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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 729 (Engine - 6.0L Diesel - F250-F550 Super Duty) >> In-Vehicle Repair >> Cylinder Head LH >> Installation

Cylinder Head LH: 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
    G03899381Courtesy 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 the gasket with the part number facing upward and verify the five top holes and head gasket push rod holes line up.
  3. Install the dowels and the cylinder head gasket.
    4. NOTE: Position the fuel lines in place before the cylinder head is installed.
    NOTE: The back two cylinder head bolts cannot be installed into the head in vehicle. Lightly lubricate the threads of two new cylinder head bolts with clean engine oil. Position these bolts in the head and secure them in position so they will clear the cylinder block deck as the head is installed.
    Fig 3: Removing Special Tools
    G03899383Courtesy of FORD MOTOR CO.
  4. Using the special tools and with the help of an assistant, install the cylinder head on the engine. Remove the special tools.
  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.
    CAUTION: Make sure the insulation blanket is not damaged (torn, cracked or fabric separated from the metallic skin) when installing the lower rear cylinder head bolt. If the insulation blanket is damaged, the entire blanket must be replaced.
    NOTE: It may be necessary to slightly compress or deform the insulation blanket to gain tool clearance to install the lower rear cylinder head bolt.
    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 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 an 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. NOTE: Install new sealing washers.
    Fig 10: Installing Fuel Line And Banjo Fitting
    G03899390Courtesy of FORD MOTOR CO.
  11. Install the fuel line and the banjo fitting.
  12. Install the fan shroud mounting stud.
    Fig 11: Installing Fan Shroud Mounting Stud
    G03899391Courtesy of FORD MOTOR CO.
  13. Position back and connect the heater hose.
    Fig 12: Connecting Heater Hose
    G03899392Courtesy of FORD MOTOR CO.
  14. Install the idler pulley and bolt.
    Fig 13: Installing Idler Pulley Bolt
    G03899393Courtesy of FORD MOTOR CO.
  15. Position the exhaust backpressure bracket assembly and install the retaining nuts.
    Fig 14: Installing Retaining Nuts
    G03899394Courtesy of FORD MOTOR CO.
  16. Tighten the exhaust backpressure tube fitting at the exhaust manifold.
    Fig 15: Tightening Exhaust Backpressure Tube Fitting
    G03899395Courtesy of FORD MOTOR CO.
  17. Position the fuel lines and install the fuel line bracket retaining bolt.
    Fig 16: Installing Fuel Line Bracket Retaining Bolt
    G03899396Courtesy of FORD MOTOR CO.
    18. NOTE: Install a new O-ring and apply clean engine oil.
    Fig 17: Installing Oil Level Indicator Tube
    G03899397Courtesy of FORD MOTOR CO.
  18. Install the oil level indicator and tube.
  19. Install the turbocharger heat shield and bolts.
    Fig 18: Installing Turbocharger Heat Shield Bolts
    G03899398Courtesy of FORD MOTOR CO.
  20. Position the turbocharger adapter pipe.
    Fig 19: Positioning Turbocharger Adapter Pipe
    G03899399Courtesy of FORD MOTOR CO.
    21. 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 20: Installing Nuts And Bolts Adapter Pipe
    G03899400Courtesy of FORD MOTOR CO.
  21. Install the nuts and bolts in the adapter pipe.
  22. Install the four glow plugs.
    Fig 21: Glow Plugs - With Torque Specification
    G03887699Courtesy of FORD MOTOR CO.
    23. 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-rings liberally with clean engine oil.
    Fig 22: Identifying O-Ring Seals, Copper Washer And Fuel Injector
    G03887397Courtesy of FORD MOTOR CO.
  23. Install new O-rings and copper washer on the fuel injector.
    24. 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 23: View Of Fuel Injector Hold-Down Clamp Bolt - With Torque Specification
    G03887398Courtesy of FORD MOTOR CO.
  24. Install the fuel injector, fuel injector hold-down and bolt.
    25. CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
    Fig 24: Identifying Fuel Injector Electrical Connector
    G03887399Courtesy of FORD MOTOR CO.
  25. Install the fuel injector electrical connector into the rocker carrier.
  26. Apply engine oil to the top fuel injector O-rings.
    Fig 25: Identifying Top Fuel Injector O-Ring Seals
    G03888010Courtesy of FORD MOTOR CO.

    27. Early build 

    NOTE: Install a new lower O-ring.
    Fig 26: Installing New Crankcase To Head Tube Assembly
    G03899406Courtesy of FORD MOTOR CO.
  27. Install a new crankcase to head tube assembly.
  28. Install the high-pressure oil rail and bolts.
    • Install the high-pressure oil rail.
    • Install the bolts finger tight.
      Fig 27: Installing High-Pressure Oil Rail Bolts
      G03899407Courtesy of FORD MOTOR CO.
  29. Tighten the bolts in the sequence shown.
    Fig 28: Tightening Bolts In Sequence
    G03899408Courtesy of FORD MOTOR CO.
  30. Install the high-pressure oil line.
    Fig 29: Installing High-Pressure Oil Line
    G03899409Courtesy of FORD MOTOR CO.
    31. NOTE: Clean and inspect the O-rings and install new as necessary.
    NOTE: Apply clean engine oil to the O-rings before installing.
    Fig 30: Installing Glow Plug Buss Bar
    G03899410Courtesy of FORD MOTOR CO.
  31. Install the glow plug buss bar.

    32. 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.
    NOTE: Install new O-rings.
    Fig 31: Identifying Crankcase-To-Head Tube Assembly
    G03887400Courtesy of FORD MOTOR CO.
  32. Apply clean engine oil and install the crankcase-to-head tube assembly.

    33. Late build 

    NOTE: Apply clean engine oil to the top fuel injector D-ring before installing the high pressure oil rail.
    Fig 32: Locating High-Pressure Oil Rail On Injector Bolts
    G03887401Courtesy of FORD MOTOR CO.
  33. 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.
  34. 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 33: Installing Oil Rail Retaining Bolts
    G03899413Courtesy of FORD MOTOR CO.

    35. Two-piece head tube 

    NOTE: Apply clean engine oil to the crankcase-to-head tube prior to installation.
    Fig 34: Crankcase-To-Head Tube Bolt With Torque Specification
    G03887403Courtesy of FORD MOTOR CO.
  35. If equipped with an updated crankcase-to-head tube, install the crankcase-to-head tube assembly.

    36. Late build 

    NOTE: Clean and apply clean engine oil to the O-rings prior to installing.
    Fig 35: View Of Glow Plug Harness And Special Tool
    G03887483Courtesy of FORD MOTOR CO.
  36. Using the special tool, install the glow plug harness.

    37. All vehicles 

    CAUTION: To prevent engine damage, do not use air powered tools when installing the valve cover.
    NOTE: Late build shown, early build similar.
    NOTE: Clean and inspect the valve cover gasket. Install a new gasket if necessary.
    Fig 36: Installing Valve Cover Bolts
    G03899416Courtesy of FORD MOTOR CO.
  37. Position the valve cover gasket. Install the valve cover and 11 bolts.
  38. Position back the oil level indicator and install the nut.
    Fig 37: Installing Nut
    G03899417Courtesy of FORD MOTOR CO.
    39. NOTE: Late build shown, early build similar.
    Fig 38: Connecting Glow Plug Connector
    G03899418Courtesy of FORD MOTOR CO.
  39. Connect the glow plug connector.
    40. NOTE: Late build shown, early build similar.
    Fig 39: Installing Fuel Injector Control Module Mounting Bracket
    G03899419Courtesy of FORD MOTOR CO.
  40. Install the fuel injector control module mounting bracket.
    41. NOTE: Install a new oil filter.
  41. Fill the crankcase with clean engine oil.
    42. NOTE: Lightly lubricate the O-ring with clean engine oil before installing.
    Fig 40: Installing Cylinder Block Drain Plug
    G03899420Courtesy of FORD MOTOR CO.
  42. Install the cylinder block drain plug.
  43. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
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