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Home >> Ford >> 2000 >> Taurus LX, 3.0 2, AX4N >> Repair and Diagnosis >> External Pages >> Different car >> Section 138 (Engine - 6.0L Diesel -- F250-F550 Super Duty) >> In-Vehicle Repair >> Cylinder Head - RH >> Installation

Cylinder Head - RH: 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 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 a new cylinder head gasket with the part number facing up and verify the top five holes and the head gasket push rod holes line up.
  2. Install the dowels and the cylinder head gasket.
  3. Using the special tools and with the help of an assistant, install the cylinder head on the engine. Remove the special tools.
    Fig 2: Installing Special Tool And Lifting Crane To Cylinder Head
    G03921550Courtesy of FORD MOTOR CO.
  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 six 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.
    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 inner 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. Install the four glow plugs.
    Fig 9: Glow Plugs - With Torque Specification
    G03887699Courtesy of FORD MOTOR CO.
    11. NOTE: Clean and apply clean engine oil to the O-ring seals.
    Fig 10: Installing Glow Plug Harness Using Special Tool
    G03887483Courtesy of FORD MOTOR CO.
  11. Using the special tool, install the glow plug harness.

    12. Early build vehicles 

  12. Position the turbocharger adapter pipe.
    Fig 11: Identifying Turbocharger Adapter Pipe
    G03906944Courtesy of FORD MOTOR CO.

    13. Late build vehicles 

  13. 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 12: Connecting Adapter Pipe Joint And Tightening Bolts
    G03907033Courtesy of FORD MOTOR CO.

    14. 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 13: Installing Nuts And Bolts - With Torque Specification
    G03906967Courtesy of FORD MOTOR CO.
  14. Install the nuts and bolts in the adapter pipe.
    15. NOTE: Apply clean engine oil to the O-ring seal prior to installing.
    Fig 14: Identifying Cylinder Block Drain Plug
    G03887452Courtesy of FORD MOTOR CO.
  15. Install the cylinder block drain plug.
  16. Install the starter. For additional information, refer to STARTING SYSTEM - DIESEL ENGINE .
    17. CAUTION: If the fuel injector oil inlet D-shaped O-ring seal is damaged, a new fuel injector must be installed.
    Fig 15: Identifying Fuel Injector O Rings And Electrical Connector
    G03887397Courtesy of FORD MOTOR CO.
  17. Install new O-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and O-ring seals liberally with clean engine oil.
    18. 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 16: Installing Fuel Injector Hold-Down Clamp Bolt - With Torque Specification
    G03887398Courtesy of FORD MOTOR CO.
  18. Install the fuel injector, fuel injector hold-down clamp and bolt.
    19. CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
    Fig 17: Identifying Fuel Injector Electrical Connector At Rocker Carrier
    G03887399Courtesy of FORD MOTOR CO.
  19. Install the fuel injector electrical connector into the rocker arm carrier.
  20. Apply engine oil to the top fuel injector O-ring seals.
    Fig 18: Identifying Top Fuel Injector O-Ring Seals
    G03888010Courtesy of FORD MOTOR CO.

    21. Early build vehicles 

    CAUTION: To prevent engine damage, check that the crankcase-to-head tube assembly bottoms out in the branch tube assembly. The oil rail, crankcase-to-head tube and fuel injectors will not function correctly if the tubes are not bottomed out.
    Fig 19: Identifying Crankcase-To-Head Tube
    G03887400Courtesy of FORD MOTOR CO.
  21. Apply clean engine oil on the crankcase-to-head tube D-ring seals and install the tube.

    22. All vehicles 

    NOTE: Apply clean engine oil on the tubes prior to installing the high-pressure oil rail.
  22. 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 rail. Install the guide studs six to seven turns.
    • Press the oil rail into the fuel injectors.
    • Make sure that the oil rail mounting feet are flat against the mounting surface.
    • Loosely install the six bolts.
      Fig 20: Locating High-Pressure Oil Rail On Injectors
      G03887401Courtesy of FORD MOTOR CO.
  23. 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 21: Installing Oil Rail Retaining Bolts In Sequence - With Torque Specifications
      G03887402Courtesy of FORD MOTOR CO.

    24. Late build vehicles 

    NOTE: Apply clean engine oil to the crankcase-to-head tube prior to installing.
    Fig 22: Crankcase-To-Head Tube - With Torque Specification
    G03887403Courtesy of FORD MOTOR CO.
  24. Install the crankcase-to-head tube assembly.

    25. All vehicles 

  25. Install the high-pressure oil rail-to-valve cover gasket.
    Fig 23: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    G03887197Courtesy of FORD MOTOR CO.
    26. CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.
    Fig 24: RH Valve Cover - With Torque Specification
    G03887405Courtesy of FORD MOTOR CO.
  26. Position the valve cover gasket. Install the valve cover and 11 bolts.
  27. If equipped, position back the transmission fluid indicator and tube. Install the retaining nut.
    Fig 25: Identifying Retaining Nut
    G03899172Courtesy of FORD MOTOR CO.
  28. Install the ICP sensor.
    Fig 26: Installing ICP Sensor
    G03906825Courtesy of FORD MOTOR CO.
    29. NOTE: Only one retainer shown.
    Fig 27: Connecting Wiring Retainers To Studs
    G03921432Courtesy of FORD MOTOR CO.
  29. Connect the wiring retainers to the studs.
  30. Install the evaporator core housing. For additional information, refer to HEATING AND VENTILATION .
  31. Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
    32. NOTE: Install a new oil filter.
  32. Fill the crankcase with clean engine oil.
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