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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 RH >> Removal

Cylinder Head RH: 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 evaporator core housing. For additional information, refer to HEATING & VENTILATION .
    5. NOTE: Only one retainer shown.
    Fig 1: Disconnecting Wiring Retainers From Studs
    G03899279Courtesy of FORD MOTOR CO.
  5. Disconnect the wiring retainers from the studs.

    6. Late build 

  6. Remove the injection control pressure (ICP) sensor.
    Fig 2: Locating Injection Control Pressure Sensor
    G03906932Courtesy of FORD MOTOR CO.

    7. All vehicles 

  7. If equipped, remove the nut and position the transmission fluid and indicator aside.
    Fig 3: Identifying Transmission Fluid Indicator Retaining Nut
    G03899172Courtesy of FORD MOTOR CO.
    8. NOTE: Late build shown, early build similar.
    NOTE: Mark the position of the valve cover bolts for the valve cover bolt installation.
  8. Remove the bolts and the valve cover.
    • Clean and inspect the valve cover gasket. Install a new gasket if necessary.
      Fig 4: Removing Valve Cover Bolts
      G03899282Courtesy of FORD MOTOR CO.

    9. Late build 

  9. Remove the high-pressure oil rail-to-valve cover gasket.
    Fig 5: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    G03887197Courtesy of FORD MOTOR CO.

    10. 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 6: Locating D-Ring Seals
    G03887376Courtesy of FORD MOTOR CO.
  10. If the high-pressure oil rail has a hex head, remove the crankcase-to-head tube assembly.
    • Remove and discard the O-ring seals.

    11. 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 7: Identifying Bolts And High-Pressure Oil Rail
    G03887377Courtesy of FORD MOTOR CO.
  11. Remove the bolts and the high-pressure oil rail.

    12. 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 8: Removing Lower Crankcase-To-Head Tube
    G03899286Courtesy of FORD MOTOR CO.
  12. If the updated crankcase-to-head tube separated, using a pair of soft jawed pliers, remove the lower crankcase-to-head tube.

    13. Early build 

  13. Disconnect the high-pressure oil rail supply line at the high-pressure oil rail.
    Fig 9: Disconnecting High-Pressure Oil Rail Supply Line
    G03899287Courtesy of FORD MOTOR CO.
  14. Remove the bolts and the high-pressure oil rail.
    Fig 10: Removing Bolts High-Pressure Oil Rail
    G03899288Courtesy of FORD MOTOR CO.
  15. Disconnect and remove the high-pressure oil supply line.
    Fig 11: Removing High-Pressure Oil Supply Line
    G03899289Courtesy of FORD MOTOR CO.

    16. All vehicles 

    CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
    Fig 12: Removing Fuel Injector Electrical Connector
    G03887380Courtesy of FORD MOTOR CO.
  16. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
  17. Prior to removing the fuel injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    18. 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 no 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 13: Identifying Fuel Injector Hold-Down Bolt
    G03887381Courtesy of FORD MOTOR CO.
  18. Remove the bolt, fuel injector hold-down clamp and fuel injector.
    19. 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.
  19. Remove the shop towels.
  20. Remove the starter. For additional information, refer to STARTERS .
  21. Remove the cylinder drain block.
    Fig 14: Locating Cylinder Block Coolant Drain Plug
    G03887451Courtesy of FORD MOTOR CO.
    22. NOTE: LH shown, RH similar.
    Fig 15: Identifying Adapter Pipe Bolts
    G03899293Courtesy of FORD MOTOR CO.
  22. Remove the nuts and bolts from the turbocharger adapter pipe.
  23. Remove the turbocharger adapter pipe.
    Fig 16: Removing Turbocharger Adapter Pipe
    G03899294Courtesy of FORD MOTOR CO.

    24. Early build 

  24. Remove and discard the crankcase to head tube assembly.
    Fig 17: Removing Crankcase To Head Tube Assembly
    G03899295Courtesy of FORD MOTOR CO.
  25. Remove the glow plug buss bar.
    Fig 18: Removing Glow Plug Buss Bar
    G03899296Courtesy of FORD MOTOR CO.

    26. 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.
  26. Remove the crankcase-to-head tube assembly.
    • Remove and discard the O-rings.
      Fig 19: Identifying Crankcase-To-Head Tube
      G03887379Courtesy of FORD MOTOR CO.

    27. Late build 

    CAUTION: Do not pull on the wiring to remove the glow plug connector or damage may occur.
    NOTE: Only one glow plug connector shown.
    Fig 20: View Of Glow Plug Harness And Special Tool
    G03887483Courtesy of FORD MOTOR CO.
  27. Using the special tool, remove the glow plug harness.

    28. All vehicles 

  28. Remove the four glow plugs.
    Fig 21: Identifying Glow Plug
    G03887484Courtesy of FORD MOTOR CO.
  29. Remove and discard the 10 inner cylinder head bolts.
    Fig 22: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
  30. Remove the eight bolts and the rocker arm assemblies.
    Fig 23: Identifying Rocker Arm Assembly Bolts
    G03887497Courtesy of FORD MOTOR CO.
  31. Mark the eight valve bridges with a permanent marker and remove.
    Fig 24: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
    32. 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 25: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
  32. Mark the location and remove the eight push rods.
  33. Remove the outer cylinder head bolts.
    Fig 26: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
  34. Install the special tool and the lifting crane. With the help of an assistant, remove the cylinder head from the vehicle.
    Fig 27: Removing Cylinder Head From Vehicle
    G03899305Courtesy of FORD MOTOR CO.
  35. Remove and discard the cylinder head gasket and dowels.
    • Clean and inspect the gasket sealing surfaces.
      Fig 28: Identifying Gasket Sealing Surfaces Area
      G03887503Courtesy of FORD MOTOR CO.
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