Cylinder Head: Removal

Both cylinder heads 

1. Remove the engine. For additional information, refer to Engine .
2. Remove the 10 bolts and flexplate.
   • Discard the bolts.
Fig 1: Identifying Flexplate/Flywheel Bolts
Courtesy of FORD MOTOR CO.
3. Mount the engine on an engine stand.
NOTE: Do not pull on the wiring to remove the glow plug connector or damage may occur.
4. Using the Glow Plug Connector Remover/Installer, remove the glow plug harness.
Fig 2: Identifying Glow Plug Harness Special Tool (303-1114)
Courtesy of FORD MOTOR CO.
5. Remove the 8 glow plugs.
Fig 3: Identifying Glow Plug
Courtesy of FORD MOTOR CO.
6. Prior to removing the exhaust manifolds, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and cylinder head. Record the measurement and compare with the specification.
NOTE: RH shown, LH similar.
7. Remove the 16 bolts, 16 spacers and the exhaust manifolds.
   • Discard the bolts.
Fig 4: Identifying Exhaust Manifolds Bolts
Courtesy of FORD MOTOR CO.

LH cylinder head 

8. Remove the left cylinder head banjo fitting and fuel line.
   • Discard the sealing washers.
Fig 5: Identifying Fuel Line Banjo Bolt
Courtesy of FORD MOTOR CO.
9. Remove the 3 bolts and the turbocharger heat shield.
Fig 6: Locating Turbocharger Heat Shield And Bolts
Courtesy of FORD MOTOR CO.
10. Remove the protective covering from the LH cylinder head.

RH cylinder head 

NOTE: Mark the location of the stud bolts.
11. Remove the RH valve cover.
    • Remove the 6 stud bolts, 5 bolts and valve cover.
    • Clean and inspect the gaskets.
    • Clean and inspect the sealing surfaces.
Fig 7: Identifying RH Stud Bolts, Bolts & Valve Cover
Courtesy of FORD MOTOR CO.
12. Remove the RH high-pressure oil rail-to-valve cover gasket.
Fig 8: Identifying High-Pressure Oil Rail-To-Valve Cover Gasket
Courtesy of FORD MOTOR CO.

Both cylinder heads 

13. Disconnect the fuel injector electrical connectors.
Fig 9: Identifying Fuel Injector Electrical Connector & Retainer Clip
Courtesy of FORD MOTOR CO.
14. Remove the crankcase-to-head tubes.
Fig 10: Locating D-Ring Seals
Courtesy of FORD MOTOR CO.
NOTE: LH cylinder head shown, RH cylinder head similar.
NOTE: Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
15. Remove the 18 bolts and the high-pressure oil rails.
Fig 11: Identifying Bolts And High-Pressure Oil Rail
Courtesy of FORD MOTOR CO.
NOTE: Use a shop towel and metal brake parts cleaner to remove the oil residue prior to removing.
16. If the crankcase-to-head tube separated, using the High Pressure Supply Tube Remover, remove the lower crankcase-to-head tube.
    • Remove and discard the D-ring seal.
Fig 12: Identifying Special Tool (303-1164)
Courtesy of FORD MOTOR CO.
17. Remove and discard the D-ring seals.
Fig 13: Identifying D-Ring Seals
Courtesy of FORD MOTOR CO.
NOTE: Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector may occur.
18. Using the Injector Connector Release Tool, push the fuel injector electrical connectors out of the rocker arm carrier.
Fig 14: Pushing Fuel Injector Electrical Connector Out Of The Rocker Arm Carrier
Courtesy of FORD MOTOR CO.
19. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
NOTE: To prevent engine damage, do not use air tools when removing and installing the fuel injectors.
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.
20. Remove the bolt, the fuel injector hold down and the fuel injectors.
    • Remove and discard the O-ring seals and copper washer.
Fig 15: Identifying Fuel Injector Hold-Down Bolt
Courtesy of FORD MOTOR CO.
21. Remove the shop towels.
NOTE: LH cylinder head shown, RH cylinder head similar.
22. Remove and discard the 20 inner cylinder head bolts.
Fig 16: Identifying Cylinder Head Retaining Bolts
Courtesy of FORD MOTOR CO.
23. Remove the 16 bolts and the rocker arm assemblies.
Fig 17: Identifying Rocker Arm Assembly Bolts
Courtesy of FORD MOTOR CO.
NOTE: LH cylinder head shown, RH cylinder head similar.
24. Remove the 4 bolts and rocker arm carriers.
    • Remove and discard the press-in-place gaskets.
    • Clean and inspect the sealing surfaces.
Fig 18: Rocker Arm Carrier Bolts
Courtesy of FORD MOTOR CO.
25. Mark the 16 valve bridges with a permanent marker and remove.
Fig 19: Identifying Valve Bridges
Courtesy of FORD MOTOR CO.
NOTE: 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 16 push rods.
Fig 20: Identifying Push Rods
Courtesy of FORD MOTOR CO.
27. Remove the 10 outer cylinder head bolts.
Fig 21: Identifying Outer Cylinder Head Bolts
Courtesy of FORD MOTOR CO.
28. Using the Cylinder Head Lifting Bracket, remove the cylinder heads.
Fig 22: Identifying Cylinder Head Lifting Bracket On Cylinder Head
Courtesy of FORD MOTOR CO.
29. Check for cylinder head distortion. For additional information, refer to Cylinder Head Distortion .
30. Remove and discard the cylinder head gaskets and dowels.
    • Clean and inspect the gasket sealing surfaces.
Fig 23: Identifying Gasket Sealing Surfaces Area
Courtesy of FORD MOTOR CO.
31. Check the cylinder head distortion. For additional information, refer to Cylinder Head Distortion .