Cylinder Head
Special Tool(s) / General Equipment
| 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge | |
|---|---|
| 303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F |
|
| 303-1310 Holding Wrench, Crankshaft | |
| 303-1587 Timing Tool, Crankshaft | |
| 303-679A Remover/Installer, Engine Front Cover Inspection Plate | |
| 303-682 Aligner, Engine Front Cover | |
| Floor Crane | |
| Mounting Stand | |
| 6 mm Drill Bit | |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Metal Surface Prep Wipes ZC-31-B | - |
| Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil XO-5W40-5QSD | WSS-M2C171-E |
| Motorcraft® Silicone Gasket and Sealant TA-30 | WSE-M4G323-A4 |
- 1.NOTE: Measure the piston protrusion of each cylinder at TDC.
Measure the distance between the piston crown and the cylinder block at the points indicated.
- 2.NOTE: The largest measurement determines the choice of the cylinder head gasket.
Using the special tool, measure the piston protrusion.
Use Special Service Tool: 100-002 (TOOL-4201-C) Holding Fixture with Dial Indicator Gauge.
- 3.
Determine the cylinder head gasket thickness. Refer to: Specifications .
- 5.NOTE: The glow plugs protrude past the lower face of the cylinder head, any impact on the tip of the glow plug may result in glow plug damage.NOTE: Use the help of an assistant to install the cylinder head.NOTE: The cylinder head bolts are torque-to-yield and must not be reused. New cylinder head bolts must be installed.NOTE: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
Install the cylinder head and the new bolts. Tighten in the sequence shown in illustration in 12 stages.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5QSD (WSS-M2C171-E)
Torque:
Stage 1: Bolts 1 - 12: 89 lb.in (10 Nm)
Stage 2: Bolts 13 - 22: 44 lb.in (5 Nm)
Stage 3: Bolts 1 - 12: 177 lb.in (20 Nm)
Stage 4: Bolts 13 - 22: 89 lb.in (10 Nm)
Stage 5: Bolts 1 - 12: 26 lb.ft (35 Nm)
Stage 6: Bolts 13 - 22: 177 lb.in (20 Nm)
Stage 7: Bolts 1 - 12: 33 lb.ft (45 Nm)
Stage 8: Bolts 13 - 22: 19 lb.ft (26 Nm)
Stage 9: Bolts 1 - 12: 90°
Stage 10: Bolts 13 - 22: 90°
Stage 11: Bolts 1 - 12: 90°
Stage 12: Bolts 13 - 22: 90°
- 6.NOTE: When the tool is properly installed, the locating pin will be approximately at the 10 o'clock position.
Using the special tool, set the crankshaft position.
Install Special Service Tool: 303-1587 Timing Tool, Crankshaft.
- 8.NOTE: The camshafts need to be installed with the slots down aligning with the timing pin holes in the cylinder head.
Lubricate with clean engine oil and install the camshafts.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5QSD (WSS-M2C171-E)
- 9.NOTE: If the upper cylinder head is not secured within 5 minutes of silicone sealant application, the silicone sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 2 mm bead of silicone sealant.
Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 10.NOTE: The component must be installed within 5 minutes of applying the sealant.
Install the upper cylinder head and the bolts. Tighten in the sequence shown in illustration in 6 stages.
Torque:
Stage 1: 1 - 26 : 62 lb.in (7 Nm)
Stage 2: 27 - 28 : 35 lb.in (4 Nm)
Stage 3: 1 - 26 : 133 lb.in (15 Nm)
Stage 4: 27 - 28 : 53 lb.in (6 Nm)
Stage 5: 1 - 26 : 17 lb.ft (23 Nm)
Stage 6: 27 - 28 : 89 lb.in (10 Nm)
- 11.NOTE: Make sure that the rocker arms do not separate.NOTE: After the valve rocker arm assembly is installed, verify that the rocker arms are properly aligned with the camshafts and the valve stems.
Install the valve rocker arm housing and the bolts. Tighten in the sequence shown in illustration in 4 stages.
Torque:
Stage 1: 44 lb.in (5 Nm)
Stage 2: 71 lb.in (8 Nm)
Stage 3: 89 lb.in (10 Nm)
Stage 4: 45°
- 12.
Install the thermostat bracket, nut and bolt.Torque:
M8 bolt : 17 lb.ft (23 Nm)
M6 nut : 89 lb.in (10 Nm)
- 15.
Install the valve cover and tighten the bolts. Tighten in the sequence shown in illustration in 3 stages.Torque:
Stage 1: 35 lb.in (4 Nm)
Stage 2: 89 lb.in (10 Nm)
Stage 3: 97 lb.in (11 Nm)
- 17.
Apply clean engine oil and install the CMP sensor and bolt.Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5QSD (WSS-M2C171-E)
Torque: 89 lb.in (10 Nm)
- 19.NOTE: If a fuel injector is being reused, make sure to install the fuel injector in the original location.NOTE: Only tighten the bolts finger tight.
Install the fuel injectors, the fuel injector clamps and the fuel injector clamp bolts finger tight.
- 20.NOTE: This uneven torque strategy is intentional as tightening bolt 2 cantilevers the fuel injector clamp about the fuel injector, increasing the clamp load imparted by bolt 1.
- Tighten bolt number 1 to:
Torque: 18 lb.in (2 Nm)
- Tighten bolt number 2 in the following stages:
Torque:
Stage 1: 35 lb.in (4 Nm)
Stage 2: 360°
- Tighten both of the number 3 bolts in the following stages:
Torque:
Stage 1: 53 lb.in (6 Nm)
Stage 2: 360°
- Tighten bolt number 1 to:
- 23.NOTE: Do not tighten the fuel rail supply tube or bolts at this time.
Install the new fuel rail supply tube and bolts.
- 24.NOTE: Do not tighten the fuel injector supply tubes at this time.
Install the fuel injector supply tubes.
- 25.
- 1.
Tighten the fuel rail supply tube and the fuel injector supply tubes at the fuel rail.Torque: 133 lb.in (15 Nm)
- 2.
Tighten the fuel injector supply tubes at the fuel injectors.Torque: 133 lb.in (15 Nm)
- 3.
Loosen the fuel rail bolts.Torque: 720°
- 4.
Tighten the fuel rail bolts.Torque: 17 lb.ft (23 Nm)
- 5.
Tighten the fuel injector supply tubes at the fuel injectors.Torque: 22 lb.ft (30 Nm)
- 6.
Tighten the fuel rail supply tube and the fuel injector supply tubes at the fuel rail.Torque: 22 lb.ft (30 Nm)
- 7.
Tighten the fuel rail supply tube bolts.Torque: 89 lb.in (10 Nm)
- 1.
- 26.NOTE: Make sure that the timing marks are aligned on the camshafts sprockets and the fuel injection pump drive sprocket.NOTE: Do not tighten the bolts at this time.
Install the timing chain, camshaft sprockets and bolts.
- 27.
Install the timing chain guides and the bolts.Torque:
1: 124 lb.in (14 Nm)
2: 23 lb.ft (31 Nm)
3: 30 lb.ft (40 Nm)
- 29.NOTE: When the tool is properly installed, the locating pin will be approximately at the 10 o'clock position.
Install Special Service Tool: 303-1587 Timing Tool, Crankshaft.
- 30.
Check the valve timing by inserting the end of 2 drill bits through the sprocket holes into the timing pin holes in the cylinder head.Use the General Equipment: 6 mm Drill Bit
Torque
Stage 1: 106 lb.in (12 Nm)
Stage 2: 24 lb.ft (33 Nm)
- 33.NOTE: When the tool is properly installed, the locating pin will be approximately at the 10 o'clock position.
Install Special Service Tool: 303-1587 Timing Tool, Crankshaft.
- 34.
Check the valve timing by inserting the end of 2 drill bits through the sprocket holes into the timing pin holes in the cylinder head. If the drill bit ends can not be inserted repeat the timing steps.Use the General Equipment: 6 mm Drill Bit
- 37.NOTE: If the engine front cover is not secured within 5 minutes of sealant application, the silicone sealant must be removed and the sealing area cleaned with metal surface prep. Allow to dry until there is no sign of wetness, or 10 minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
Apply a 3 mm bead of silicone sealant to the new engine front cover.
Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B
- 38.NOTE: The component must be installed within 5 minutes of applying the sealant.
Apply a 3 mm bead of silicone sealant at the T-joints.
Material: Motorcraft® Silicone Gasket and Sealant / TA-30 (WSE-M4G323-A4)
- 39.
Using the special tool to align the engine front cover, install the engine front cover, nuts and bolts. Tighten in the sequence shown in illustration in 3 stages.Use Special Service Tool: 303-682 Aligner, Engine Front Cover.
Torque:
Stage 1: 44 lb.in (5 Nm)
Stage 2: 89 lb.in (10 Nm)
Stage 3: 89 lb.in (10 Nm)
- 40.NOTE: The new crankshaft front seal is supplied with an alignment sleeve which must be removed after installation.NOTE: Do not remove the alignment sleeve from the crankshaft front seal prior to installation on the crankshaft.
Position the crankshaft front seal on the crankshaft.
- 41.
Using the special tool, install the crankshaft front seal.Use Special Service Tool: 303-679A Remover/Installer, Engine Front Cover Inspection Plate.
Torque: 168 lb.in (19 Nm)
- 44.
Using the special tool, tighten the crankshaft pulley bolts. Tighten in 5 stages.Use Special Service Tool: 303-1310 Holding Wrench, Crankshaft.
Torque:
Stage 1: 177 lb.in (20 Nm)
Stage 2: 33 lb.ft (45 Nm)
Stage 3: 66 lb.ft (90 Nm)
Stage 4: 45°
Stage 5: 45°
- 46.
Install the accessory drive belt idler assembly and bolts. Install the idler pulley assembly.Torque: 35 lb.ft (48 Nm)
- 48.
Lubricate the new fuel injector return line fitting O-ring seals.Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5QSD (WSS-M2C171-E)
- 49.
Install the fuel pump supply and return tubes assemblies. Refer to: Quick Release Coupling .
- 52.NOTE: Manually align the brake vacuum pump drive key with the camshaft slot before installation.
Install the vacuum pump and bolts.
Torque: 17 lb.ft (23 Nm)
- 54.NOTE: Make sure that the mating surfaces are clean and free of foreign material.
Replace the turbocharger mounting studs.
Torque: 124 lb.in (14 Nm)
- 55.
Install the turbocharger and the new upper turbocharger nut. Tighten in 2 stages.Torque:
Stage 1: 133 lb.in (15 Nm)
Stage 2: 17 lb.ft (23 Nm)
- 56.
Install the new lower turbocharger nuts. Tighten in 2 stages.Torque:
Stage 1: 133 lb.in (15 Nm)
Stage 2: 17 lb.ft (23 Nm)
- 57.
Install a new gasket and lubricate the O-ring with engine oil.Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5QSD (WSS-M2C171-E)
- 58.
- 1.
Position the turbocharger drain tube in the cylinder block.
- 2.
Install the cylinder block bolt finger tight.
- 3.
Install the bolts at the turbocharger finger tight.
- 1.
- 60.
- 1.
Tighten the cylinder block bolt.Torque: 17 lb.ft (23 Nm)
- 2.
Tighten the bolts at the turbocharger.Torque: 89 lb.in (10 Nm)
- 1.
- 62.
Install the new turbocharger oil supply tube assembly, the new washers and the new banjo bolts.Torque: 177 lb.in (20 Nm)
- 68.
Install the lifting eye, bracket and bolts. Tighten in the sequence shown in illustration in 3 stages.Torque:
M8 bolts:
Stage 1: 133 lb.in (15 Nm)
Stage 2: 17 lb.ft (23 Nm)
Stage 3: 17 lb.ft (23 Nm)
M10 bolts:
Stage 4: 177 lb.in (20 Nm)
Stage 5: 35 lb.ft (48 Nm)
Stage 6: 35 lb.ft (48 Nm)
- 71.
Connect the harness to the valve cover and connect the fuel injector electrical connectors. Install the ground wire and the nut. Connect the wire retainer.Torque: 62 lb.in (7 Nm)
- 76.
Install the bolts. Connect the electrical connectors and the wire retainer.Torque:
Front bolt : 44 lb.in (5 Nm)
Rear bolt : 89 lb.in (10 Nm)
- 77.
Connect the electrical connector and the wire retainer. Install the nut and the cover.Torque: 89 lb.in (10 Nm)
- 78.
Connect the hose to the crankcase vent hose. Connect the electrical connectors and the wire harness retainers.
- 89.
-
NOTE: Do not allow the crankshaft to turn during installation of the flywheel.
Install the flexplate and the bolts.
- Install Special Service Tool: 303-103 (T74P-6375-A) Holding Tool, Flywheel.
- Tighten the bolts in the sequence shown in illustration in 3 stages.
Torque:
Stage 1: 18 lb.ft (25 Nm)
Stage 2: 33 lb.ft (45 Nm)
Stage 3: 45°
-