Cylinder Head - RH: Installation
WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
- Install new D-ring seals on the crankcase-to-head tube assemblies.
- Install the dowels and the cylinder head gasket.
- Using the special tools and with the help of an assistant, install the cylinder head on the engine. Remove the special tools.
- Install the outer cylinder head bolts finger-tight.
- Apply clean engine oil to each end of the push rods and insert them into their respective positions.
- Install the 8 valve bridges.
- Install the rocker arm assemblies and the 16 bolts.
- Tighten to 31 Nm (23 lb-ft).
- Install the 10 inner cylinder head retaining bolts finger-tight.
- Tighten the cylinder head bolts in 7 stages in the following sequence:
- Stage 1: Tighten bolts 1 through 10 to 88 Nm (65 lb-ft).
- Stage 2: Tighten bolts 1 through 10 to 115 Nm (85 lb-ft).
- Stage 3: Tighten bolts in sequence 1 through 10, 90 degrees.
- Stage 4: Tighten bolts in sequence 1 through 10, a second time, 90 degrees.
- Stage 5: Tighten bolts in sequence 1 through 10, a third time, 90 degrees.
- Stage 6: Tighten bolts 11 through 15 to 24 Nm (18 lb-ft).
- Stage 7: Tighten bolts 11 through 15 to 31 Nm (23 lb-ft).
- Install the 4 glow plugs.
- Tighten to 19 Nm (14 lb-ft).
- Using the special tool, install the glow plug harness.
- Position the 2 parts of the turbocharger adapter pipe into the vehicle. Install the gasket, connect the adapter pipe joint and install the bolts. Position the turbocharger adapter pipe on the exhaust manifolds.
- Tighten to 27 Nm (20 lb-ft).
- Install the nuts and bolts in the adapter pipe.
- Tighten to 27 Nm (20 lb-ft).
- Install the cylinder block coolant drain plug.
- Tighten to 20 Nm (15 lb-ft).
- Install the starter. For additional information, refer to STARTING SYSTEM - DIESEL ENGINE .
- Install new O-ring seals and copper washer on the fuel injector. Lubricate the fuel injector and O-ring seals liberally with clean engine oil.
- Install the fuel injector, fuel injector hold-down clamp and bolt.
- Early build vehicles (T40 Torx®), tighten to 33 Nm (24 lb-ft).
- Late build vehicles (T45 Torx®), tighten to 35 Nm (26 lb-ft).
- Install the fuel injector electrical connector into the rocker arm carrier.
- Apply engine oil to the top fuel injector O-ring seals.
- Position the oil rail on the fuel injectors.
- Place the oil rail on top of the carrier so that the 4 single ball tubes are engaging the injector lead angle.
- Insert 3 guide bolts, 2 on the ends of the straight side of the oil rail and 1 in the middle of the wavy side of the rail. Install the guide studs 6 to 7 turns.
- Manually press the oil rail into the fuel injectors.
- Make sure that the oil rail mounting feet are flat against the mounting surface.
- Loosely install the 6 bolts.
- Remove the 3 guide bolts, install the remaining bolts and tighten the 9 bolts in the sequence shown.
- Tighten to 13 Nm (10 lb-ft).
- Apply clean engine oil and reassemble the crankcase-to-head tube. Install the crankcase-to-head tube.
- Tighten to 82 Nm (60 lb-ft).
- Install the high pressure oil rail-to-valve cover gasket.
- Position the valve cover gasket. Install the valve cover and 11 bolts.
- Tighten to 9 Nm (80 lb-in).
- If equipped, position back the transmission fluid indicator and tube. Install the retaining nut.
- Install the ICP sensor.
- Tighten to 12 Nm (9 lb-ft).
- Connect the wiring retainers to the studs.
- Install the evaporator core housing. For additional information, refer to CLIMATE CONTROL .
- Install the intake manifold. For additional information, refer to INTAKE MANIFOLD .
- Fill the crankcase with clean engine oil.
CAUTION:
Install new D-ring seals on the crankcase-to-head tube. It requires several hours after installation for the D-ring seals to relax back to their original size. If the tube assembly is installed before the D-ring seals have relaxed, damage to the D-ring seals can occur.
NOTE:
Use care to avoid scratching the blue compound on the cylinder head gasket. Install a new cylinder head gasket with the part number facing up and verify the top 5 holes and the head gasket push rod holes line up.
CAUTION:
To prevent engine damage, keep the push rods in the order in which they were removed. Install all push rods back in their original positions.
NOTE:
On early build vehicles, higher mileage engines require push rods to be cleaned so the copper-colored end of the push rod can be identified and installed with the copper-colored end up. Push rods on late build vehicles and service push rods do not have a copper-colored end and can be installed with either end up.
NOTE:
Coat the end of each valve stem with clean engine oil.
CAUTION:
Rotate the crankshaft until the damper locating dowel notch is in the 6 o'clock position or engine damage can occur.
NOTE:
Apply clean engine oil to the top center of each valve bridge.
CAUTION:
Using too much engine oil on the threads of the cylinder head bolts can 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 can affect the true torque value of the bolts.
NOTE:
Lightly lubricate the new cylinder head bolt threads and flanges with clean engine oil.
NOTE:
Clean and apply clean engine oil to the O-ring seals.
NOTE:
Apply anti-seize lubricants to the bolt threads prior to installing the bolts.
NOTE:
Do not tighten until after the turbocharger is installed.
NOTE:
Apply clean engine oil to the O-ring seal prior to installing.
CAUTION:
If the fuel injector oil inlet D-shaped O-ring seal is damaged, a new fuel injector must be installed.
CAUTION:
Failure to tighten the injector properly can lead to engine failure.
CAUTION:
To prevent engine damage, do not use air tools to install the fuel injectors. The snap ring that extracts the injector can dislodge and fall into the oil drain hole.
CAUTION:
Make sure the injector wiring is clear of all moving parts or engine damage can occur.
CAUTION:
Using the bolts to push the high pressure oil rail into the fuel injectors can damage the fuel injectors and high pressure oil rail.
NOTE:
Apply clean engine oil on the tubes prior to installing the high pressure oil rail.
CAUTION:
To prevent engine damage, do not use air-powered tools when installing the valve cover.
NOTE:
Only one retainer shown.
NOTE:
Install a new oil filter.