Cylinder Head

WARNING: This page is about a different variant/trim than selected.

For information on Ford Color Coded Illustrations refer to OEM Color Coding .

Special Tool(s) / General Equipment

Courtesy of FORD MOTOR COMPANY	303-103 (T74P-6375-A) Holding Tool, Flywheel T74P-77000-A TKIT-2009TC-F
Courtesy of FORD MOTOR COMPANY	303-1310 Holding Wrench, Crankshaft
Courtesy of FORD MOTOR COMPANY	303-1587 Timing Tool, Crankshaft
Courtesy of FORD MOTOR COMPANY	303-679A Remover/Installer, Engine Front Cover Inspection Plate
Courtesy of FORD MOTOR COMPANY	303-682 Aligner, Engine Front Cover
Floor Crane
Mounting Stand
6 mm Drill Bit

Materials

Name	Specification
Motorcraft® High Performance Engine RTV Silicone TA-357	WSE-M4G323-A6
Motorcraft® Metal Surface Prep Wipes ZC-31-B	-
Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil XO-5W40-5Q3SD	WSS-M2C171-F1

NOTE: During engine repair procedures, cleanliness is extremely important. All parts must be thoroughly cleaned and any foreign material, including any material created while cleaning gasket surfaces, that enters the oil passages, coolant passages or the oil pan, can cause engine failure.

NOTE: During the removal or installation of components, cap, tape or otherwise appropriately protect all openings and tubes/fittings to prevent the ingress of dirt or other contamination. Remove caps, tape and other protective materials prior to installation.

NOTE: The largest measurement determines the choice of the cylinder head gasket.

Check the piston protrusion. Refer to: Piston Protrusion Check .
Install the dowels and the cylinder head gasket.

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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 12 stages.

Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)

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 deg. Stage 10: Bolts 13 - 22: 90 deg. Stage 11: Bolts 1 - 12: 90 deg. Stage 12: Bolts 13 - 22: 90 deg.

Fig 1: Cylinder Head Tightening Sequence
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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.

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Remove Special Service Tool: 303-1587 Timing Tool, Crankshaft.

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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-5W40-5Q3SD (WSS-M2C171-F1)

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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 2.5 mm (0.10 in) bead of silicone sealant.

Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

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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 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)

Fig 2: Upper Cylinder Head Tightening Sequence
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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 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 deg.

Fig 3: Valve Rocker Arm Housing Tightening Sequence
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Install the thermostat bracket, nut and bolt.
Torque: M8 bolt : 17 lb.ft (23 Nm) M6 nut : 89 lb.in (10 Nm)

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Install the valve cover seals.

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Install the valve cover gasket.

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Install the valve cover and tighten the bolts. Tighten in the sequence shown 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)

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Install the NVH padding.

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Apply clean engine oil and install the CMP sensor and bolt.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)

Torque: 89 lb.in (10 Nm)

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Install the new fuel injector sealing washers.

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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.

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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 deg.
- Tighten both of the number 3 bolts in the following stages:
  Torque: Stage 1: 53 lb.in (6 Nm) Stage 2: 360 deg.
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Install the fuel rail, bracket and bolts.
Torque: 18 lb.in (2 Nm)

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Connect the glow plug electrical connector.

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NOTE: Do not tighten the fuel rail supply tube or bolts at this time.

Install the new fuel rail supply tube and bolts.

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NOTE: Do not tighten the fuel injector supply tubes at this time.

Install the fuel injector supply tubes.

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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 deg.
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)
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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.

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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)

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1. Install the timing chain tensioner and bolts.
  Torque: 133 lb.in (15 Nm)
2. Remove the pin.
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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.

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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)

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Remove Special Service Tool: 303-1587 Timing Tool, Crankshaft.

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NOTE: Only rotate the crankshaft clockwise.

Rotate the engine two revolutions.
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.

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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

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Remove Special Service Tool: 303-1587 Timing Tool, Crankshaft.

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Install the new engine front cover gasket.

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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® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

Material: Motorcraft® Metal Surface Prep Wipes / ZC-31-B

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NOTE: The component must be installed within 5 minutes of applying the sealant.

Apply a 5 mm (0.20 mm) bead of silicone sealant at the T-joints.

Material: Motorcraft® High Performance Engine RTV Silicone / TA-357 (WSE-M4G323-A6)

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Using the special tool to align the engine front cover, install the engine front cover, nuts and bolts. Tighten in the sequence shown 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)

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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.

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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)

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Install the crankshaft pulley washer.

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Install the crankshaft pulley and the new bolts.

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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 deg. Stage 5: 45 deg.

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Install the coolant connector, nut and bolts.
Torque: 17 lb.ft (23 Nm)

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Install the accessory drive belt idler assembly and bolts. Install the idler pulley assembly.
Torque: 35 lb.ft (48 Nm)

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Install the new fuel injector fuel return line fitting retaining clips into the fuel injectors.

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Lubricate the new fuel injector return line fitting O-ring seals.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)

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Install the fuel pump supply and return tubes assemblies. Refer to: Quick Release Coupling .

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Install the fuel return tube bracket and bolt.
Torque: 62 lb.in (7 Nm)

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NOTE: Install the new seal by hand with no lubricant.

Install the vacuum pump seal.

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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)

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Install the oil level indicator tube assembly and bolt.
Torque: 17 lb.ft (23 Nm)

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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)

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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)

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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)

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Install a new gasket and lubricate the O-ring with engine oil.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)

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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.
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Install the bolt for the turbocharger drain tube finger tight.

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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)
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Tighten the bolt for the turbocharger drain tube.
Torque: 17 lb.ft (23 Nm)

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Install the new turbocharger oil supply tube assembly, the new washers and the new banjo bolts.
Torque: 177 lb.in (20 Nm)

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Install the turbocharger heat shield and bolts.
Torque: 18 lb.ft (25 Nm)

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Install the turbocharger heat shield bolt.
Torque: 18 lb.ft (25 Nm)

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Install the bracket assembly and bolts.
Torque: 18 lb.ft (25 Nm)

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Connect the vacuum hose at the vacuum pump.

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Connect the vacuum hose and the retaining clip.

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Install the lifting eye, bracket and bolts. Tighten in the sequence shown 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)

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Install the generator and bolts.
Torque: 35 lb.ft (48 Nm)

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Position the engine wire harness and if equipped, the block heater cord.

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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)

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Connect the electrical connectors and the wire retainer.

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Connect the TP electrical connector and wire retainer.

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Connect the oil pressure switch electrical connector and wire retainer.

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Connect the wire retainers and the electrical connector. If equipped, connect the block heater.

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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)

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Connect the electrical connector and the wire retainer. Install the nut and the cover.
Torque: 89 lb.in (10 Nm)

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Connect the hose to the crankcase vent hose. Connect the electrical connectors and the wire harness retainers.

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Connect the electrical connectors and the wire harness retainers.

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Connect the CKP electrical connector.

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Install the heat shield and the bolt.
Torque: 21 lb.ft (28 Nm)

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Connect the coolant hoses and tighten the clamps.
Torque: 35 lb.in (4 Nm)

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Position the coolant hose and connect the retainers. Install the bolt.
Torque: 35 lb.in (4 Nm)

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Connect the coolant hose.

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Install the RH engine mount bracket and the bolts.
Torque: 46 lb.ft (63 Nm)

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Install the LH engine mount bracket and the bolts.
Torque: 46 lb.ft (63 Nm)

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Install the floor crane. Use the General Equipment: Floor Crane

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Remove the engine from the mounting stand. Use the General Equipment: Mounting Stand

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- 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 3 stages.
  Torque: Stage 1: 18 lb.ft (25 Nm) Stage 2: 33 lb.ft (45 Nm) Stage 3: 45 deg.
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Install the engine. Refer to: Engine .