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Home >> Ford >> 2002 >> Excursion 5.4 L, 4WD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1723 (Engine - 6.0L Diesel -- F250-F550 Super Duty 6.0L (99P F450/550)) >> In-Vehicle Servicing >> Cylinder Head - RH >> Installation

Cylinder Head - RH: Installation

WARNING: This page is about a different car, the 2007 Ford Pickup, 2007 Ford F550 Super Duty, 2007 Ford F450 Super Duty, and 2007 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
Fig 1: Identifying D-Ring Seals
G03899308Courtesy of FORD MOTOR CO.
    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.
  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 5 holes and the head gasket push rod holes line up.
  2. Install the dowels and the cylinder head gasket.
    3. Fig 2: Special Tool
    GF0005746Courtesy 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. Fig 3: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
  4. Install the outer cylinder head bolts finger-tight.
    5. Fig 4: Identifying Push Rods
    G03887392Courtesy 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.
  5. Apply clean engine oil to each end of the push rods and insert them into their respective positions.
    6. Fig 5: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
    NOTE: Coat the end of each valve stem with clean engine oil.
  6. Install the 8 valve bridges.
    7. Fig 6: Identifying Rocker Arm Assembly Bolts
    G03887497Courtesy of FORD MOTOR CO.
    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.
  7. Install the rocker arm assemblies and the 16 bolts.
    • Tighten to 31 Nm (23 lb-ft).
    8. Fig 7: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy 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.
    NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
  8. Install the 10 inner cylinder head retaining bolts finger-tight.
    9. Fig 8: Cylinder Head Bolt Torque Sequence
    GF0005747Courtesy of FORD MOTOR CO.
  9. Tighten the cylinder head bolts in 7 stages in the following sequence:
    • 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).
    10. Fig 9: Identifying Glow Plug
    G03887484Courtesy of FORD MOTOR CO.
  10. Install the 4 glow plugs.
    • Tighten to 19 Nm (14 lb-ft).
    11. Fig 10: Identifying Glow Plug Harness Special Tool (303-1114)
    G04614327Courtesy of FORD MOTOR CO.
    NOTE: Clean and apply clean engine oil to the O-ring seals.
  11. Using the special tool, install the glow plug harness.
    12. Fig 11: Locating Turbocharger Pipe Nuts
    G03889747Courtesy of FORD MOTOR CO.
  12. 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).
    13. Fig 12: Identifying Adapter Pipe Bolts
    G03899293Courtesy 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.
  13. Install the nuts and bolts in the adapter pipe.
    • Tighten to 27 Nm (20 lb-ft).
    14. Fig 13: Locating Cylinder Block Coolant Drain Plug
    G03887451Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine oil to the O-ring seal prior to installing.
  14. Install the cylinder block coolant drain plug.
    • Tighten to 20 Nm (15 lb-ft).
  15. Install the starter. For additional information, refer to STARTING SYSTEM - DIESEL ENGINE article.
    16. Fig 14: Identifying O-Ring Seals, Copper Washer And Fuel Injector
    G03887397Courtesy of FORD MOTOR CO.
    CAUTION: If the fuel injector oil inlet D-shaped O-ring seal is damaged, a new fuel injector must be installed.
  16. 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.
    17. Fig 15: Identifying Fuel Injector Hold-Down Bolt
    G03887381Courtesy of FORD MOTOR CO.
    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.
  17. Install the fuel injector, fuel injector hold-down clamp and bolt.
    • Tighten to 35 Nm (26 lb-ft).
    18. Fig 16: Identifying Fuel Injector Electrical Connector
    G03887399Courtesy of FORD MOTOR CO.
    CAUTION: Make sure the injector wiring is clear of all moving parts or engine damage can occur.
  18. Install the fuel injector electrical connector into the rocker arm carrier.
    19. Fig 17: Identifying Top Fuel Injector O-Ring Seals
    G03888010Courtesy of FORD MOTOR CO.
  19. Apply engine oil to the top fuel injector O-ring seals.
    20. Fig 18: Locating High-Pressure Oil Rail On Injector Bolts
    G03887401Courtesy 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.
  20. 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.
    21. Fig 19: High-Pressure Oil Rail Torque Sequence
    GF0005748Courtesy of FORD MOTOR CO.
  21. 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).
    22. Fig 20: Locating D-Ring Seals
    G03887376Courtesy of FORD MOTOR CO.
  22. Apply clean engine oil and reassemble the crankcase-to-head tube. Install the crankcase-to-head tube.
    • Tighten to 82 Nm (60 lb-ft).
    23. Fig 21: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    G03887197Courtesy of FORD MOTOR CO.
  23. Install the high-pressure oil rail-to-valve cover gasket.
    24. Fig 22: Identifying Valve Cover, Stud Bolts, And Bolts
    G03887372Courtesy of FORD MOTOR CO.
    CAUTION: To prevent engine damage, do not use air-powered tools when installing the valve cover.
  24. Position the valve cover gasket. Install the valve cover and 11 bolts.
    • Tighten to 9 Nm (80 lb-in).
    25. Fig 23: Identifying Transmission Fluid Indicator Retaining Nut
    G03899172Courtesy of FORD MOTOR CO.
  25. If equipped, position back the transmission fluid indicator and tube. Install the retaining nut.
    26. Fig 24: Locating Injection Control Pressure Sensor
    G03906932Courtesy of FORD MOTOR CO.
  26. Install the ICP sensor.
    • Tighten to 12 Nm (9 lb-ft).
    27. Fig 25: Wiring Harness Retainer
    GF0005743Courtesy of FORD MOTOR CO.
    NOTE: Only one retainer shown.
  27. Connect the wiring retainers to the studs.
  28. Install the evaporator core housing. For additional information, refer to CLIMATE CONTROL article.
  29. Install the intake manifold. For additional information, refer to Intake Manifold .
    30. NOTE: Install a new oil filter.
  30. Fill the crankcase with clean engine oil.
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