Cylinder Head - LH: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

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: Identifying D-Ring Seals

Courtesy of FORD MOTOR CO.

Install new D-ring seals on the crankcase-to-head tube assemblies.

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.

Install the dowels and the cylinder head gasket.

NOTE: The back 2 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 tubes in place before the cylinder head is installed.

Fig 2: Identifying Special Tool

Courtesy of FORD MOTOR CO.

Using the special tools and with the help of an assistant, install the cylinder head on the engine. Remove the special tools.
Install the outer cylinder head bolts finger-tight.

Fig 3: Identifying Outer Cylinder Head Bolts
Courtesy of FORD MOTOR CO.

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: On early build vehicles, higher mileage engines require push rods to be cleaned so the copper-colored end of the push rod can be identified and installed with the copper-colored end up. Push rods on late build vehicles and service push rods do not have a copper-colored end and can be installed with either end up.

Fig 4: Identifying Push Rods

Courtesy of FORD MOTOR CO.

Apply clean engine oil to each end of the push rods and insert them into their respective positions.

NOTE: Coat the end of each valve stem with clean engine oil.

Fig 5: Identifying Valve Bridges

Courtesy of FORD MOTOR CO.

Install the 8 valve bridges.

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.

Install the rocker arm assemblies and 8 bolts.
- Tighten to 31 Nm (23 lb-ft).
  
  Fig 6: Identifying Rocker Arm Assembly Bolts
  Courtesy of FORD MOTOR CO.

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

Courtesy of FORD MOTOR CO.

Install the 10 cylinder head retaining bolts finger-tight.
Tighten the cylinder head bolts in 7 stages in the sequence shown:
- Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
- Stage 2: Tighten bolts 1 through 10 to 115 Nm (85 lb-ft).
- Stage 3: Tighten bolts in sequence 1 through 10, 90 degrees.
- Stage 4: Tighten bolts in sequence 1 through 10, a second time, 90 degrees.
- Stage 5: Tighten bolts in sequence 1 through 10, a third time, 90 degrees.
- Stage 6: Tighten bolts 11 through 15 to 24 Nm (18 lb-ft).
- Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
  
  Fig 8: Identifying Cylinder Head Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.

NOTE: Install new sealing washers.

Install the fuel tube and the banjo fitting.
- Tighten to 38 Nm (28 lb-ft).
  
  Fig 9: Identifying Fuel Line Banjo Bolt
  Courtesy of FORD MOTOR CO.
Connect the heater hose.

Fig 10: Identifying Clamp And Heater Hose
Courtesy of FORD MOTOR CO.
Position the fuel tubes and install the fuel tube bracket bolt.
- Tighten to 13 Nm (10 lb-ft).
  
  Fig 11: Locating Fuel Tube Bracket Bolt
  Courtesy of FORD MOTOR CO.

NOTE: Install a new O-ring seal and apply clean engine oil.

Fig 12: Locating Oil Level Indicator And Tube

Courtesy of FORD MOTOR CO.

Install the oil level indicator and tube.
Position the turbocharger heat shield and install the 3 bolts.
1. Tighten to 49 Nm (36 lb-ft).
2. Tighten to 11 Nm (8 lb-ft).
  
  Fig 13: Locating Turbocharger Heat Shield Bolts
  Courtesy of FORD MOTOR CO.
Position the 2 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.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 14: Locating Turbocharger Pipe Nuts
  Courtesy of FORD MOTOR CO.

NOTE: Apply anti-seize lubricants to the bolt threads prior to installing the bolts.

NOTE: Do not tighten until after the turbocharger is installed.

Install the nuts and bolts in the adapter pipe.
- Tighten to 27 Nm (20 lb-ft).
  
  Fig 15: Identifying Adapter Pipe Bolts
  Courtesy of FORD MOTOR CO.
Install the 4 glow plugs.
- Tighten to 19 Nm (14 lb-ft).
  
  Fig 16: Identifying Glow Plug
  Courtesy of FORD MOTOR CO.

NOTE: Clean and apply clean engine oil to the O-ring seals prior to installing.

Fig 17: Identifying Glow Plug Harness Special Tool (303-1114)

Courtesy of FORD MOTOR CO.

Using the special tool, install the glow plug harness.

CAUTION: If the fuel injector oil inlet D-shaped O-ring seal is damaged, a new fuel injector must be installed.

Fig 18: Identifying O-Ring Seals, Copper Washer And Fuel Injector

Courtesy of FORD MOTOR CO.

Install new O-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and O-rings liberally with clean engine oil.

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.

Install the fuel injector, fuel injector hold-down and bolt.
- Early build vehicles (T40 Torx®), tighten to 33 Nm (24 lb-ft).
- Late build vehicles (T45 Torx®), tighten to 35 Nm (26 lb-ft).
  
  Fig 19: Identifying Fuel Injector Hold-Down Bolt
  Courtesy of FORD MOTOR CO.

CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.

Fig 20: Identifying Fuel Injector Electrical Connector

Courtesy of FORD MOTOR CO.

Install the fuel injector electrical connector into the rocker carrier.
Apply engine oil to the top fuel injector O-ring seals.

Fig 21: Identifying Top Fuel Injector O-Ring Seals
Courtesy of FORD MOTOR CO.

CAUTION: Using the bolts to push the high pressure oil rail into the fuel injectors can damage the fuel injectors and high pressure oil rail.

NOTE: Apply clean engine oil on the tubes prior to installing the high pressure oil rail.

Position the oil rail on the fuel injectors.
- Place the oil rail on top of the carrier so that the 4 single ball tubes are engaging the injector lead angle.
- Insert 3 guide bolts, 2 on the ends of the straight side of the oil rail and 1 in the middle of the wavy side of the rail. Install the guide studs 6 to 7 turns.
- Manually 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 6 bolts.
  
  Fig 22: Locating High-Pressure Oil Rail On Injector Bolts
  Courtesy of FORD MOTOR CO.
Remove the 3 guide bolts, install the remaining bolts and tighten the 9 bolts in the sequence shown.
- Tighten to 13 Nm (10 lb-ft).
  
  Fig 23: Identifying Oil Rail Bolts Tightening Sequence
  Courtesy of FORD MOTOR CO.
Apply clean engine oil and reassemble the crankcase-to-head tube. Install the crankcase-to-head tube.
- Tighten to 82 Nm (60 lb-ft).
  
  Fig 24: Locating D-Ring Seals
  Courtesy of FORD MOTOR CO.

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.

Position the valve cover gasket, the valve cover and install the stud bolts and the bolts.
- Tighten to 9 Nm (80 lb-in).
  
  Fig 25: Locating Valve Cover Stud Bolts
  Courtesy of FORD MOTOR CO.
Position back the oil level indicator and install the nut. Connect the wire retainer.

Fig 26: Locating Wire Harness Retainer
Courtesy of FORD MOTOR CO.
Install the fuel injector control module mounting bracket and the nuts.
- Tighten to 8 Nm (71 lb-in).
  
  Fig 27: Locating Fuel Injector Control Module Mounting Bracket Nuts
  Courtesy of FORD MOTOR CO.
Position the EP sensor tube and connect the fitting at the exhaust manifold and install the nut.
- Tighten the EP sensor tube support bracket nut to 13 Nm (10 lb-ft).
- Tighten the EP sensor tube fitting at the exhaust manifold to 30 Nm (22 lb-ft).
  
  Fig 28: Locating EP Sensor Tube Support Bracket Nut
  Courtesy of FORD MOTOR CO.

NOTE: Install a new oil filter.

Fill the crankcase with clean engine oil.

NOTE: Lightly lubricate the O-ring seal with clean engine oil before installing.

Install the cylinder block coolant drain plug.
- Tighten to 20 Nm (15 lb-ft).
  
  Fig 29: Locating Cylinder Block Coolant Drain Plug
  Courtesy of FORD MOTOR CO.
Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .