Cylinder Head - Body Off - RH
WARNING: This page is about a different car, the 2021 Ford F-150. However, it is still accessible from the selected car via links, so may be relevant.
For information on Ford Color Coded Illustrations refer to OEM COLOR CODING INFORMATION
Special Tool(s) / General Equipment
| 303-1670 Pins, Camshaft Locking | |
|---|---|
| 303-1671 Pin, Locking Crankshaft | |
| 303-1674 Tool, Holding Camshaft Sprocket | |
| 303-1675 Adapter, Seal Remover | |
| 308-375 Remover, Input Shaft Seal, TKIT-2005U-M, TKIT-1999-F/FLM/LT | |
| 310-266 Remover, Fuel Injector | |
| Hose Clamp Remover/Installer |
Materials
| Name | Specification |
|---|---|
| Motorcraft® Metal Brake Parts Cleaner PM-4-A, PM-4-B | - |
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, can cause engine failure.
NOTE:
It is recommended that this component be serviced with the vehicle body removed. If the body cannot be removed, refer to Cylinder Head - Body On in this information.
- Remove the following items:
- Remove the turbocharger oil return tube. Refer to: Turbocharger Oil Return Tube .
- Remove the body. Refer to: Body - 3.0L Power Stroke Diesel .
- Roll the chassis out from under the body.
- Install wheel chocks at the front and back of one wheel.
- Disconnect the transmission vent tube. Disconnect the wire harness housing and position aside.
- Remove the nuts and position aside the exhaust. Discard the nuts.
- Disconnect the coolant hose. Disconnect the retainer and position aside the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer
- Remove the upper radiator hose. Use the General Equipment: Hose Clamp Remover/Installer
- Disconnect the coolant hose. Disconnect the retainers and remove the coolant hoses.
- Disconnect the electrical connector and the wire retainer.
-
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.
- Disconnect the coolant hose connector and the retainer.
- Remove the A/C belt and the accessory drive belt.
- Disconnect the electrical connector and the generator output wire.
- Remove the bolts and the generator.
- Disconnect and position aside the fuel tubes. Refer to: Quick Release Coupling
.
- Remove the LH fuel injector noise insulator.
- Remove the RH fuel injector noise insulator.
- Disconnect the oil pump electrical connector and the wire retainers.
- Disconnect the TB (throttle body) electrical connector and the wire retainer.
- Disconnect the CMP electrical connector and the wire retainer.
- Disconnect the CKP electrical connector and the wire retainer.
- Disconnect the EGR valve and the EP (exhaust pressure) sensor electrical connectors. Disconnect the wire retainers.
- Disconnect the EOP sensor electrical connector.
- Disconnect the electrical connectors and the wire retainers.
- Disconnect the fuel injectors electrical connectors and the wire retainers.
- Disconnect the electrical connectors and the wire retainer.
- Disconnect the turbocharger actuator electrical connector. Disconnect the EGRT electrical connector and the wire retainers.
- Disconnect the electrical connectors and the wire retainers.
- Disconnect the fuel injectors electrical connectors and the wire retainers.
- Disconnect the electrical connectors and the wire retainer.
- Disconnect the electrical connector and remove the bolt. Disconnect the wire harness retainers and remove the engine wire harness.
- Disconnect the vacuum pump connector. Remove the retainers and remove the vacuum hose assembly. Refer to: Quick Release Coupling
.
- Remove the bolts and the valve bracket.
- Remove the bolts and the lifting bracket.
- Remove the retainers and the vacuum pump.
- Remove and discard the vacuum pump gasket.
-
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.
-
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.
- Remove and discard the exhaust crossover pipe gaskets and the studs.
- Remove the bolt and the coolant return tube.
-
- Remove and discard the turbocharger coolant return tube O-ring seal.
-
NOTE: Use brake cleaner and a nylon brush to clean. Do not use a metal brush, damage to sealing area will result in leaks.
Clean the turbocharger coolant tube sealing surfaces. Inspect the sealing surfaces for debris or damage and make sure the retaining bracket is not bent, check for squareness of the O-ring area. Install new components if needed.
Material: Motorcraft® Metal Brake Parts Cleaner / PM-4-A, PM-4-B
- Remove the bolts and the turbocharger oil supply tube. Discard the turbocharger oil supply tube.
- Remove the bolt for the turbocharger coolant supply tube. Disconnect the turbocharger coolant supply tube from the engine.
- Remove the nuts and the turbocharger. Discard the nuts.
- Remove and discard the turbocharger gasket and the studs.
-
NOTE: Make note of turbocharger coolant tube manifold orientation to aid in proper installation.
Remove the bolt and the turbocharger coolant tube manifold. Discard the turbocharger coolant tube manifold.
- Remove the bolts and the coolant tube assembly. Use the General Equipment: Hose Clamp Remover/Installer
- Remove and discard the coolant tube assembly O-ring.
- Remove the bolts and the coolant tube bracket.
- Remove the bolt and the accessory drive belt tensioner.
- Remove the bolts and the fan pulley.
- Remove the nuts and the CAC tube bracket.
- Remove the bolts and the accessory drive belt tensioner.
- Remove the bolts and the crankshaft vibration damper.
-
- 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.
-
NOTE: Mark the locations of the fasteners before removal.
Remove the bolts, the stud bolts and the timing belt cover.
- Remove and discard the timing belt cover gasket.
- Disconnect the fuel lines. Remove the bolt and the secondary fuel filter. Discard the secondary fuel filter. Refer to: Quick Release Coupling
.
- Remove the bolt. Disconnect and remove the fuel supply tube. Refer to: Quick Release Coupling
.
- Disconnect and remove the fuel supply tube. Refer to: Quick Release Coupling
.
- Disconnect and remove the fuel return tube assembly. Discard the fuel return tube assembly. Refer to: Quick Release Coupling
.
- Remove the bolts and the front engine lifting eye.
-
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.
- Remove and discard the intake manifold gaskets.
- Remove the bolts and the heater hose support bracket.
- Remove the retainers and the engine support bracket.
- Remove the RH engine cover stud assemblies.
- Disconnect and position aside the RH fuel return hose assembly.
- Remove and discard the RH fuel supply tube.
-
- Remove the bolt and the clamp.
- Remove and discard the RH fuel injector supply tubes.
-
- Remove the bolts and the clamps.
- Remove and discard the fuel injection pump balance tube.
- Remove the bolts and the RH fuel rail.
- Remove the RH fuel injector noise insulator.
- Remove the bolts for the RH fuel injectors.
-
NOTE: Only one fuel injector shown.
Using the special tool, remove the fuel injectors. Use Special Service Tool: 310-266 Remover, Fuel Injector.
- Remove and discard the sealing washer, the O-rings and the fuel injector hold down.
- Remove the bolts and the RH fuel rail bracket.
- Remove the nuts and the RH fuel tube bracket.
- Remove the nut, the bolt and the turbocharger heat shield.
- Disconnect the RH glow plug electrical connector.
-
NOTE: Mark the location of the fasteners prior to removing the valve cover.
Loosen the fasteners and remove the RH valve cover.
- Remove and discard the RH valve cover gasket.
- Clean and prepare the RTV sealing surface. Refer to: RTV Sealing Surface Cleaning and Preparation
.
- Remove the timing pin bolt at the left front of the engine.
- 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.
-
- Remove the bolts and the fan drive.
-
- Using the special tools, verify the camshaft timing. Use Special Service Tool: 303-1670 Pins, Camshaft Locking.
- Loosen the bolts on the camshaft pulleys.
-
NOTE: The crankshaft or camshafts must not be rotated while the timing belt is removed.
- Loosen the timing belt tensioner bolt.
- Rotate the timing belt tensioner clockwise.
- Remove the timing belt.
-
NOTE: Replace the timing belt tensioner if damage or excessive wear is found.
Remove the bolt and the timing belt tensioner. Discard the bolt.
-
NOTE: Note the position of the camshaft pulley prior to removal.
Remove the bolts and the RH camshaft pulley.
-
NOTE: Use the original bolts for the special tool.
Using the special tool, remove the bolts and the RH camshaft gear hub. Discard the bolt. Use Special Service Tool: 303-1674 Tool, Holding Camshaft Sprocket.
- Remove the bolts and the coolant outlet connector.
- Remove and discard the oil cooler O-ring.
- Remove and discard the coolant outlet connector gaskets.
- Remove the dust shield.
- 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.
- Compress the camshaft chain and install the retaining pin.
-
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.
- Remove the bolts and the RH camshafts, camshaft chain and the secondary timing chain tensioner.
-
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 RH camshaft roller follower and hydraulic lash adjuster assemblies.
- 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.
-
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 RH cylinder head.
- Remove the cylinder head.
- Remove and discard the RH cylinder head gasket and the cylinder head dowels.
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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 .