MOTOR CO.
  16. If removed, cover the LH cylinder head with an appropriate covering.
  17. Install the RH high-pressure oil rail-to-valve cover gasket.
    18. Fig 15: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    G03887197Courtesy of FORD MOTOR CO.
    NOTE: To prevent engine damage, do not use air-powered tools when installing the valve cover.
  18. Position the RH valve cover gasket. Install the RH valve cover, 6 stud bolts and 5 bolts.
    • Tighten to 9 Nm (80 lb-in).
    19. Fig 16: Identifying RH Stud Bolts, Bolts & Valve Cover
    GF0044560Courtesy of FORD MOTOR CO.
  19. Install the engine in the vehicle. For additional information, refer to Engine .
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