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Home >> Ford >> 2003 >> Mustang Base, 2D Convertible, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1635 (Engine - 6.0L Diesel -- F250-F550 Super Duty 6.0L (99P F450/550)) >> In-Vehicle Servicing >> Cylinder Head - LH >> Removal

Cylinder Head - LH: Removal

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.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING AND LIFTING article.
  2. Drain the engine oil.
  3. Remove the intake manifold. For additional information, refer to Intake Manifold .
    4. Fig 1: Cylinder Block Drain Plug
    GF0005749Courtesy of FORD MOTOR CO.
  4. Remove the LH cylinder block coolant drain plug.
    5. Fig 2: EP Sensor Tube & Nut
    GF0005690Courtesy of FORD MOTOR CO.
  5. Disconnect the exhaust pressure (EP) sensor tube fitting at the exhaust manifold and remove the nut and the EP sensor tube.
    6. Fig 3: Fuel Injector Control Module Mounting Bracket
    GF0005750Courtesy of FORD MOTOR CO.
  6. Remove the fuel injector control module mounting bracket.
    7. Fig 4: Locating Wire Harness Retainer
    G03907047Courtesy of FORD MOTOR CO.
  7. Disconnect the wire retainer and remove the nut and position the oil level indicator and tube aside.
    8. Fig 5: Valve Cover Fasteners
    GF0005695Courtesy of FORD MOTOR CO.
    NOTE: Mark the position of the valve cover bolts for valve cover bolt installation.
  8. Remove the bolts, stud bolts and the valve cover.
    • Clean and inspect the valve cover gasket. Install a new gasket if necessary.
    9. Fig 6: Locating D-Ring Seals
    G03887376Courtesy of FORD MOTOR CO.
  9. Remove the crankcase-to-head tube assembly.
    • Remove and discard the D-ring seals.
    10. Fig 7: Identifying Bolts And High-Pressure Oil Rail
    G03887377Courtesy of FORD MOTOR CO.
    NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
  10. Remove the bolts and the high-pressure oil rail.
    11. Fig 8: Identifying Special Tool (303-1164)
    G04519461Courtesy of FORD MOTOR CO.
    NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.
  11. If the crankcase-to-head tube separated, using the special tool, remove the lower crankcase-to-head tube.
    • Remove and discard the D-ring seal.
    12. Fig 9: Locating Fuel Injector Electrical Connector
    GF0005745Courtesy of FORD MOTOR CO.
    CAUTION: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
  12. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
  13. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    14. Fig 10: Identifying Fuel Injector Hold-Down Bolt
    G03887381Courtesy of FORD MOTOR CO.
    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 article.
  14. Remove the bolt, fuel injector hold-down and fuel injector.
    15. 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.
  15. Remove the shop towels.
    16. Fig 11: Identifying Glow Plug Harness Special Tool (303-1114)
    G04614327Courtesy of FORD MOTOR CO.
    CAUTION: Do not pull on the glow plug wire or damage may occur.
    NOTE: Only one glow plug connector shown.
  16. Using the special tool, remove the glow plug harness and position aside.
    17. Fig 12: Identifying Glow Plug
    G03887484Courtesy of FORD MOTOR CO.
  17. Remove the 4 glow plugs.
    18. Fig 13: Identifying Adapter Pipe Bolts
    G03899293Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  18. Remove the nuts and bolts from the turbocharger adapter pipe.
    19. Fig 14: Locating Turbocharger Pipe Nuts
    G03889747Courtesy of FORD MOTOR CO.
  19. 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 2 parts of the turbocharger adapter pipe.
    20. Fig 15: Oil Level Indicator Tube
    GF0005751Courtesy of FORD MOTOR CO.
    NOTE: Remove and discard the O-ring seal.
  20. Remove the oil level indicator and tube.
    21. Fig 16: Locating Turbocharger Heat Shield Bolts
    G03907003Courtesy of FORD MOTOR CO.
  21. Remove the bolts and turbocharger heat shield.
    22. Fig 17: Fuel Tube Bracket Bolt
    GF0005752Courtesy of FORD MOTOR CO.
  22. Remove the retaining bolt from the fuel tube bracket and position the fuel tubes aside.
    23. Fig 18: Identifying Clamp And Heater Hose
    G03921453Courtesy of FORD MOTOR CO.
  23. Disconnect the heater hose from the front cover and position aside.
    24. Fig 19: Identifying Fuel Line Banjo Bolt
    G03887486Courtesy of FORD MOTOR CO.
    NOTE: Remove and discard the sealing washers.
  24. Remove the banjo fitting and the fuel tube.
    25. Fig 20: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
    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 2 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.
  25. Remove and discard the inner cylinder head bolts.
    26. Fig 21: Identifying Rocker Arm Assembly Bolts
    G03887497Courtesy of FORD MOTOR CO.
  26. Remove the 8 bolts and the rocker arm assemblies.
    27. Fig 22: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
  27. Mark the 8 valve bridges with a permanent marker and remove.
    28. Fig 23: 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.
  28. Mark the location and remove the 8 push rods.
    29. Fig 24: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
  29. Remove the outer cylinder head bolts.
    30. Fig 25: Special Tool
    GF0005753Courtesy of FORD MOTOR CO.
  30. Install the special tool and the lifting crane. With the help of an assistant, remove the cylinder from the vehicle.
  31. Check for cylinder head distortion. For additional information, refer to Cylinder Head Distortion .
    32. Fig 26: Identifying Gasket Sealing Surfaces Area
    G03887503Courtesy of FORD MOTOR CO.
  32. Remove and discard the cylinder head gasket and dowels.
    • Clean and inspect the gasket sealing surfaces.
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