LEMON Manuals: Even more car manuals for everyone
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 >> Removal

Cylinder Head - LH: Removal

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 

  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND 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
    G03906986Courtesy of FORD MOTOR CO.

    5. Late build vehicles 

  5. To remove the exhaust pressure sensor tube assembly, remove the exhaust pressure sensor tube retaining nut and disconnect the exhaust pressure sensor tube fitting at the exhaust manifold.
    Fig 2: Removing Exhaust Pressure Sensor Tube
    G03906987Courtesy of FORD MOTOR CO.

    6. All vehicles 

  6. Remove the fuel injector control module mounting bracket.
    Fig 3: Removing Fuel Injector Control Module Mounting Bracket
    G03921585Courtesy of FORD MOTOR CO.
  7. Disconnect the wire retainer. Remove the nut and position the oil level indicator and tube aside.
    Fig 4: Locating Wire Harness Retainer
    G03907047Courtesy of FORD MOTOR CO.
    8. NOTE: Mark the position of the valve cover bolts for valve cover bolt installation.
  8. Remove the 11 bolts and the valve cover.
    • Clean and inspect the valve cover gasket. Install a new gasket if necessary.
      Fig 5: Removing Bolts And Valve Cover
      G03921587Courtesy of FORD MOTOR CO.

    9. Late build vehicles 

  9. Remove the crankcase-to-head tube assembly.
    • Remove and discard the D-ring seals.
      Fig 6: Removing D-Ring Seals
      G03887376Courtesy of FORD MOTOR CO.

    10. All vehicles 

    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.
  10. Remove the bolts and the high-pressure oil rail.

    11. Early build vehicles 

    NOTE: The rings on the crankcase-to-head tube must be used to pry the tube assembly from the branch tube assembly or the oil rail assembly.
  11. Remove the crankcase-to-head tube assembly.
    • Remove and discard the D-ring seals.
      Fig 8: Identifying Crankcase-To-Head Tube
      G03887379Courtesy of FORD MOTOR CO.

    12. Late build vehicles 

    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 brake parts cleaner to remove the oil residue prior to removing.
  12. If the crankcase-to-head tube separated, using a pair of soft-jawed pliers, remove the lower crankcase-to-head tube.
    • Remove and discard the D-ring seal.
      Fig 9: Removing Lower Crankcase-To-Head Tube
      G03887378Courtesy of FORD MOTOR CO.

    13. All vehicles 

    CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
    Fig 10: Removing Fuel Injector Electrical Connector
    G03887380Courtesy of FORD MOTOR CO.
  13. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
  14. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    15. 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 AND CONTROLS - 6.0L DIESEL .
    Fig 11: Locating Bolt, Fuel Injector Hold-Down Clamp And Fuel Injector
    G03887381Courtesy of FORD MOTOR CO.
  15. Remove the bolt, fuel injector hold-down and fuel injector.
    16. 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.
  16. Remove the shop towels.
    17. CAUTION: Do not pull on the glow plug wire or damage may occur.
    NOTE: Only one glow plug connector shown.
    Fig 12: Removing/Installing Glow Plug Harness Using Special Tool
    G03887483Courtesy of FORD MOTOR CO.
  17. Using the special tool, remove the glow plug harness. Position the wiring harness aside.
  18. Remove the four glow plugs.
    Fig 13: Identifying Glow Plugs
    G03887484Courtesy of FORD MOTOR CO.
    19. NOTE: LH shown, RH similar.
    Fig 14: Locating LH Turbocharger Adapter Pipe Nuts
    G03899293Courtesy of FORD MOTOR CO.
  19. Remove the nuts and bolts from the turbocharger adapter pipe.

    20. Early build vehicles 

  20. Remove the turbocharger adapter pipe.
    Fig 15: Identifying Turbocharger Adapter Pipe
    G03906944Courtesy of FORD MOTOR CO.

    21. Late build vehicles 

  21. Position the turbocharger adapter pipe to gain access to the adapter pipe joint. Remove the bolts, separate the adapter pipe joint and remove the gasket. Remove the two parts of the turbocharger adapter pipe.
    Fig 16: Locating Turbocharger Adapter Pipe Nuts
    G03889747Courtesy of FORD MOTOR CO.

    22. All vehicles 

    NOTE: Remove and discard the O-ring seal.
    Fig 17: Removing Oil Level Indicator And Tube
    G03907002Courtesy of FORD MOTOR CO.
  22. Remove the oil level indicator and tube.
    23. NOTE: Late build shown, early build similar.
    Fig 18: Removing Bolts And Turbocharger Heat Shield
    G03907003Courtesy of FORD MOTOR CO.
  23. Remove the bolts and turbocharger heat shield.

    24. Early build vehicles 

  24. Disconnect the exhaust pressure tube at the exhaust manifold.
    Fig 19: Locating Exhaust Pressure Tube
    G03907004Courtesy of FORD MOTOR CO.
  25. Remove the retaining nuts. Remove the exhaust pressure bracket assembly.
    Fig 20: Removing Retaining Nuts And Exhaust Pressure Bracket Assembly
    G03906852Courtesy of FORD MOTOR CO.

    26. All vehicles 

  26. Remove the retaining bolt from the fuel line bracket and position the fuel lines aside.
    Fig 21: Removing Fuel Line Bracket
    G03907006Courtesy of FORD MOTOR CO.
  27. Disconnect the heater hose from the front cover and position aside.
    Fig 22: Identifying Heater Hose
    G03921453Courtesy of FORD MOTOR CO.
    28. NOTE: Remove and discard the sealing washers.
    Fig 23: Removing Banjo Fitting And Fuel Line
    G03887486Courtesy of FORD MOTOR CO.
  28. Remove the banjo fitting and the fuel line.
    29. 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 24: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
  29. Remove and discard the inner cylinder head bolts.
  30. Remove the eight bolts and the rocker arm assemblies.
    Fig 25: Identifying Rocker Arm Assembly Bolts
    G03887497Courtesy of FORD MOTOR CO.
  31. Mark the eight valve bridges with a permanent marker and remove.
    Fig 26: 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 27: 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 28: 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 from the vehicle.
    Fig 29: Removing Cylinder Head From Vehicle Using Lifting Crane
    G03907015Courtesy of FORD MOTOR CO.
  35. Remove and discard the cylinder head gasket and dowels.
    • Clean and inspect the gasket sealing surfaces.
      Fig 30: Cleaning And Inspecting Gasket Sealing Surfaces
      G03887503Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals