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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 >> Removal

Cylinder Head LH: Removal

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.

    All vehicles 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Drain the engine oil.
  3. Remove the intake manifold. For additional information, refer to INTAKE MANIFOLD .
  4. Remove the LH cylinder block drain plug.
    Fig 1: Removing LH Cylinder Block Drain Plug
    G03899345Courtesy of FORD MOTOR CO.
    5. NOTE: Late build shown, early build similar.
    Fig 2: Removing Fuel Injector Control Module Mounting Bracket
    G03899346Courtesy of FORD MOTOR CO.
  5. Remove the fuel injector control module mounting bracket.
    6. NOTE: Late build shown, early build similar.
    Fig 3: Disconnecting Glow Plug Connector
    G03899347Courtesy of FORD MOTOR CO.
  6. Disconnect the glow plug connector and position aside.
  7. Remove the nut and position the oil level indicator and tube aside.
    Fig 4: Removing Nut
    G03899348Courtesy of FORD MOTOR CO.
    8. NOTE: Late build shown, early build similar.
    NOTE: Mark the position of the valve cover bolts for valve cover bolt installation.
    Fig 5: Removing Valve Cover Bolts
    G03899349Courtesy of FORD MOTOR CO.
  8. Remove the eleven bolts and the valve cover. Remove the valve cover gasket.

    9. Early build 

  9. Disconnect the high-pressure oil rail supply line at the high-pressure oil rail.
    Fig 6: Disconnecting High-Pressure Oil Rail Supply Line
    G03899350Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the high-pressure oil rail.
    Fig 7: Removing Bolts High-Pressure Oil Rail
    G03899351Courtesy of FORD MOTOR CO.
  11. Disconnect and remove the high-pressure oil supply line.
    Fig 8: Removing High-Pressure Oil Supply Line
    G03899352Courtesy of FORD MOTOR CO.
  12. Remove and discard the crankcase-to-head tube assembly.
    Fig 9: Removing Crankcase-To-Head Tube Assembly
    G03899353Courtesy of FORD MOTOR CO.
  13. Remove the glow plug buss bar.
    Fig 10: Removing Glow Plug Buss Bar
    G03899354Courtesy of FORD MOTOR CO.

    14. Two-piece head tube 

    NOTE: Some engines may have been updated with a new two-piece crankcase-to-head tube. If the crankcase-to-head tube has been updated it will have a hex head.
    Fig 11: Locating D-Ring Seals
    G03887376Courtesy of FORD MOTOR CO.
  14. If the high-pressure oil rail has a hex head, remove the crankcase-to-head tube assembly.
    • Remove and discard the O-ring seals.

    15. Late build 

    NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
    Fig 12: Identifying Bolts And High-Pressure Oil Rail
    G03887377Courtesy of FORD MOTOR CO.
  15. Remove the bolts and the high-pressure oil rail.

    16. One-piece head tube 

    NOTE: The rings on the crankcase-to-head tube are to be used to pry the tube assembly from the branch tube assembly or the oil rail assembly.
    Fig 13: Identifying Crankcase-To-Head Tube
    G03887379Courtesy of FORD MOTOR CO.
  16. Remove the crankcase-to-head tube assembly.
    • Remove and discard the O-rings.

    17. Two-piece head tube 

    CAUTION: Use care not to deform the lower crankcase-to-head tube during removal. If the tube is damaged, a new tube must be installed.
    NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.
    Fig 14: Removing Lower Crankcase-To-Head Tube
    G03899358Courtesy of FORD MOTOR CO.
  17. If the updated crankcase-to-head tube separated, using a pair of soft jawed pliers, remove the lower crankcase-to-head tube.

    18. Late build 

    CAUTION: Do not pull on the glow plug wire or damage may occur.
    NOTE: Only one glow plug connector shown.
    Fig 15: View Of Glow Plug Harness And Special Tool
    G03887483Courtesy of FORD MOTOR CO.
  18. Using the special tool, remove the glow plug harness.

    19. All vehicles 

  19. Remove the four glow plugs.
    Fig 16: Identifying Glow Plug
    G03887484Courtesy of FORD MOTOR CO.
    20. CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
    Fig 17: Removing Fuel Injector Electrical Connector
    G03887380Courtesy of FORD MOTOR CO.
  20. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
  21. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    22. CAUTION: Failure to account for all snap rings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snap ring can be ingested into the lube oil system causing severe engine damage.
    CAUTION: To prevent engine damage, do not use air tools to remove the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
    NOTE: There is not any need to drain the fuel rail.
    NOTE: If engine coolant is found in the combustion chambers, it may be necessary to install a new injector sleeve. For additional information, refer to FUEL CHARGING & CONTROLS - 6.0L DIESEL .
    Fig 18: Identifying Fuel Injector Hold-Down Bolt
    G03887381Courtesy of FORD MOTOR CO.
  22. Remove the bolt, fuel injector hold down and fuel injector.
    23. 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.
  23. Remove the shop towels.
    24. NOTE: LH shown, RH similar.
    Fig 19: Identifying Adapter Pipe Bolts
    G03899293Courtesy of FORD MOTOR CO.
  24. Remove the nuts and bolts from the turbocharger adapter pipe.
  25. Remove the turbocharger adapter pipe.
    Fig 20: Removing Turbocharger Adapter Pipe
    G03899364Courtesy of FORD MOTOR CO.
    26. NOTE: Remove and discard the O-ring.
    Fig 21: Removing Oil Level Indicator Tube
    G03899365Courtesy of FORD MOTOR CO.
  26. Remove the oil level indicator and tube.
  27. Remove the bolts and turbocharger heat shield.
    Fig 22: Locating Turbocharger Heat Shield And Bolts
    G03887333Courtesy of FORD MOTOR CO.
  28. Disconnect the exhaust backpressure tube at the exhaust manifold.
    Fig 23: Disconnecting Exhaust Backpressure Tube
    G03899367Courtesy of FORD MOTOR CO.
  29. Remove the retaining nuts. Remove the exhaust backpressure bracket assembly.
    Fig 24: Removing Retaining Nuts
    G03899368Courtesy of FORD MOTOR CO.
  30. Remove the retaining bolt from the fuel line bracket and position the fuel lines aside.
    Fig 25: Removing Retaining Bolt From Fuel Line Bracket
    G03899369Courtesy of FORD MOTOR CO.
  31. Remove the bolt and the idler pulley.
    Fig 26: Removing Idler Pulley Bolt
    G03899370Courtesy of FORD MOTOR CO.
  32. Disconnect the heater hose from the front cover and position aside.
    Fig 27: Disconnecting Heater Hose From Front Cover
    G03899371Courtesy of FORD MOTOR CO.
  33. Remove the fan shroud mounting stud.
    Fig 28: Removing Fan Shroud Mounting Stud
    G03899372Courtesy of FORD MOTOR CO.
    34. NOTE: Remove and discard the sealing washers.
    Fig 29: Identifying Fuel Line Banjo Bolt
    G03887486Courtesy of FORD MOTOR CO.
  34. Remove the banjo fitting and the fuel line.
    35. CAUTION: Make sure the insulation blanket is not damaged (torn, cracked or fabric separated from the metallic skin) when removing 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 remove the lower rear cylinder head bolt.
    NOTE: The back two cylinder head bolts cannot be removed from the head in vehicle. Raise these bolts and secure them in position so they will clear the cylinder block deck as the head is removed.
    Fig 30: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
  35. Remove and discard the inner cylinder head bolts.
  36. Remove the eight bolts and the rocker arm assemblies.
    Fig 31: Identifying Rocker Arm Assembly Bolts
    G03887497Courtesy of FORD MOTOR CO.
  37. Mark the eight valve bridges with a permanent marker and remove.
    Fig 32: Marking Valve Bridges With Permanent Marker
    G03899376Courtesy of FORD MOTOR CO.
    38. 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.
    Fig 33: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
  38. Mark the location and remove the eight push rods.
  39. Remove the outer cylinder head bolts.
    Fig 34: Removing Outer Cylinder Head Bolts
    G03899378Courtesy of FORD MOTOR CO.
  40. Install the special tool and the lifting crane. With the help of an assistant, remove the cylinder from the vehicle.
    Fig 35: Installing Special Tool And Lifting Crane
    G03899379Courtesy of FORD MOTOR CO.
  41. Remove and discard the cylinder head gasket and dowels.
    • Clean and inspect the gasket sealing surfaces.
      Fig 36: Identifying Gasket Sealing Surfaces Area
      G03887503Courtesy of FORD MOTOR CO.
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