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Cylinder Head: Installation

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Both cylinder heads 

  1. Install the new cylinder head dowels.
  2. Install the cylinder head gasket(s).

    Right cylinder head 

  3. With the help of an assistant, install the RH cylinder head.
  4. NOTE: Using too much engine oil on the threads of the cylinder head bolts may 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 may affect the true torque value of the bolts.
    NOTE: Lightly lubricate the new 12 mm cylinder head bolt threads and flanges with clean engine oil.

    Install the 22 cylinder head bolts.

    • Tighten finger-tight.
  5. Tighten the cylinder head bolts in 8 stages, in the sequence shown in the illustration.
    • Stage 1: Tighten bolts 1 through 18 to 20 Nm (177 lb-in).
    • Stage 2: Tighten bolts 1 through 18 to 49 Nm (36 lb-ft).
    • Stage 3: Tighten bolts 1 through 18, a second time to 49 Nm (36 lb-ft).
    • Stage 4: Tighten bolts 1 through 18, a third time to 49 Nm (36 lb-ft).
    • Stage 5: Tighten bolts 1 through 18, an additional 90 degrees.
    • Stage 6: Tighten bolts 1 through 18, a second time, an additional 90 degrees.
    • Stage 7: Tighten bolts 1 through 18, a third time, an additional 90 degrees.
    • Stage 8: Tighten bolts 19 through 22 to 30 Nm (22 lb-ft).
      Fig 1: Identifying Tightening Sequence Of Right Cylinder Head Bolts
      G08593210Courtesy of FORD MOTOR CO.
  6. Position back the engine wiring harness and connect the fuel volume control valve electrical connector.
    Fig 2: Locating Fuel Volume Control Valve Electrical Connector
    G08593211Courtesy of FORD MOTOR CO.
  7. Install the secondary coolant pump and 4 bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 3: Locating Secondary Coolant Pump Mounting Bolts
      G08593212Courtesy of FORD MOTOR CO.
  8. NOTE: The quick connect coupling illustrated is to show the spring clip in the released location only. The quick connect coupling on the hose may differ.

    Connect the coolant hoses to the secondary coolant pump.

    • Make sure the spring clip is in place and the coolant hose quick connect coupling is secure.
      Fig 4: Locating Coolant Pump Hose Spring Clip
      G08593213Courtesy of FORD MOTOR CO.
  9. Install the accessory drive belt tensioner and bolt.
    • Tighten to 48 Nm (35 lb-ft).
      Fig 5: Locating Accessory Drive Belt Tensioner Mounting Bolts
      G08593214Courtesy of FORD MOTOR CO.

    Right cylinder head with dual generator 

  10. Install the generator. For additional information, refer to CHARGING SYSTEM .

    Left cylinder head 

  11. With the help of an assistant, install the LH cylinder head.
  12. NOTE: Using too much engine oil on the threads of the cylinder head bolts may 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 may affect the true torque value of the bolts.
    NOTE: Lightly lubricate the new M12 cylinder head bolt threads and flanges with clean engine oil.

    Install the 23 cylinder head bolts.

    • Tighten finger-tight.
  13. Tighten the cylinder head bolts in 8 stages, in the sequence shown in the illustration.
    • Stage 1: Tighten bolts 1 through 18 to 20 Nm (177 lb-in).
    • Stage 2: Tighten bolts 1 through 18 to 49 Nm (36 lb-ft).
    • Stage 3: Tighten bolts 1 through 18, a second time to 49 Nm (36 lb-ft).
    • Stage 4: Tighten bolts 1 through 18, a third time to 49 Nm (36 lb-ft).
    • Stage 5: Tighten bolts 1 through 18, an additional 90 degrees.
    • Stage 6: Tighten bolts 1 through 18, a second time, an additional 90 degrees.
    • Stage 7: Tighten bolts 1 through 18, a third time, an additional 90 degrees.
    • Stage 8: Tighten bolts 19 through 23 to 30 Nm (22 lb-ft).
      Fig 6: Identifying Tightening Sequence Of Left Cylinder Head Bolts
      G08593215Courtesy of FORD MOTOR CO.
  14. Position back the ground strap and install the bolt. Connect the wire retainer.
    • Tighten to 10 Nm (98 lb-in).
      Fig 7: Locating Ground Strap Bolt And Wire Retainer
      G08593216Courtesy of FORD MOTOR CO.
  15. NOTE: Engine shown removed for clarity.

    Install the power steering bracket and 4 bolts.

    • Tighten to 24 Nm (18 lb-ft).
      Fig 8: Locating Power Steering Bracket Mounting Bolts
      G08593217Courtesy of FORD MOTOR CO.
  16. If equipped, connect the turbocharger wastegate control vacuum and electrical connector.
    Fig 9: Locating Turbocharger Wastegate Control Vacuum And Electrical Connector
    G08593218Courtesy of FORD MOTOR CO.
  17. NOTE: Boot positioned back for clarity.

    Connect the generator electrical connector, the generator B+ terminal and install the nut.

    • Tighten to 17 Nm (150 lb-in).
      Fig 10: Locating Generator Electrical Connector Mounting Nut And B+ Terminal
      G08593219Courtesy of FORD MOTOR CO.
  18. Connect the lower engine wire harness retainer to the power steering bracket.
    Fig 11: Locating Lower Engine Wire Harness Retainer
    G08593220Courtesy of FORD MOTOR CO.
  19. NOTE: The third bolt is located behind the power steering tube.

    Position back the power steering pump and install the 3 bolts.

    • Tighten to 24 Nm (18 lb-ft).
      Fig 12: Locating Power Steering Pump Mounting Bolts
      G08593221Courtesy of FORD MOTOR CO.
  20. Position the power steering tube into the retainer.
    Fig 13: Locating Power Steering Tube Retainer
    G08593222Courtesy of FORD MOTOR CO.
  21. Install the CAC tube and the clamp.
    • Tighten to 9 Nm (80 lb-in).
      Fig 14: Locating Charge Air Cooler Tube Clamp
      G08593223Courtesy of FORD MOTOR CO.
  22. Connect the CAC temperature sensor and wire retainer.
    Fig 15: Locating Charge Air Cooler Temperature Sensor And Wire Retainer
    G08593224Courtesy of FORD MOTOR CO.

    Both cylinder heads 

  23. Install the coolant crossover manifold assembly. For additional information, refer to ENGINE COOLING - DIESEL ENGINES .
  24. Install the LH rocker arms or RH rocker arms. For additional information, refer to ROCKER ARM .
  25. Install the LH exhaust manifold or RH exhaust manifold. For additional information, refer to EXHAUST MANIFOLD - LH  or EXHAUST MANIFOLD - RH .
  26. Install the accessory drive belt. For additional information, refer to ACCESSORY DRIVE .
  27. NOTE: Engine shown removed for clarity.

    Position the cooling fan stator and install the 4 nuts.

    • Tighten to 17 Nm (150 lb-in).
      G08593225
  28. Install the cooling fan. For additional information, refer to ENGINE COOLING - DIESEL ENGINES .
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