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    Ford Pick-Ups/Expedition/Navigator 1997-2000

    Cylinder Head

    Print

    REMOVAL & INSTALLATION



    4.2L Engine

    Relieve the fuel system pressure before starting any work that involves disconnecting the fuel lines. Refer toFuel System.

    1. The A/C system, should be discharged by a qualified mechanic using an approved refrigerant recovery/recycling machine.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Drain the cooling system.
    6.  
    7. Remove the upper and lower intake manifolds and related components.
    8.  
    9. Remove the valve covers.
    10.  
    11. Remove the exhaust manifold (s).
    12.  
    13. If removing the left-hand cylinder head, perform the following:
      1. Position the power steering pump reservoir aside and remove the A/C compressor.
      2.  
      3. Remove and support the A/C compressor bracket and power steering pump aside.
      4.  

    14.  
    15. If removing the right-hand cylinder head, perform the following:
      1. Remove the alternator.
      2.  
      3. Remove the idler pulley.
      4.  
      5. Remove the alternator bracket.
      6.  

    16.  

    If the cylinder head components, such as rocker arms, valve springs, etc., are to be reinstalled, they must be installed in the same position. Mark the components for original location.

    1. Remove the six rocker arms by removing the retaining bolts.
    2.  
    3. Pull the pushrods out of the engine. Once again, be sure to label or mark the components removed for reinstallation in their original location.
    4.  
    5. Remove and discard the eight cylinder head mounting bolts. New bolts are a must for installation.
    6.  
    7. Lift the cylinder head off of the engine block. Remove the cylinder head gasket and discard.
    8.  

    To install:

    1. Clean and inspect the cylinder head for flatness.
    2.  
    3. Install a new cylinder head gasket on the cylinder block with the small hole to the front of the engine, then install the cylinder head.
    4.  


    WARNING
    Always use new cylinder head bolts for installation.

    1. Lubricate the cylinder head bolts with clean engine oil prior to installation.
    2.  

    Be sure to tighten the cylinder head bolts in three (3) steps.

    1. Install the new cylinder head bolts. Tighten the cylinder head bolts in the sequence shown and in three steps to the following values:
    2.  



    Step 1-14 ft. lbs. (20 Nm)
     
    Step 2-29 ft. lbs. (40 Nm)
     
    Step 3-36 ft. lbs. (50 Nm)
     



    Click image to see an enlarged view

    Fig. Fig. 1 Cylinder head torque sequence-4.2L engines


    WARNING
    Do not loosen all of the cylinder head bolts at one time. Each cylinder head bolt must be loosened and the final tightening performed prior to loosening the next bolt in the sequence.

    1. In the same sequence as used previously, loosen the cylinder head bolt three turns, then tighten the cylinder head bolt to the specific value according to its length. The short bolts (A) should be tightened to 15-32 ft. lbs. (20-30 Nm) and the long bolts (B) to 30-36 ft. lbs. (40-50 Nm). Finally, tighten each cylinder head bolt, in sequence, an additional 175-185 degrees (C). It would be very helpful to utilize a degree socket wrench for this last step.
    2.  
    3. Lubricate the pushrods with clean engine oil prior to installation, then install them into their original positions.
    4.  
    5. Install the rocker arms. Tighten the rocker arm mounting bolts to 23-29 ft. lbs. (30-40 Nm).
    6.  
    7. If the valvetrain components were replaced with new components, inspect the valve clearance.
    8.  
    9. If installing the right-hand cylinder head, perform the following:
      1. Position the alternator bracket in place, then install the two long bolts to 31-39 ft. lbs. (41-54 Nm). Install the short bolt and tighten to 18-22 ft. lbs. (24-31 Nm).
      2.  
      3. Install the idler pulley. Tighten the center retaining bolt to 35-46 ft. lbs. (47-63 Nm).
      4.  
      5. Install the alternator.
      6.  

    10.  
    11. If installing the left-hand cylinder head, complete the following steps:
      1. Position the A/C compressor bracket and power steering pump in place, then start the A/C compressor bracket bolt. Install the three compressor bracket bolts to 30-40 ft. lbs. (40-55 Nm). Then, install the two compressor bracket nuts to 16-21 ft. lbs. (21-29 Nm).
      2.  
      3. Install the A/C compressor.
      4.  
      5. Install the power steering pump reservoir. Tighten the hold-down bolts to 80-107 inch lbs. (9-12 Nm).
      6.  

    12.  
    13. Install the exhaust manifold.
    14.  
    15. Install the two rocker arm covers. Inspect the rocker arm cover gaskets for damage prior to installation; replace them if necessary.
    16.  
    17. Install the lower intake manifold and related components.
    18.  
    19. Install the upper intake manifold and related components.
    20.  
    21. Fill the cooling system and connect the negative battery cable.
    22.  
    23. Change the engine oil.
    24.  
    25. Start the engine and check for any fuel, coolant and vacuum leaks.
    26.  

    4.6L, 5.4L and 6.8L Engines


    Click image to see an enlarged view

    Fig. Fig. 2 Remove the cylinder head bolts and ...



    Click image to see an enlarged view

    Fig. Fig. 3 ... carefully lift the cylinder head off of the engine block and place it in a safe location



    Click image to see an enlarged view

    Fig. Fig. 4 Remove the head gasket from the engine block



    Click image to see an enlarged view

    Fig. Fig. 5 Thoroughly clean the cylinder head and ...



    Click image to see an enlarged view

    Fig. Fig. 6 ... engine block of any gasket material left



    Click image to see an enlarged view

    Fig. Fig. 7 After the gasket material has been removed, wipe the head and ...



    Click image to see an enlarged view

    Fig. Fig. 8 ... engine block clean using a suitable solvent

    Relieve the fuel system pressure before starting any work that involves disconnecting the fuel lines. Refer toFuel System

    1. The A/C system, should be discharged by an EPA certified mechanic utilizing the appropriate refrigerant recovery/recycling machine.
    2.  
    3. Disconnect the negative battery cable.
    4.  
    5. Remove the valve covers.
    6.  
    7. Remove the intake manifold(s).
    8.  
    9. Remove the timing chains from the engine.
    10.  
    11. Remove the exhaust manifolds.
    12.  
    13. Remove the two heater hose retaining bolts, then compress and slide the hose clamp back to remove the heater water hose.
    14.  
    15. Remove the cylinder head bolts, then lift the cylinder head from the engine block.
    16.  
    17. Discard the cylinder head gasket and clean the engine block surface.
    18.  

    To install:


    WARNING
    Cylinder head bolts must be replaced with new ones. They are torque-to-yield designed and cannot be reused.

    1. Turn the crankshaft to position the key-way at the 12 o'clock position.
    2.  
    3. Clean and inspect the cylinder head for damage or warpage. Install the cylinder head gasket over the dowel pins. Then, install the cylinder head onto the engine block. Loosely install NEW cylinder head bolts.
    4.  

    Be sure to tighten the head bolts in three steps.

    1. Tighten the cylinder head bolts in the sequence shown in three steps, as follows:
      1. Step 1-27-31 ft. lbs. (37-43 Nm).
      2.  
      3. Step 2-tighten an additional 85-95 degrees.
      4.  
      5. Step 3-tighten another 85-95 degrees.
      6.  

    2.  



    Click image to see an enlarged view

    Fig. Fig. 9 Tighten the cylinder head bolts in three steps using the sequence shown-4.6L and 5.4L engines



    Click image to see an enlarged view

    Fig. Fig. 10 Be sure to tighten the cylinder head bolts in three steps using the sequence shown-6.8L engine

    1. Install the heater water hose and slide the hose clamp back into position. Install the two heater water hose bolts.
    2.  
    3. Install the exhaust manifolds.
    4.  
    5. Install the timing chains.
    6.  
    7. Install the intake manifold.
    8.  
    9. Install the valve covers.
    10.  
    11. Connect the negative battery cable, then start the engine and check for leaks.
    12.  
    13. If the vehicle is equipped with A/C, have the system evacuated and recharged by an EPA certified mechanic utilizing the appropriate refrigerant recovery/recycling machine.
    14.  
    15. Change the engine oil.
    16.  
    17. Connect the negative battery cable.
    18.  

    5.8L Engine

    Relieve the fuel system pressure before starting any work that involves disconnecting the fuel lines. Refer toFuel System

    1. Disconnect the negative battery cable.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove the intake manifolds.
    6.  
    7. Remove the valve cover(s).
    8.  
    9. If the right cylinder head is to be removed:
    10.  



    Lift the tensioner and remove the drive belt
     
    Loosen the alternator adjusting arm bolt and remove the alternator mounting bracket bolt and spacer
     
    Swing the alternator down and out of the way.
     

    1. Remove the air cleaner inlet duct.
    2.  
    3. If the left cylinder head is being removed:

      Remove the air conditioning compressor
       
      Remove the oil dipstick and tube
       
      Remove the cruise control bracket
       

    4.  
    5. Disconnect the exhaust manifold(s) from the muffler inlet pipe(s).
    6.  
    7. Loosen the rocker arm stud nuts so the rocker arms can be rotated to the side. Remove the pushrods and identify them so they can be reinstalled in their original positions.
    8.  
    9. Remove the cylinder head bolts and lift the cylinder head from the block. Remove the discard the gasket.
    10.  

    To install:

    1. Clean the cylinder head, intake manifold, the valve cover and the head gasket surfaces.
    2.  


    WARNING
    A specially treated composition head gasket is used. Do not apply sealer to a composition gasket.

    1. Position the new gasket over the locating dowels on the cylinder block.
    2.  
    3. Position the cylinder head on the block and install the attaching bolts.
    4.  
    5. The cylinder head bolts are tightened in progressive steps. Tighten all the bolts in the proper sequence to:
    6.  



    Step 1-85 ft. lbs.(115 Nm)
     
    Step 2-95 ft. lbs. (129 Nm)
     
    Step 3-105-112 ft. lbs. (143-152 Nm)
     

    1. Clean the pushrods. Blow out the oil passage in the rods with compressed air. Check the pushrods for straightness by rolling them on a piece of glass. Never try to straighten a pushrod; always replace it.
    2.  
    3. Apply Lubriplate® to the ends of the pushrods and install them in their original positions.
    4.  
    5. Apply Lubriplate® to the rocker arms and their fulcrum seats and install the rocker arms. Adjust the valves.
    6.  
    7. Position a new gasket(s) on the muffler inlet pipe(s) as necessary. Connect the exhaust manifold(s) at the muffler inlet pipe(s).
    8.  
    9. If the right cylinder head was removed, install the alternator, air cleaner duct, and the drive belt. If the left cylinder head was removed, install the compressor, the dipstick and cruise control bracket.
    10.  
    11. Clean the valve rocker arm cover and the cylinder head gasket surfaces. Place the new gaskets in the covers, making sure the tabs of the gasket engage the notches provided in the cover. Evacuate, charge and leak test the air conditioning system.
    12.  
    13. Install the intake manifold and related parts.
    14.  
    15. Fill and bleed the cooling system.
    16.  
    17. Change the engine oil.
    18.  
    19. Connect the negative battery cable.
    20.  



    Click image to see an enlarged view

    Fig. Fig. 11 Cylinder head bolt torque sequence-5.8L and 7.5L engines

    7.5L Engine

    Relieve the fuel system pressure before starting any work that involves disconnecting the fuel lines. Refer toFuel System

    1. Disconnect the negative battery cable.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove the upper and lower intake manifolds..
    6.  
    7. Disconnect the exhaust pipe from the exhaust manifold.
    8.  
    9. Remove the drive belts.
    10.  
    11. Loosen the alternator attaching bolts and remove the bolt attaching the alternator bracket to the right cylinder head.
    12.  
    13. Disconnect the air conditioning compressor from the engine and move it aside, out of the way. Do not discharge the air conditioning system.
    14.  
    15. Remove the bolts securing the power steering reservoir bracket to the left cylinder head. Position the reservoir and bracket out of the way. On motor home chassis, remove the oil filler tube.
    16.  
    17. Remove the valve covers.
    18.  
    19. Remove the rocker arm bolts, rocker arms, oil deflectors, fulcrums and pushrods in sequence so they can be reinstalled in their original positions.
    20.  
    21. Remove the cylinder head bolts and lift the head and exhaust manifold off the engine. If necessary, pry at the forward corners of the cylinder head against the casting bosses provided on the cylinder block. Do not damage the gasket mating surfaces of the cylinder head and block by prying against them.
    22.  

    To install:

    1. Remove all gasket material from the cylinder head and block. Clean all gasket material from the mating surfaces of the intake manifold. If the exhaust manifold was removed, clean the mating surfaces of the cylinder head and exhaust manifold. Apply a thin coat of graphite grease to the cylinder head exhaust port areas and install the exhaust manifold.
    2.  
    3. Position the two long cylinder head bolts in the two rear lower bolt holes of the left cylinder head. Place a long cylinder head bolt in the rear lower bolt hole of the right cylinder head. Use rubber bands to keep the bolts in position until the cylinder heads are installed on the cylinder block.
    4.  
    5. Position new cylinder head gaskets on the cylinder block dowels. Do not apply sealer to the gaskets, heads, or block.
    6.  
    7. Place the cylinder heads on the block, guiding the exhaust manifold studs into the exhaust pipe connections. Install the remaining cylinder head bolts. The longer bolts go in the lower row of holes.
    8.  
    9. Tighten all the cylinder head attaching bolts in the proper sequence in three stages: 80-90 ft. lbs. (109-122 Nm), 100-110 ft. lbs. (136-149 Nm), and finally to 130-140 ft. lbs. (176-190 Nm). When this procedure is used, it is not necessary to retighten the heads after extended use.
    10.  
    11. Be sure the oil holes in the pushrods are open and install the pushrods in their original positions. Place a dab of Lubriplate® to the ends of the pushrods before installing them.
    12.  
    13. Lubricate and install the valve rockers. Be sure the pushrods remain seated in their lifters.
    14.  
    15. Connect the exhaust pipes to the exhaust manifolds.
    16.  
    17. Install the upper and lower intake manifolds.
    18.  
    19. Install the air conditioning compressor.
    20.  
    21. Install the power steering reservoir.
    22.  
    23. Install the valve covers.
    24.  
    25. Install the alternator and adjust the drive belts.
    26.  
    27. On motor home chassis, install the oil filler tube.
    28.  
    29. Fill and bleed the cooling system.
    30.  
    31. Change the engine oil.
    32.  
    33. Connect the negative battery cable.
    34.  
    35. Start the engine and check for leaks.
    36.  

    7.3L Diesel Engine
    RIGHT CYLINDER HEAD


    Click image to see an enlarged view

    Fig. Fig. 12 Remove the oil rail drain plug as shown-7.3L DI turbo diesel engine



    Click image to see an enlarged view

    Fig. Fig. 13 Remove the injector using special tools as shown-7.3L DI turbo diesel engine



    Click image to see an enlarged view

    Fig. Fig. 14 Special fuel injector protection sleeve and holding rack-7.3L DI turbo diesel engine



    Click image to see an enlarged view

    Fig. Fig. 15 Install a lifting eye as shown



    Click image to see an enlarged view

    Fig. Fig. 16 Use a suitable bore brush to clean out the injector bores



    Click image to see an enlarged view

    Fig. Fig. 17 Cylinder head bolt tightening sequence-7.3L DI turbo diesel engine



    Click image to see an enlarged view

    Fig. Fig. 18 Install the injectors using the special tool as shown-7.3L DI turbo diesel engine

    1. Disconnect both negative battery cables.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove the radiator.
    6.  
    7. Remove the turbocharger assembly.
    8.  
    9. Disconnect the fuel lines by disconnecting them from the rear of both cylinder heads and the fuel pump.
    10.  
    11. Label and disconnect the wiring from the alternator.
    12.  
    13. Remove the adjusting bolts and pivot bolts from the alternator and the vacuum pump and remove both units.
    14.  
    15. Remove the alternator and its bracket.
    16.  
    17. Remove the engine oil dipstick tube.
    18.  
    19. Remove the MAP sensor and position it aside.
    20.  
    21. Remove the valve cover
    22.  
    23. Remove the connectors from the injectors and glow plugs.
    24.  
    25. Remove the valve cover gasket.
    26.  
    27. Remove the high pressure oil pump supply line to the right cylinder head.
    28.  
    29. Remove the exhaust back pressure line.
    30.  
    31. Remove the three glow plug relay bracket nuts and the ground wire.
    32.  
    33. Disconnect the heater hose from the cylinder head.
    34.  
    35. Remove the outer half of the heater distribution box.
    36.  
    37. Remove the four outboard fuel injector hold-down bolts, retaining screws and four oil deflectors.
    38.  


    WARNING
    Remove the oil drain plugs prior to removing the injectors or oil could enter the combustion chamber which could result in hydrostatic lock and severe engine damage.

    1. Remove the oil rail drain plugs.
    2.  
    3. Remove the fuel injectors using Injector Remover No. T94T-9000-AH1, or equivalent. Position the tool's fulcrum beneath the fuel injector hold-down plate and over the edge of the cylinder head. Install the remover screw in the threaded hole of the fuel injector plate (see illustration). Tighten the screw to lift out the injector from its bore. Place the injector in a suitable protective sleeve such as Rotunda Injector Protective Sleeve, No. 014-00933-2, and set the injector in a suitable holding rack.
    4.  
    5. Use a suitable vacuum tool, such as Rotunda Vacuum Pump, No. 021-00037, or equivalent to remove the oil and fuel left over in the injector bores.
    6.  
    7. Remove the rocker arms and pushrods, KEEP EVERYTHING IN ORDER.
    8.  
    9. Remove the four glow plugs.
    10.  
    11. Remove the right turbo exhaust inlet pipe.
    12.  
    13. Remove the ground strap from the rear of the cylinder head.
    14.  
    15. Disconnect the fuel return line at the front of the cylinder head.
    16.  
    17. Remove the four inboard fuel injector shoulder bolts.
    18.  
    19. Remove the cylinder head bolts and attach a Rotunda Cylinder Head Lifting Bracket, 014-00932-2, or equivalent.
    20.  
    21. Carefully lift the cylinder head out of the engine compartment and remove the head gaskets.
    22.  

    To install:

    To prepare a good seat for the fuel injector O-rings, use a suitable injector sleeve brush to clean any debris from the bore.

    1. Carefully clean the cylinder block and head mating surfaces.
    2.  
    3. Position the cylinder head gasket on the engine block and carefully lower the cylinder head in place.
    4.  
    5. Install the cylinder head bolt and torque in 3 steps using the sequence shown in the illustration.
    6.  

    Lubricate the threads and the mating surfaces of the bolt heads and washers with engine oil.

    1. Connect the fuel return line to the cylinder head.
    2.  
    3. Install the four inboard injector shoulder bolts. Tighten them to 9 ft. lbs. (12 Nm).
    4.  
    5. Install the fuel injectors using special tools as follows:
      1. Lubricate the injectors with clean engine oil. Using new copper washers, carefully push the injectors square into the bore using hand pressure only to seat the O-rings.
      2.  
      3. Position the open end of Injector Replacer, No. T94T-9000-AH2, or equivalent between the fuel injector body and injector hold-down plate, while positioning the opposite end of the tool over the edge of the cylinder head.
      4.  
      5. Align the hole in the tool with the threaded hole in the cylinder head and install the bolt from the tool kit. Tighten the bolt to fully seat the injector, then remove the bolt and tool.
      6.  

    6.  
    7. Install the four outboard fuel injector hold-down bolts, the four oil deflectors and retaining screws. Tighten them to 9 ft. lbs. (12 Nm).
    8.  
    9. Dip the pushrod ends in clean engine oil and install the pushrods with the copper colored ends toward the rocker arms, making sure the pushrods are fully seated in the tappet pushrod seats.
    10.  
    11. Install the rocker arms and posts in their original positions. Apply Lubriplate® grease to the valve stem tips. Turn the engine over by hand until the timing mark is at the 11 o'clock position as viewed from the front. Install the rocker arm posts, bolts and tighten to 27 ft. lbs. (37 Nm). Install the valve covers.
    12.  
    13. Install the fuel rail drain plugs, tightening them to 8 ft. lbs. (11 Nm).
    14.  
    15. Install the oil rail drain plugs, tightening them to 53 inch lbs. (6 Nm).
    16.  
    17. Install the heater distribution box.
    18.  
    19. Install the heater hose to the cylinder head.
    20.  
    21. Install the glow plug relay bracket and ground wire.
    22.  
    23. Install the exhaust back pressure line.
    24.  
    25. Install the oil supply line to the cylinder head, tightening it to 19 ft. lbs. (26 Nm).
    26.  
    27. Install the dipstick tube.
    28.  
    29. Install the MAP sensor and screws.
    30.  
    31. Install the valve cover gasket.
    32.  
    33. Connect the wiring to the fuel injectors and glow plugs.
    34.  
    35. Install the valve cover, tightening the bolts to 8 ft. lbs. (11 Nm).
    36.  
    37. Connect the injector wiring harness to the valve cover gasket.
    38.  
    39. Install the alternator, tightening the bracket bolts to 40-55 ft. lbs. (54-75 Nm).
    40.  
    41. Connect the alternator wiring and install the drive belt.
    42.  
    43. The remainder of the installation is the reverse of the removal. Tighten the fuel pump-to-fuel line banjo bolt to 40 ft. lbs. (54 Nm).
    44.  
    45. Connect both negative battery cables.
    46.  
    47. Refill and bleed the cooling system.
    48.  
    49. Run the engine and check for fuel, coolant and exhaust leaks.
    50.  

    LEFT CYLINDER HEAD


    Click image to see an enlarged view

    Fig. Fig. 19 Remove the oil rail drain plug as shown-7.3L DI turbo diesel engine



    Click image to see an enlarged view

    Fig. Fig. 20 Remove the injector using special tools as shown-7.3L DI turbo diesel engine



    Click image to see an enlarged view

    Fig. Fig. 21 Special fuel injector protection sleeve and holding rack-7.3L DI turbo diesel engine



    Click image to see an enlarged view

    Fig. Fig. 22 Install a lifting eye as shown



    Click image to see an enlarged view

    Fig. Fig. 23 Use a suitable bore brush to clean out the injector bores



    Click image to see an enlarged view

    Fig. Fig. 24 Cylinder head bolt tightening sequence-7.3L DI turbo diesel engine



    Click image to see an enlarged view

    Fig. Fig. 25 Install the injectors using the special tool as shown-7.3L DI turbo diesel engine

    1. Disconnect both negative battery cables.
    2.  
    3. Drain the cooling system.
    4.  
    5. Remove the radiator.
    6.  
    7. Remove the turbocharger assembly.
    8.  
    9. Remove the two crankcase breather screws and the breather.
    10.  
    11. Disconnect the wiring from the air conditioning compressor.
    12.  
    13. Remove the four left accessory bracket bolts.
    14.  
    15. Disconnect the vacuum hose at the brake vacuum pump.
    16.  
    17. Disconnect the A/C lines from the compressor.
    18.  
    19. Remove the power steering lines from the pump.
    20.  
    21. Remove the left accessory bracket and accessories as an assembly.
    22.  
    23. Remove the valve cover
    24.  
    25. Disconnect the fuel line assembly between the cylinder heads and fuel pump.
    26.  
    27. Remove the fuel line nut from the intake manifold stud.
    28.  
    29. Disconnect the fuel return line from the cylinder head.
    30.  
    31. Remove the high pressure oil pump supply line from the cylinder head.
    32.  
    33. Raise the vehicle and support it safely on jackstands.
    34.  
    35. Remove the left turbo exhaust pipe from the manifold.
    36.  
    37. Lower the vehicle.
    38.  
    39. Remove the oil rail drain plugs.
    40.  
    41. Remove the four outboard fuel injector hold-down bolts, retaining screws and four oil deflectors.
    42.  


    WARNING
    Remove the oil drain plugs prior to removing the injectors or oil could enter the combustion chamber which could result in hydrostatic lock and severe engine damage.

    1. Remove the oil rail drain plugs.
    2.  
    3. Remove the fuel injectors using Injector Remover No. T94T-9000-AH1, or equivalent. Position the tool's fulcrum beneath the fuel injector hold-down plate and over the edge of the cylinder head. Install the remover screw in the threaded hole of the fuel injector plate (see illustration). Tighten the screw to lift out the injector from its bore. Place the injector in a suitable protective sleeve such as Rotunda Injector Protective Sleeve, No. 014-00933-2, and set the injector in a suitable holding rack.
    4.  
    5. Use a suitable vacuum tool, such as Rotunda Vacuum Pump, No. 021-00037, or equivalent to remove the oil and fuel left over in the injector bores.
    6.  
    7. Remove the rocker arms and pushrods, KEEP EVERYTHING IN ORDER.
    8.  
    9. Remove the four glow plugs.
    10.  
    11. Remove the left turbo exhaust inlet pipe.
    12.  
    13. Remove the main engine harness connectors in the left fender well and position the harness aside.
    14.  
    15. Remove the four inboard fuel injector shoulder bolts.
    16.  
    17. Remove the cylinder head bolts and attach a Rotunda Cylinder Head Lifting Bracket, 014-00932-2, or equivalent.
    18.  
    19. Carefully lift the cylinder head out of the engine compartment and remove the head gaskets.
    20.  

    To install:

    To prepare a good seat for the fuel injector O-rings, use a suitable injector sleeve brush to clean any debris from the bore.

    1. Carefully clean the cylinder block and head mating surfaces.
    2.  
    3. Position the cylinder head gasket on the engine block and carefully lower the cylinder head in place.
    4.  
    5. Install the cylinder head bolt and torque in 3 steps using the sequence shown in the illustration.
    6.  

    Lubricate the threads and the mating surfaces of the bolt heads and washers with engine oil.

    1. Apply anti-seize paste and install the glow plugs, tightening them to 14 ft. lbs. (19 Nm).
    2.  
    3. Install the four outboard fuel injector hold-down bolts, the four oil deflectors and retaining screws. Tighten them to 9 ft. lbs. (12 Nm).
    4.  
    5. Dip the pushrod ends in clean engine oil and install the pushrods with the copper colored ends toward the rocker arms, making sure the pushrods are fully seated in the tappet pushrod seats.
    6.  
    7. Install the rocker arms and posts in their original positions. Apply Lubriplate® grease to the valve stem tips. Turn the engine over by hand until the timing mark is at the 11 o'clock position as viewed from the front. Install the rocker arm posts, bolts and tighten to 27 ft. lbs. (37 Nm). Install the valve covers.
    8.  
    9. Install the four inboard injector shoulder bolts. Tighten them to 9 ft. lbs. (12 Nm).
    10.  
    11. Install the fuel injectors using special tools as follows:
      1. Lubricate the injectors with clean engine oil. Using new copper washers, carefully push the injectors square into the bore using hand pressure only to seat the O-rings.
      2.  
      3. Position the open end of Injector Replacer, No. T94T-9000-AH2, or equivalent between the fuel injector body and injector hold-down plate, while positioning the opposite end of the tool over the edge of the cylinder head.
      4.  
      5. Align the hole in the tool with the threaded hole in the cylinder head and install the bolt from the tool kit. Tighten the bolt to fully seat the injector, then remove the bolt and tool.
      6.  

    12.  
    13. Install the fuel rail drain plugs, tightening them to 8 ft. lbs. (11 Nm).
    14.  
    15. Install the oil rail drain plugs, tightening them to 53 inch lbs. (6 Nm).
    16.  
    17. Install the heater distribution box.
    18.  
    19. Install the valve cover gasket.
    20.  
    21. Connect the wiring to the fuel injectors and glow plugs.
    22.  
    23. Install the valve cover, tightening the bolts to 8 ft. lbs. (11 Nm).
    24.  
    25. Connect the engine wiring harness.
    26.  
    27. Raise and safely support the vehicle on jackstands.
    28.  
    29. Loosely install the turbo exhaust pipe to the manifold.
    30.  
    31. Lower the vehicle.
    32.  
    33. The remainder of the installation is the reverse of the removal. Tighten the fuel pump-to-fuel line banjo bolt to 40 ft. lbs. (54 Nm).
    34.  
    35. Connect both negative battery cables.
    36.  
    37. Refill and bleed the cooling system.
    38.  
    39. Run the engine and check for fuel, coolant and exhaust leaks.
    40.  

     
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