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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 - RH >> Removal

Cylinder Head - RH: 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. Remove the evaporator core housing. For additional information refer to CLIMATE CONTROL article.
    5. Fig 1: Wiring Harness Retainer
    GF0005743Courtesy of FORD MOTOR CO.
    NOTE: Only one retainer shown.
  5. Disconnect the wiring harness retainers from the studs.
    6. Fig 2: Locating Injection Control Pressure Sensor
    G03906932Courtesy of FORD MOTOR CO.
  6. Remove the injection control pressure (ICP) sensor.
    7. Fig 3: Identifying Transmission Fluid Indicator Retaining Nut
    G03899172Courtesy of FORD MOTOR CO.
  7. If equipped, remove the nut and position the transmission fluid and indicator aside.
    8. Fig 4: Valve Cover Fastener
    GF0005744Courtesy of FORD MOTOR CO.
    NOTE: Mark the position of the valve cover bolts for the 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 5: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
    G03887197Courtesy of FORD MOTOR CO.
  9. Remove the high-pressure oil rail-to-valve cover gasket.
    10. Fig 6: Locating D-Ring Seals
    G03887376Courtesy of FORD MOTOR CO.
  10. Remove the crankcase-to-head tube assembly.
    • Remove and discard the D-ring seals.
    11. 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.
  11. Remove the bolts and the high-pressure oil rail.
    12. 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.
  12. 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.
    13. 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.
  13. Using the special tool, push the fuel injector electrical connector out of the rocker arm carrier.
  14. Prior to removing the fuel injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
    15. 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 into service can cause engine damage. A missing snap ring can be ingested into the lube oil system and cause 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.
  15. Remove the bolt, fuel injector hold-down clamp 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. Remove the starter. For additional information, refer to STARTING SYSTEM - DIESEL ENGINE article.
    18. Fig 11: Locating Cylinder Block Coolant Drain Plug
    G03887451Courtesy of FORD MOTOR CO.
  18. Remove the cylinder block coolant drain plug.
    19. Fig 12: Identifying Adapter Pipe Bolts
    G03899293Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  19. Remove the nuts and bolts from the turbocharger adapter pipe.
    20. Fig 13: Locating Turbocharger Pipe Nuts
    G03889747Courtesy of FORD MOTOR CO.
  20. 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.
    21. Fig 14: Identifying Glow Plug Harness Special Tool (303-1114)
    G04614327Courtesy of FORD MOTOR CO.
    CAUTION: Do not pull on the wiring to remove the glow plug connector or damage may occur.
    NOTE: Only one glow plug connector shown.
  21. Using the special tool, remove the glow plug harness and position aside.
    22. Fig 15: Identifying Glow Plug
    G03887484Courtesy of FORD MOTOR CO.
  22. Remove the 4 glow plugs.
    23. Fig 16: Identifying Cylinder Head Retaining Bolts
    G03887496Courtesy of FORD MOTOR CO.
  23. Remove and discard the 10 inner cylinder head bolts.
    24. Fig 17: Identifying Rocker Arm Assembly Bolts
    G03887497Courtesy of FORD MOTOR CO.
  24. Remove the 8 bolts and the rocker arm assemblies.
    25. Fig 18: Identifying Valve Bridges
    G03887499Courtesy of FORD MOTOR CO.
  25. Mark the 8 valve bridges with a permanent marker and remove.
    26. Fig 19: 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.
  26. Mark the location and remove the 8 push rods.
    27. Fig 20: Identifying Outer Cylinder Head Bolts
    G03887501Courtesy of FORD MOTOR CO.
  27. Remove the outer cylinder head bolts.
    28. Fig 21: Special Tool
    GF0005746Courtesy of FORD MOTOR CO.
  28. Install the special tool and the lifting crane. With the help of an assistant, remove the cylinder head from the vehicle.
  29. Check for cylinder head distortion. For additional information, refer to Cylinder Head Distortion .
    30. Fig 22: Identifying Gasket Sealing Surfaces Area
    G03887503Courtesy of FORD MOTOR CO.
  30. Remove and discard the cylinder head gasket and dowels.
    • Clean and inspect the gasket sealing surfaces.
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