Cylinder Head: Assembly
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NOTE: If installing the original valves, make sure the valves are installed in the same position from which they were removed. Coat the valve stems with clean engine oil.
Lubricate with clean engine oil and install the valve in the cylinder head.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
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NOTE: Use commercially available valve stem seal pliers.
Lubricate with clean engine oil and install the valve seal.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
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NOTE: Use a commercially available valve spring compressor.NOTE: Use a small screwdriver and multi-purpose grease to install the valve collets. Check the seating of the valve collets.
Install the valve spring, valve spring retainer and the valve collets.
Material: Motorcraft® Multi-Purpose Grease Spray / XL-5-A (ESB-M1C93-B)
- Repeat the above steps for each valve.
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NOTE: It will be necessary to install a second bolt for alignment of the bracket.
Install the lifting bracket and the bolt.
Torque: 17 lb.ft (23 Nm)
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NOTE: Only use hand tools when loosening or tightening the exhaust manifold studs or damage to the stud torx head or cylinder head threads can occur.
Install the new exhaust manifold studs and the new gasket.
Torque: 133 lb.in (15 Nm)
- Install the exhaust manifold and the new nuts.
Torque: Stage 1: 89 lb.in (10 Nm) Stage 2: 177 lb.in (20 Nm) Stage 3: 26 lb.ft (35 Nm) Stage 4: 26 lb.ft (35 Nm)
- Install the glow plugs.
Torque: 115 lb.in (13 Nm)
- Install the glow plug harness.
Torque: Stage 1: 9 lb.in (1 Nm) Stage 2: 21 lb.in (2.4 Nm)
- Install the intake manifold and the bolts.
Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 115 lb.in (13 Nm) Stage 3: 142 lb.in (16 Nm)
- Apply clean engine oil to the O-ring and install a new gasket.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)
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NOTE: Do not tighten the bolts at this time.
Install the mixer tube and the bolts.
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NOTE: Do not tighten the bolts at this time.
Install the EGR valve and the nuts.
- Position a new EGR cooler gasket on the EGR cooler.
- Install the EGR cooler and the bolt.
Torque: 17 lb.ft (23 Nm)
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NOTE: Make sure that a new EGR cooler vee-clamp and a new nut is installed.
Install a new EGR clamp in the position as shown. Tighten the EGR cooler vee-clamp nut.
Torque: 80 lb.in (9 Nm)
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NOTE: After alignment of the EGR cooler the lower bolt will be removed.
Using a new gasket, install the EGR valve bolts.
Torque: 17 lb.ft (23 Nm)
- Tighten the mixer tube nuts.
Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 89 lb.in (10 Nm)
- Tighten the mixer tube bolts.
Torque: 89 lb.in (10 Nm)
- Remove the EGR valve bolt.
- Install the heat shield and the bolts.
Torque: 89 lb.in (10 Nm)
- Install the coolant tube and the bolts. Tighten the hose clamp.
Torque: Bolts: 17 lb.ft (23 Nm) Hose clamps: 35 lb.in (4 Nm)
- Install the coolant hose and tighten the clamps.
Torque: 35 lb.in (4 Nm)