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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 898 (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 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

    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.
    NOTE: Late build shown, early build similar.
    Fig 1: Installing New D-Ring Seals On The Crankcase-To-Head Tube Assemblies
    G03899308Courtesy of FORD MOTOR CO.
  1. Install new D-ring seals on the crankcase-to-head tube assemblies.
    2. 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 5 top holes and head gasket push rod holes line up.
  2. Install the dowels and the cylinder head gasket.
    3. NOTE: The back two cylinder head bolts cannot be installed into the head in vehicle. Lightly lubricate the threads of 2 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.
    NOTE: Position the fuel lines in place before the cylinder head is installed.
    Fig 2: Installing Cylinder Head
    G03907015Courtesy of FORD MOTOR CO.
  3. Using the special tools and with the help of an assistant, install the cylinder head on the engine. Remove the special tools.
  4. Install the outer cylinder head bolts finger-tight.
    Fig 3: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
    5. 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 4: Identifying Push Rods
    G03887392Courtesy of FORD MOTOR CO.
  5. Apply clean engine oil to each end of the push rods. Insert them into their respective positions with the copper-colored end up.
    6. NOTE: Coat the end of each valve stem with clean engine oil.
    Fig 5: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
  6. Install the eight valve bridges.
    7. CAUTION: Rotate the crankshaft until the damper locating dowel notch is in the 6 o'clock position or engine damage can occur.
    NOTE: Apply clean engine oil to the top center of each valve bridge.
    Fig 6: Locating Rocker Arm Assembly Bolts - With Torque Specification
    G03887670Courtesy of FORD MOTOR CO.
  7. Install the rocker arm assemblies and eight bolts.
    8. 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 7: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
  8. Install the 10 cylinder head retaining bolts finger-tight.
  9. Tighten the head bolts in the following sequence.
    1. Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
    2. Tighten bolts 1 through 10 to 115 Nm (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 to 24 Nm (18 lb-ft).
    7. Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
      Fig 8: Tightening Cylinder Head Retaining Bolts In Sequence
      G03887672Courtesy of FORD MOTOR CO.
    10. NOTE: Install new sealing washers.
    Fig 9: Installing Fuel Line And Banjo Fitting
    G03887721Courtesy of FORD MOTOR CO.
  10. Install the fuel line and the banjo fitting.
  11. Position back and connect the heater hose.
    Fig 10: Identifying Heater Hose
    G03921453Courtesy of FORD MOTOR CO.

    12. Early build vehicles 

  12. Position the exhaust pressure bracket assembly and install the retaining nuts.
    Fig 11: Locating Retaining Nuts And Exhaust Backpressure Assembly - With Torque Specification
    G03906879Courtesy of FORD MOTOR CO.
  13. Tighten the exhaust pressure tube fitting at the exhaust manifold.
    Fig 12: Exhaust Pressure Tube Fitting - With Torque Specification
    G03906880Courtesy of FORD MOTOR CO.

    14. All vehicles 

  14. Position the fuel lines and install the fuel line bracket retaining bolt.
    Fig 13: Installing Fuel Line Bracket Retaining Bolt
    G03907030Courtesy of FORD MOTOR CO.
    15. NOTE: Install a new O-ring seal and apply clean engine oil.
    Fig 14: Installing Oil Level Indicator And Tube
    G03907002Courtesy of FORD MOTOR CO.
  15. Install the oil level indicator and tube.
    16. NOTE: Late build shown, early build similar.
    Fig 15: Installing Turbocharger Heat Shield And Bolts
    G03907032Courtesy of FORD MOTOR CO.
  16. Install the turbocharger heat shield and bolts.

    17. Early build vehicles 

  17. Position the turbocharger adapter pipe.
    Fig 16: Identifying Turbocharger Adapter Pipe
    G03906944Courtesy of FORD MOTOR CO.

    18. Late build vehicles 

  18. Position the two parts of the turbocharger adapter pipe into the vehicle. Install the gasket, connect the adapter pipe joint and install the bolts. Position the turbocharger adapter pipe on the exhaust manifolds.
    Fig 17: Connecting Adapter Pipe Joint Tightening Bolts
    G03907033Courtesy of FORD MOTOR CO.

    19. All vehicles 

    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 18: Installing Nuts And Bolts - With Torque Specification
    G03906967Courtesy of FORD MOTOR CO.
  19. Install the nuts and bolts in the adapter pipe.
  20. Install the four glow plugs.
    Fig 19: Glow Plugs - With Torque Specification
    G03887699Courtesy of FORD MOTOR CO.
    21. NOTE: Clean and apply clean engine oil to the O-ring seals prior to installing.
    Fig 20: Removing/Installing Glow Plug Harness Using Special Tool
    G03887483Courtesy of FORD MOTOR CO.
  21. Using the special tool, install the glow plug harness.
    22. CAUTION: If the fuel injector oil inlet D-shaped O-ring seal is damaged, a new fuel injector must be installed.
    Fig 21: Identifying Fuel Injector O Rings And Electrical Connector
    G03887397Courtesy of FORD MOTOR CO.
  22. Install new O-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and O-rings liberally with clean engine oil.
    23. 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 22: Installing Fuel Injector Hold-Down Clamp Bolt - With Torque Specification
    G03887398Courtesy of FORD MOTOR CO.
  23. Install the fuel injector, fuel injector hold-down and bolt.
    24. CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
    Fig 23: Identifying Fuel Injector Electrical Connector At Rocker Carrier
    G03887399Courtesy of FORD MOTOR CO.
  24. Install the fuel injector electrical connector into the rocker carrier.
  25. Apply engine oil to the top fuel injector O-ring seals.
    Fig 24: Locating Top Fuel Injector O-Ring Seals
    G03888010Courtesy of FORD MOTOR CO.

    26. Early build vehicles 

    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.
    Fig 25: Identifying Crankcase-To-Head Tube Assembly
    G03887400Courtesy of FORD MOTOR CO.
  26. Apply clean engine oil and install the crankcase-to-head tube assembly.

    27. All vehicles 

    NOTE: Apply clean engine oil on the tubes prior to installing the high-pressure oil rail.
  27. 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.
      Fig 26: Locating High-Pressure Oil Rail On Injector Bolts
      G03887401Courtesy of FORD MOTOR CO.
  28. 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 27: Installing Oil Rail Retaining Bolts In Sequence - With Torque Specifications
      G03887402Courtesy of FORD MOTOR CO.

    29. Late build vehicles 

    NOTE: Apply clean engine oil to the crankcase-to-head tube prior to installing.
    Fig 28: Crankcase-To-Head Tube - With Torque Specification
    G03887403Courtesy of FORD MOTOR CO.
  29. Install the crankcase-to-head tube assembly.

    30. All vehicles 

    CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.
    NOTE: Clean and inspect the valve cover gasket. Install a new gasket if necessary.
    Fig 29: Installing Valve Cover And Bolts
    G03921429Courtesy of FORD MOTOR CO.
  30. Position the valve cover gasket. Install the valve cover and 11 bolts.
  31. Position back the oil level indicator and install the nut. Connect the wire retainer.
    Fig 30: Locating Wire Harness Retainer
    G03907047Courtesy of FORD MOTOR CO.
  32. Install the fuel injector control module mounting bracket.
    Fig 31: Installing Fuel Injector Control Module Mounting Bracket
    G03906838Courtesy of FORD MOTOR CO.

    33. Late build vehicles 

  33. Connect the exhaust pressure sensor tube fitting to the exhaust manifold and install the exhaust pressure sensor retaining nut.
    Fig 32: Connecting Exhaust Pressure Sensor Tube Fittings
    G03906833Courtesy of FORD MOTOR CO.

    34. All vehicles 

    NOTE: Install a new oil filter.
  34. Fill the crankcase with clean engine oil.
    35. NOTE: Lightly lubricate the O-ring seal with clean engine oil before installing.
    Fig 33: Installing Cylinder Block Drain Plug
    G03907050Courtesy of FORD MOTOR CO.
  35. Install the cylinder block drain plug.
  36. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
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