Cylinder Head - Body Off - LH

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

Special Tool(s) / General Equipment 

Courtesy of FORD MOTOR COMPANY	303-1670 Pins, Camshaft Locking
Courtesy of FORD MOTOR COMPANY	303-1671 Pin, Locking Crankshaft
Courtesy of FORD MOTOR COMPANY	303-1674 Tool, Holding Camshaft Sprocket
Courtesy of FORD MOTOR COMPANY	303-1675 Adapter, Seal Remover
Courtesy of FORD MOTOR COMPANY	303-1678 Remover, Fuel Pump Pulley Holding Tool
Courtesy of FORD MOTOR COMPANY	308-375 Remover, Input Shaft Seal TKIT-2005U-M TKIT-1999-F/FLM/LT
Courtesy of FORD MOTOR COMPANY	310-266 Remover, Fuel Injector
Hose Clamp Remover/Installer

1. Remove the body. Refer to: Body - 3.0L Power Stroke Diesel .
2. Roll the chassis out from under the body.
   • Install wheel chocks at the front and back of one wheel.

3. Disconnect the vacuum hose retainer and the transmission vent tube. Disconnect the wire harness housing and position aside.

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4. Disconnect the coolant hose. Disconnect the retainers and position aside the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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5. Remove the upper radiator hose. Use the General Equipment: Hose Clamp Remover/Installer

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6. Disconnect the coolant hose. Disconnect the retainers and remove the coolant hoses.

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7. Disconnect the electrical connector and the wire retainer.

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8. NOTE: The turbocharger compressor vanes can be damaged by even the smallest particles. When removing any turbocharger or engine air intake system component, ensure that no debris enters the system. Failure to do so may result in damage to the turbocharger.

   Loosen the clamp, release the clip and remove the LH CAC intake pipe.

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9. Disconnect the coolant hose connector and the retainer.

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10. Remove the A/C belt and the accessory drive belt.

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11. Disconnect the electrical connector and the generator output wire.

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12. Remove the bolts and the generator.

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13. Disconnect and position aside the fuel tubes. Refer to: QUICK RELEASE COUPLING .

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14. Remove the LH fuel injector noise insulator.

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15. Remove the RH fuel injector noise insulator.

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16. Disconnect the retainer. Disconnect and remove the brake vacuum hose. Refer to: QUICK RELEASE COUPLING .

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17. Disconnect the oil pump electrical connector and the wire retainers.

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18. Disconnect the TB (throttle body) electrical connector and the wire retainer.

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19. Disconnect the CMP electrical connector and the wire retainer.

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20. Disconnect the CKP electrical connector and the wire retainer.

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21. Disconnect the EGR valve and the EP (exhaust pressure) sensor electrical connectors. Disconnect the wire retainers.

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22. Disconnect the EOP sensor electrical connector.

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23. Disconnect the electrical connectors and the wire retainers.

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24. Disconnect the fuel injectors electrical connectors and the wire retainers.

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25. Disconnect the electrical connectors and the wire retainer.

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26. Disconnect the turbocharger actuator electrical connector. Disconnect the EGRT electrical connector and the wire retainers.

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27. Disconnect the electrical connectors and the wire retainers.

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28. Disconnect the fuel injectors electrical connectors and the wire retainers.

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29. Disconnect the electrical connectors and the wire retainers.

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30. Disconnect the electrical connector and remove the bolt. Disconnect the wire harness retainers and remove the engine wire harness.

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31. Remove the nut and the ground strap.

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32. Disconnect the vacuum pump connector. Remove the retainers and remove the vacuum hose assembly. Refer to: QUICK RELEASE COUPLING .

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33. NOTE: If any snaps become undone on the exhaust crossover pipe wrap. Replace the exhaust crossover pipe wrap.

    Remove the bolts for the exhaust crossover pipe.

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34. NOTE: If any snaps become undone on the exhaust crossover pipe wrap. Replace the exhaust crossover pipe wrap.

    Remove the nuts and the exhaust crossover pipe. Discard the nuts.

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35. Remove and discard the exhaust crossover pipe gaskets and the studs.

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36. Release the clamp and disconnect the EGR cooler coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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37. Remove the bolts and the coolant tube assembly. Use the General Equipment: Hose Clamp Remover/Installer

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38. Remove and discard the coolant tube assembly O-ring.

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39. Remove the bolts and the coolant tube bracket.

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40. Remove the bolt and the accessory drive belt tensioner.

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41. Remove the bolts and the fan pulley.

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42. Remove the nuts and the CAC tube bracket.

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43. Remove the bolts and the accessory drive belt tensioner.

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44. Remove the bolts and the crankshaft vibration damper.

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45. • Disconnect the wire retainers.
    • Remove the retainer from the timing belt cover.
    • Remove the retainers and the EGR outlet tube.
    • Remove and discard the gaskets.

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46. NOTE: Mark the locations of the fasteners before removal.

    Remove the bolts, the stud bolts and the timing belt cover.

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47. Remove and discard the timing belt cover gasket.

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48. Remove the nuts and the fuel tube support bracket.

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49. Remove the nut and the front fuel tube support bracket.

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50. Remove the nut, the bolt and the LH exhaust manifold heat shield.

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51. Remove the stud bolt. Disconnect the tube nut and remove the EP sensor assembly.

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52. Remove the oil level indicator.

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53. • Disconnect the wire retainers from the oil level indicator tube.
    • Remove the stud bolt, the bolt and the oil level indicator tube.

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54. Remove the bolts and the EGR coolant tube.

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55. Remove and discard the EGR coolant tube O-ring and the grommet.

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56. Remove the bolts and the EGR cooler-to-exhaust manifold pipe. Remove and discard the gaskets.

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57. Remove the bolts and the EGR cooler.

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58. Remove the bolts and the EGR cooler bracket.

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59. Disconnect the fuel lines. Remove the bolt and the secondary fuel filter. Discard the secondary fuel filter. Refer to: QUICK RELEASE COUPLING .

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60. Disconnect the retainers. Remove the nut, the bolt and the wiring harness bracket.

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61. Remove the accessory drive cover.

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62. Remove the stud bolts and the accessory drive cover.

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63. Remove the bolt. Disconnect and remove the fuel supply tube. Refer to: QUICK RELEASE COUPLING .

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64. Disconnect and remove the fuel return tube assembly. Discard the fuel return tube assembly. Refer to: QUICK RELEASE COUPLING .

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65. Remove the bolts and the front engine lifting eye.

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66. NOTE: Lift the front of the intake manifold up and slide the intake manifold to the right to remove.

    Remove the stud bolt, the bolt and the intake manifold.

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67. Remove and discard the intake manifold gaskets.

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68. Remove the bolt and the wire harness bracket.

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69. Remove the LH engine cover stud assemblies.

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70. Disconnect and position aside the LH fuel return hose assembly.

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71. Remove the bolt. Remove and discard the LH fuel supply tube.

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72. • Remove the bolts and the clamp. Remove and discard the fuel injection pump balance tube. Remove the bolts and the clamps.
    • Remove and discard the LH fuel injector supply tubes.

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73. • Remove the bolts and the clamp.
    • Remove and discard the fuel injection pump balance tube.

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74. Remove the bolts and the LH fuel rail.

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75. Remove the LH fuel injector noise insulator.

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76. Remove the bolts for the LH fuel injectors.

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77. NOTE: Only one fuel injector shown.

    Using the special tool, remove the fuel injectors. Use Special Service Tool: 310-266 Remover, Fuel Injector.

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78. Remove and discard the sealing washer, the O-rings and the fuel injector hold down.

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79. Remove the bolts and the LH fuel rail bracket.

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80. Remove the nuts and the LH fuel tube bracket.

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81. Disconnect the LH glow plug electrical connector.

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82. NOTE: Mark the location of the fasteners prior to removing the valve cover.

    Loosen the fasteners and remove the LH valve cover.

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83. Remove and discard the LH valve cover gasket.

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84. Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation .

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85. Remove the timing pin bolt at the left front of the engine.

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86. Install special tool.
    • NOTE: Only rotate the crankshaft clockwise.
      NOTE: Verify that the camshaft timing holes are aligned with the cylinder head.
      NOTE: The Locking Crankshaft Pin must be bottomed out against the cylinder block.

      Rotate the crankshaft clockwise so the crankshaft contacts the locking crankshaft pin. Use Special Service Tool: 303-1671 Pin, Locking Crankshaft.

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87. Using the special tool, rotate the fuel pump sprocket to push down on the READ belt tensioner until the openings are aligned, install the lock pin. Use Special Service Tool: 303-1678 Remover, Fuel Pump Pulley Holding Tool.

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88. NOTE: Note the position of the camshaft pulley prior to removal.

    Remove the bolts, the camshaft pulley and the READ belt.

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89. Remove the bolt and the READ belt tensioner.

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90. NOTE: Use the original bolts for the special tool.

    Using the special tool, remove the bolt and the camshaft gear hub. Discard the bolt. Use Special Service Tool: 303-1674 Tool, Holding Camshaft Sprocket.

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91. Remove the nut, the bolt and the accessory drive cover.

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92. Remove the bolts and the fan drive.

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93. • Using the special tools, verify the camshaft timing. Use Special Service Tool: 303-1670 Pins, Camshaft Locking.
    • Loosen the bolts on the camshaft pulleys.

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94. 1. NOTE: The crankshaft or camshafts must not be rotated while the timing belt is removed.

       Loosen the timing belt tensioner bolt.

    2. Rotate the timing belt tensioner clockwise.
    3. Remove the timing belt.

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95. NOTE: Replace the timing belt tensioner if damage or excessive wear is found.

    Remove the bolt and the timing belt tensioner. Discard the bolt.

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96. NOTE: Note the position of the camshaft pulley prior to removal.

    Remove the bolts and the LH camshaft pulley.

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97. NOTE: Use the original bolts for the special tool.

    Using the special tool, remove the bolts and the LH camshaft gear hub. Discard the bolt. Use Special Service Tool: 303-1674 Tool, Holding Camshaft Sprocket.

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98. Remove the bolts and the coolant outlet connector.

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99. Remove and discard the oil cooler O-ring.

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100. Remove and discard the coolant outlet connector gaskets.

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101. Remove the dust shield.

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102. Using the special tools, remove and discard the camshaft seals. Use Special Service Tool: 303-1675 Adapter, Seal Remover., 308-375 Remover, Input Shaft Seal.

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103. Compress the camshaft chain and install the retaining pin.

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104. NOTE: Cylinder head camshaft bearing caps are numbered to verify that they are assembled in their original positions.

     Remove the bolts and the camshaft bearing caps.

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105. Remove the bolts and the LH camshafts, camshaft chain and the secondary timing chain tensioner.

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106. NOTE: If the components are to be reinstalled, they must be installed in the same positions. Mark the components for installation into their original locations.

     Remove the LH camshaft roller follower and hydraulic lash adjuster assemblies.

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107. Inspect the hydraulic lash adjuster and roller follower for damage. If any damage is found, inspect the camshaft lobes and valves for damage. Replace damaged components as necessary.

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108. NOTE: Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Any foreign material (including any material created while cleaning gasket surfaces) that enters the oil passages or the oil pan, may cause engine failure.
     NOTE: Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface
     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: The cylinder head bolts must be discarded and new bolts must be installed. They are tighten-to-yield designed and cannot be reused.
     • Remove and discard the bolts from the LH cylinder head.
     • Remove the cylinder head.

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109. Remove and discard the LH cylinder head gasket and the cylinder head dowels.

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110. NOTE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges that make leak paths. Use a plastic scraping tool to remove all traces of the head gasket.
     NOTE: Clean the cylinder block bolt holes using compressed air. Make sure all coolant, oil or other foreign material is removed.
     • Clean and inspect the cylinder head-to-cylinder block mating surfaces of both the cylinder head and the cylinder block surface.
     • Check the cylinder head distortion. Refer to: Cylinder Head Distortion .
     • Check the cylinder block distortion. Refer to: Cylinder Block Distortion .