Cylinder Head - Body Off - RH

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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	303-1673 Installer, Camshaft Seal
Courtesy of FORD MOTOR COMPANY	303-1674 Tool, Holding Camshaft Sprocket
Oil Drain Equipment
Hose Clamp Remover/Installer

Materials

Name	Specification
Motorcraft® High Performance Engine RTV Silicone TA-357	WSE-M4G323-A6
Flange Sealant CU7Z-19B508-A	WSS-M2G348-A11
Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil XO-5W30-QFA	WSS-M2C214-B1
Motorcraft® Orange Concentrated Antifreeze/Coolant VC-3-B	WSS-M97B44-D

NOTE: During engine repair procedures, cleanliness is extremely important. Any foreign material, including any material created while cleaning gasket surfaces that enters the oil passages, coolant passages or the oil pan, may cause engine failure.

NOTE: It is recommended that this component be serviced with the vehicle body removed. Refer to BODY - 3.0L POWER STROKE DIESEL . If the body was not removed, refer to Cylinder Head - Body On - RH .

NOTE: Make sure that the same gasket thickness is reinstalled.

Install the RH cylinder head dowels and head gasket.

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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: 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: Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.

Install the RH cylinder head and the new bolts.

Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 30 lb.ft (40 Nm) | Stage 3: 59 lb.ft (80 Nm) | Stage 4: 180°

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NOTE: If the original hydraulic lash adjusters and roller followers are to be reinstalled, they must be installed in their original locations.
1. Lubricate the RH hydraulic lash adjusters and roller followers with clean engine oil.
  Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)
2. Install the hydraulic lash adjusters and roller followers.
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NOTE: Lubricate the camshafts with clean engine oil prior to installation.

NOTE: Align the timing marks on the camshafts with the timing marks on the secondary timing chain.

Install the RH camshafts, camshaft chain, secondary timing chain tensioner and the bolts.

Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

Torque: 89 lb.in (10 Nm)

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Apply sealer to the RH bearing caps.
Material: Flange Sealant / CU7Z-19B508-A (WSS-M2G348-A11)

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

NOTE: Tighten the camshaft bearing cap bolts one turn at a time.

Apply clean engine oil to the camshaft bearing caps. Install camshaft bearing caps and the bolts.

Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

Torque: Stage 1: 9 lb.in (1 Nm) | Stage 2: 44 lb.in (5 Nm) | Stage 3: 89 lb.in (10 Nm)

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Remove the retaining pin.

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Using the special tool, install the camshaft seal. Use Special Service Tool : 303-1673 Installer, Camshaft Seal.

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Install the dust shield.

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Install the coolant outlet connector gaskets.

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Install the oil cooler O-ring and lubricate.
Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

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Install the coolant outlet connector and the bolts.
Torque: 89 lb.in (10 Nm)

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NOTE: Use the original bolts for the special tool.

Using the special tool, install the RH camshaft gear hub and bolts. Use Special Service Tool : 303-1674 Tool, Holding Camshaft Sprocket.

Torque: Stage 1: 59 lb.ft (80 Nm) | Stage 2: 80°

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NOTE: Only tighten the bolts finger tight at this stage.

Install the RH camshaft pulley and the bolts.

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Install Special Service Tool : 303-1670 Pins, Camshaft Locking.

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NOTE: Only tighten the bolt finger tight at this stage.

Install the timing belt tensioner and the bolt.

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NOTE: Make sure that a new component is installed.

NOTE: Make sure that the crankshaft is against the Crankshaft Locking Pin.

NOTE: It may be necessary to rotate the camshaft pulleys slightly to ensure the bolts are not at the end of the slots.
1. Install the timing belt.
2. Rotate the timing belt tensioner.
3. Tighten the timing belt tensioner bolt.
  Torque: Stage 1: 177 lb.in (20 Nm) | Stage 2: 45°
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If the timing belt tensioner pointer is not visible in the window, the timing belt tensioning step must be repeated.

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Tighten the camshaft pulley bolts.
Torque: 17 lb.ft (23 Nm)

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Remove Special Service Tool : 303-1670 Pins, Camshaft Locking.

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Remove Special Service Tool : 303-1671 Pin, Locking Crankshaft.

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NOTE: Only rotate the crankshaft clockwise.

This step is to verify that the timing is correct. Rotate the engine 1 7/8 revolutions.
Install special tool.
- NOTE: Only rotate the crankshaft clockwise.
  
  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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NOTE: The special tool can only be installed if the valve timing is correct.

If the special tools do not install correctly, repeat the timing belt installation steps. Install Special Service Tool : 303-1670 Pins, Camshaft Locking.

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Install the fan drive and the bolts.
Torque: 61 lb.ft (83 Nm)

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Remove Special Service Tool : 303-1670 Pins, Camshaft Locking.

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Remove Special Service Tool : 303-1671 Pin, Locking Crankshaft.

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Install the timing pin bolt.
Torque: 17 lb.ft (23 Nm)

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Install the RH valve cover gasket.

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NOTE: If the valve cover is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

Apply an 6 mm dot of Motorcraft® High Performance Engine RTV Silicone to the locations shown below.

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

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Install the RH valve cover and tighten the fasteners.
Torque: Stage 1: Tighten bolt number 1 to : 9 lb.in (1 Nm) | Stage 2: Tighten bolts 2 thru 14 to : 89 lb.in (10 Nm)

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Connect the RH glow plug electrical connector.

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Install the turbocharger heat shield, the nut and the bolt.
Torque: Nut : 53 lb.in (6 Nm) Bolt : 18 lb.ft (24 Nm)

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Install the RH fuel tube bracket and the nuts.
Torque: 89 lb.in (10 Nm)

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Install the RH fuel rail bracket and the bolts.
Torque: 17 lb.ft (23 Nm)

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Install the sealing washer, the O-rings and the fuel injector hold down.

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Install the RH fuel injectors and bolts.
Torque: 89 lb.in (10 Nm)

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Install the RH fuel injector noise insulator.

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Install the RH fuel rail and the bolts.
Torque: 17 lb.ft (23 Nm)

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NOTE: The component must be installed by hand before final tightening.

Install the fuel injection pump balance tube, the clamps and the bolts.

Torque: Stage 1: Tighten the clamp bolts to: : 89 lb.in (10 Nm) | Stage 2: Tighten the fuel injection pump balance tube to: 89 lb.in (10 Nm) | Stage 3: Tighten the fuel injection pump balance tube to: 142 lb.in (16 Nm) | Stage 4: Tighten the fuel injection pump balance tube: 50°

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NOTE: The component must be installed by hand before final tightening.

Install the RH fuel injector supply tubes, the clamp and the bolt.

Torque: Stage 1: Tighten the clamp bolt to: : 89 lb.in (10 Nm) | Stage 2: Tighten at the fuel rail to: 89 lb.in (10 Nm) | Stage 3: Tighten at the fuel injector to: 89 lb.in (10 Nm) | Stage 4: Tighten at the fuel rail to: 142 lb.in (16 Nm) | Stage 5: Tighten at the fuel injector to: 142 lb.in (16 Nm) | Stage 6: Tighten at the fuel rail: 50° | Stage 7: Tighten at the fuel injector: 50°

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NOTE: The component must be installed by hand before final tightening.

Install the RH fuel rail supply tube and the bolt.

Torque: Stage 1: Tighten the clamp bolt to: : 89 lb.in (10 Nm) | Stage 2: Tighten at the fuel rail to: 89 lb.in (10 Nm) | Stage 3: Tighten at the fuel injection pump to: 89 lb.in (10 Nm) | Stage 4: Tighten at the fuel rail to: 142 lb.in (16 Nm) | Stage 5: Tighten at the fuel injection pump to: 142 lb.in (16 Nm) | Stage 6: Tighten at the fuel rail: 50° | Stage 7: Tighten at the fuel injection pump: 50°

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Position back and connect the RH fuel return hose assembly.

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Install the RH engine cover stud assemblies.
Torque: 1 : 44 lb.in (5 Nm) 2 : 62 lb.in (7 Nm)

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Install the engine support bracket and the retainers.
Torque: 62 lb.in (7 Nm)

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Install the heater hose support bracket and the bolts.
Torque: 89 lb.in (10 Nm)

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Install new gaskets on the intake manifold. Lubricate the gaskets with clean engine oil.
Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

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NOTE: Install the intake manifold into the LH valve cover, then into the RH valve cover.

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

Torque: 89 lb.in (10 Nm)

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Install the front engine lifting eye and the bolts.
Torque: 17 lb.ft (23 Nm)

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Install the fuel return tube assembly. Refer to: QUICK RELEASE COUPLING

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Install the fuel supply tube. Refer to: QUICK RELEASE COUPLING

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Install the fuel supply tube and the bolt. Refer to: QUICK RELEASE COUPLING
Torque: 17 lb.ft (23 Nm)

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Install the secondary fuel filter and the bolt. Connect the fuel lines. Refer to: QUICK RELEASE COUPLING
Torque: 89 lb.in (10 Nm)

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Install a new timing belt cover gasket.

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Install the timing belt cover, the stud bolts and the bolts.
Torque: 89 lb.in (10 Nm)

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- Using new gaskets, install the EGR outlet tube and the bolts.
  Torque: 89 lb.in (10 Nm)
- Install the retainer in the timing belt cover.
  Torque: 31 lb.in (3.5 Nm)
- Connect the wire retainers.
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Install the crankshaft vibration damper and the bolts.
Torque: 18 lb.ft (25 Nm)

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Install the accessory drive belt tensioner and the bolts.
Torque: 18 lb.ft (25 Nm)

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Install the CAC bracket and the nuts.
Torque: 53 lb.in (6 Nm)

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Install the fan pulley and the bolts.
Torque: 18 lb.ft (25 Nm)

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Install the accessory drive belt tensioner and the bolt.
Torque: 35 lb.ft (48 Nm)

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Install the coolant tube bracket and the bolts.
Torque: 89 lb.in (10 Nm)

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Install the coolant tube assembly O-ring and lubricate.
Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

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Install the coolant tube assembly and the bolts. Use the General Equipment: Hose Clamp Remover/Installer
Torque: 89 lb.in (10 Nm)

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Lubricate the O-ring seals with clean engine coolant. Install the new turbocharger coolant tube manifold and the bolt.
Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

Torque: 89 lb.in (10 Nm)

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Install the turbocharger studs and the gasket.
Torque: 115 lb.in (13 Nm)

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Install the turbocharger and the nuts.
Torque: Stage 1: 89 lb.in (10 Nm) | Stage 2: 18 lb.ft (24 Nm)

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Position back the turbocharger coolant supply tube into the engine and install the bolt.
Torque: 89 lb.in (10 Nm)

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NOTE: Fully seat the turbocharger oil supply tube O-rings into the turbocharger and engine bore holes prior to fastener tightening.

Lubricate the turbocharger oil supply tube O-rings with clean engine oil. Install the turbocharger oil supply tube and the bolts.

Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

Torque: 89 lb.in (10 Nm)

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Install a new turbocharger coolant return tube O-ring seal. Lubricate the new O-ring seal and the tube sealing surface with clean engine coolant.
Material: Motorcraft® Orange Concentrated Antifreeze/Coolant / VC-3-B (WSS-M97B44-D)

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Install the coolant return tube and the bolt.
Torque: 89 lb.in (10 Nm)

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Install the studs and the exhaust crossover pipe gaskets.
Torque: 115 lb.in (13 Nm)

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NOTE: If any snaps become undone on the exhaust crossover pipe wrap. Install a new exhaust crossover pipe wrap.

Install the exhaust crossover pipe, the nuts and the bolts.
- Hand start the RH exhaust manifold nuts.
- Hand start the LH exhaust manifold nuts.
- Hand start the exhaust crossover pipe bracket bolts.
- Tighten the RH exhaust manifold nuts in the following sequence: 1, 2, 3, 1, 2.
  Torque: 18 lb.ft (24 Nm)
- Tighten the LH exhaust manifold nuts in the following sequence: 1, 2, 3, 1, 2.
  Torque: 18 lb.ft (24 Nm)
- Tighten the exhaust crossover pipe bracket bolts in the sequence shown below.
  Torque: 18 lb.ft (24 Nm)
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Install the vacuum pump gasket.

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NOTE: If the vacuum pump is not installed and the fasteners tightened within 10 minutes, the sealant must be removed and the sealing area cleaned.

Apply an 6 mm dot of Motorcraft® High Performance Engine RTV Silicone to the locations shown below.

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

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NOTE: Manually align the brake vacuum pump drive key with the camshaft slot before installation.

Align the brake vacuum pump drive key with the camshaft slot before installation.

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Install the vacuum pump and the retainers.
Torque: Stage 1: Tighten bolt number 1 to: : 17 lb.ft (23 Nm) | Stage 2: Tighten bolt number 2 to: : 17 lb.ft (23 Nm) | Stage 3: Tighten bolt number 1 a second time to: : 17 lb.ft (23 Nm) | Stage 4: Tighten the nut number 3 to: : 17 lb.ft (23 Nm)

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Install the lifting bracket and the bolts.
Torque: 17 lb.ft (23 Nm)

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Install the valve bracket and the bolts.
Torque: 89 lb.in (10 Nm)

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Install the vacuum hose assembly and the retainers. Connect the vacuum pump connector. Refer to: QUICK RELEASE COUPLING

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Position the engine wire harness on the engine and install the bolt. Connect the electrical wire retainers and the electrical connector.
Torque: 89 lb.in (10 Nm)

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Connect the electrical connectors and the wire retainers.

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Connect the fuel injectors electrical connectors and the wire retainers.

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Connect the electrical connectors and the wire retainers.

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Connect the EGRT electrical connector and the wire retainers. Connect the turbocharger actuator electrical connector.

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Connect the electrical connectors and the wire retainer.

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Connect the fuel injectors electrical connectors and the wire retainers.

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Connect the electrical connectors and the wire retainers.

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Connect the EOP sensor electrical connector.

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Connect the EGR valve and the EP sensor electrical connectors. Disconnect the wire retainers.

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Connect the CKP electrical connector and the wire retainer.

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Connect the CMP electrical connector and the wire retainer.

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

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Connect the oil pump electrical connector and the wire retainers.

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Install the brake vacuum hose and connect the retainer. Refer to: QUICK RELEASE COUPLING

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Remove the RH fuel injector noise insulator.

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Install the LH fuel injector noise insulator.

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Position back and connect the fuel tubes. Refer to: QUICK RELEASE COUPLING

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

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NOTE: When installing the B+ terminal nut to the generator, finger-start the nut before tightening or component damage may occur.

Connect the electrical connector and the generator output wire.

Torque: 159 lb.in (18 Nm)

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Install the accessory drive belt and the A/C belt.

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Connect the coolant hose connector and the retainer.

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Inspect the turbocharger or engine air intake system components and clean, if necessary.
Install the LH CAC intake pipe and the clip. Tighten the clamp.
Torque: 44 lb.in (5 Nm)

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Connect the electrical connector and the wire retainer.

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Install the coolant hoses and connect the coolant hose connector.

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

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Position back the coolant hose and connect the retainers. Connect the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

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Position back the exhaust and install the nuts.
Torque: 30 lb.ft (40 Nm)

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Position back the wire harness housing. Connect the vacuum hose retainer and the transmission vent tube.

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NOTE: The oil filter housing needs a minimum of 1 minute to allow the oil to drain out of the oil filter housing to minimize oil spillage.

Loosen the oil filter cap and let the oil filter housing drain. Remove the oil filter cap.

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Remove and discard the oil filter cap O-ring seal.

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Remove and discard the oil filter. Use the General Equipment: Oil Drain Equipment

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Install a new oil filter.

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Install a new oil filter cap O-ring seal and lubricate.
Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

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Install the oil filter cap.
Torque: 18 lb.ft (25 Nm)

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Remove the oil pan plug and drain the engine oil. Use the General Equipment: Oil Drain Equipment
Torque: 18 lb.ft (25 Nm)

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Fill the engine with clean engine oil. Refer to: Specifications .
Material: Motorcraft® SAE 5W-30 F-150 Diesel Motor Oil / XO-5W30-QFA (WSS-M2C214-B1)

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Remove the wheel chocks.
- Roll the chassis back to the markings on the floor.
Install the following items:
1. Install the body. Refer to: Body - 3.0L Power Stroke Diesel .
2. Install the turbocharger oil return tube. Refer to: Turbocharger Oil Return Tube .