in-vehicle repair

303-01C-1 303-01C-1Engine — 6.0L Diesel

IN-VEHICLE REPAIRMaterialCylinder Head — RH

Item Specification

Special Tool(s) SAE 15W-40 Super Duty WSS-M2C171-DMotor Oil

Lifting Bracket, Cylinder Head XO-15W40-QSD (US);303-759 CXO-15W40-LSD12

(Canada); or equivalent

High Temperature Nickel ESE-M12A4-AAnti-Seize LubricantXL-2 (US); CXG-2-B(Canada)

Metal Brake Parts Cleaner —Heavy Duty Floor CranePM-4-A or PM-4-B (US);014-00071CPM-4 (Canada)

Removal

1. With the vehicle in NEUTRAL, position it on ahoist. For additional information, refer to

Release Tool, Injector Section 100-02.Connector303-1115

2. Drain the engine oil.

3. Remove the intake manifold. For additionalinformation, refer to Intake Manifold in thissection.

Remover/ Installer, Glow PlugConnector 4. Remove the evaporator core housing. For303-1114 additional information refer to Section 412-01.

5. NOTE: Only one retainer shown.

Disconnect the wiring harness retainers fromthe studs.

Remover, High-Pressure SupplyTube303-1164

Copyright 2005, Ford Motor CompanyLast updated: 9/20/2008 2006 F-250, 350, 450, 550 Super Duty, 6/2005


IN-VEHICLE REPAIR (Continued)

6. Remove the injection control pressure (ICP) 9. Remove the high-pressure oil rail-to-valve coversensor. gasket.

7. If equipped, remove the nut and position the 10. Remove the crankcase-to-head tube.transmission fluid and indicator aside.

11. NOTE: Do not remove the oil rail end plugs or8. NOTE: Mark the position of the valve cover acoustic wave attenuator port fitting. Service

bolts for the valve cover bolt installation. parts are not available to support thecomponents.Remove the bolts, stud bolts and the valve

cover. Remove the bolts and the high-pressure oil rail.

• Clean and inspect the valve cover gasket.Install a new gasket if necessary.

2006 F-250, 350, 450, 550 Super Duty, 6/2005



12. NOTE: Use a shop towel and metal brake partscleaner to remove the oil residue prior toremoving.

If the crankcase-to-head tube separated, usingthe special tool, remove the lowercrankcase-to-head tube.

15. NOTICE: Do not attempt to apply batteryvoltage to the fuel injector or damage to thefuel injector will occur.

Using the special tool, push the fuel injectorelectrical connector out of the rocker armcarrier.

13. Inspect the D-ring seals for damage (nicks, cutsand gouges). If damaged, replace thecrankcase-to-head tube.

16. Prior to removing the fuel injector assembly,insert clean shop towels in the oil drain holesadjacent to each glow plug.

14. NOTE: Early build cylinder heads, headgaskets, cylinder block, rocker arm carriers andinjector hold-down clamps are notinterchangeable with late build engines. It isnecessary to identify the head style prior toworking on the cylinder heads. Early buildheads are equipped with injector hold-downclamps with a square end and a T40 Torxbolt. Late build heads have injector hold-downclamps with a tapered end and a T45 Torxbolt.

Determine if the cylinder heads are early build(left frame of illustration) or late build (rightframe of illustration).

2006 F-250, 350, 450, 550 Super Duty, 6/2005



17. NOTICE: Failure to account for all snaprings or pieces prior to placing the vehicleback into service can cause engine damage.A missing snap ring can be ingested into thelube oil system and cause severe enginedamage.

NOTICE: To prevent engine damage, do notuse air tools to remove the fuel injectors. Thesnap ring that extracts the injector candislodge and fall into the oil drain hole.

NOTE: There is no need to drain the fuel rail.

NOTE: If engine coolant is found in thecombustion chambers, it may be necessary to 21. NOTE: LH shown, RH similar.install a new injector sleeve. For additional Remove the nuts and bolts from theinformation, refer to Section 303-04C. turbocharger adapter pipe.NOTE: The bolt is part of the fuel injectorhold-down assembly.

Loosen the bolt and remove the bolt and fuelinjector hold-down assembly and the fuelinjector.

22. Position the turbocharger adapter pipe to gainaccess to the adapter pipe joint. Remove thebolts, separate the adapter pipe joint andremove the gasket. Remove the 2 parts of theturbocharger adapter pipe.

18. NOTE: If a snap ring or piece of a snap ring ismissing from the injector hold-down assembly,it must be located prior to removing the shoptowels.

Remove the shop towels.

19. Remove the starter. For additional information,refer to Section 303-06B.

20. Remove the cylinder block coolant drain plug.

2006 F-250, 350, 450, 550 Super Duty, 6/2005



23. NOTICE: Do not pull on the wiring to 26. Remove the 8 bolts and the rocker armremove the glow plug connector or damage assemblies.may occur.

NOTE: Only one glow plug connector shown.

Using the special tool, remove the glow plugharness and position aside.

27. Mark the 8 valve bridges with a permanentmarker and remove.

24. Remove the 4 glow plugs.

28. NOTICE: To prevent engine damage, keepthe push rods in the order in which theywere removed. Install all push rods back intheir original positions.

25. Remove and discard the 10 inner cylinder headMark the location and remove the 8 push rods.bolts.

2006 F-250, 350, 450, 550 Super Duty, 6/2005



29. Remove the outer cylinder head bolts. 33. Check for cylinder block distortion. Foradditional information, refer to Cylinder BlockDistortion in this section.

Installation

1. NOTE: Use care to avoid scratching the bluecompound on the cylinder head gasket. Install anew cylinder head gasket with the part numberfacing up and verify the top 5 holes and thehead gasket push rod holes line up.

Install the dowels and the cylinder head gasket.

2. Using the special tools and with the help of anassistant, install the cylinder head on the

30. Install the special tool and the lifting crane. engine. Remove the special tools.With the help of an assistant, remove thecylinder head from the vehicle.

3. Install the outer cylinder head bolts finger-tight.

31. Check for cylinder head distortion. Foradditional information, refer to Cylinder HeadDistortion in this section.

32. Remove and discard the cylinder head gasketand dowels.

• Clean and inspect the gasket sealingsurfaces.

2006 F-250, 350, 450, 550 Super Duty, 6/2005



4. NOTICE: To prevent engine damage, keep 6. NOTICE: Rotate the crankshaft until thethe push rods in the order in which they damper locating dowel notch is in the 6were removed. Install all push rods back in o’clock position or engine damage can occur.their original positions. NOTE: Apply clean engine oil to the top centerNOTE: On early build vehicles, higher mileage of each valve bridge.engines require push rods to be cleaned so the Install the rocker arm assemblies and the 16copper-colored end of the push rod can be bolts.identified and installed with the copper-colored

• Tighten to 31 Nm (23 lb-ft).end up. Push rods on late build vehicles andservice push rods do not have a copper-coloredend and can be installed with either end up.

Apply clean engine oil to each end of the pushrods and insert them into their respectivepositions.

7. NOTICE: Using too much engine oil on thethreads of the cylinder head bolts can causedamage to the threads and poor sealing.Using anti-seize compounds, grease or anyother lubricants other than engine oil on thecylinder head bolt threads can affect the

5. NOTE: Coat the end of each valve stem with true torque value of the bolts.clean engine oil.

NOTE: Lightly lubricate the new cylinder headInstall the 8 valve bridges. bolt threads and flanges with clean engine oil.

Install the 10 inner cylinder head retaining boltsfinger-tight.

2006 F-250, 350, 450, 550 Super Duty, 6/2005



8. Tighten the cylinder head bolts in 7 stages inthe following sequence:

• Stage 1: Tighten bolts 1 through 10 to 88Nm (65 lb-ft).


• Stage 3: Tighten bolts in sequence 1 through10, 90 degrees.

• Stage 4: Tighten bolts in sequence 1 through10, a second time, 90 degrees.

• Stage 5: Tighten bolts in sequence 1 through10, a third time, 90 degrees.



9. Install the 4 glow plugs.

• Tighten to 19 Nm (14 lb-ft).

2006 F-250, 350, 450, 550 Super Duty, 6/2005



10. NOTE: Clean and apply clean engine oil to theO-ring seals.

Using the special tool, install the glow plugharness.

13. NOTE: Apply clean engine oil to the O-ringseal prior to installing.

Install the cylinder block coolant drain plug.


11. Position the 2 parts of the turbocharger adapterpipe into the vehicle. Install the gasket, connectthe adapter pipe joint and install the bolts.Position the turbocharger adapter pipe on theexhaust manifolds.


14. Install the starter. For additional information,refer to Section 303-06B.

12. NOTE: Apply anti-seize lubricants to the boltthreads prior to installing the bolts.

NOTE: Do not tighten until after theturbocharger is installed.

Install the nuts and bolts in the adapter pipe.


2006 F-250, 350, 450, 550 Super Duty, 6/2005



15. NOTICE: If the fuel injector oil inlet 17. NOTICE: Make sure the injector wiring isD-shaped O-ring seal is damaged, a new fuel clear of all moving parts or engine damageinjector must be installed. can occur.

Install new O-ring seals and copper washer on Install the fuel injector electrical connector intothe fuel injector. Lubricate the fuel injector and the rocker arm carrier.O-ring seals liberally with clean engine oil.

18. Apply engine oil to the top fuel injector O-ring16. NOTICE: Failure to tighten the injector seals.

properly can lead to engine failure.

NOTICE: To prevent engine damage, do notuse air tools to install the fuel injectors. Thesnap ring that extracts the injector candislodge and fall into the oil drain hole.

Assemble the fuel injector hold-down and bolton the fuel injector and install the assembly.

• Early build vehicles (T40 Torx), tighten to33 Nm (24 lb-ft).

• Late build vehicles (T45 Torx), tighten to35 Nm (26 lb-ft).

2006 F-250, 350, 450, 550 Super Duty, 6/2005



19. NOTICE: Using the bolts to push the 21. Apply clean engine oil to the D-ring seals andhigh-pressure oil rail into the fuel injectors reassemble the crankcase-to-head tube ifcan damage the fuel injectors and necessary. Install the crankcase-to-head tube.high-pressure oil rail. • Tighten to 82 Nm (60 lb-ft).NOTE: Apply clean engine oil on the tubesprior to installing the high-pressure oil rail.

Position the oil rail on the fuel injectors.

• Place the oil rail on top of the carrier sothat the 4 single ball tubes are engaging theinjector lead angle.

• Insert 3 guide bolts, 2 on the ends of thestraight side of the oil rail and 1 in themiddle of the wavy side of the rail. Installthe guide studs 6 to 7 turns.

• Manually press the oil rail into the fuelinjectors.

• Make sure that the oil rail mounting feet are 22. Install the high-pressure oil rail-to-valve coverflat against the mounting surface. gasket.

• Loosely install the 6 bolts.

20. Remove the 3 guide bolts, install the remainingbolts and tighten the 9 bolts in the sequenceshown.


2006 F-250, 350, 450, 550 Super Duty, 6/2005



23. NOTICE: To prevent engine damage, do notuse air-powered tools when installing thevalve cover.

Position the valve cover gasket. Install thevalve cover and 11 bolts.

• Tighten to 9 Nm (80 lb-in).

26. NOTE: Only one retainer shown.

Connect the wiring retainers to the studs.

24. If equipped, position back the transmission fluidindicator and tube. Install the retaining nut.

27. Install the evaporator core housing. Foradditional information, refer to Section 412-01.

28. Install the intake manifold. For additionalinformation, refer to Intake Manifold in thissection.

29. NOTE: Install a new oil filter.25. Install the ICP sensor.Fill the crankcase with clean engine oil.• Tighten to 12 Nm (9 lb-ft).

2006 F-250, 350, 450, 550 Super Duty, 6/2005

in-vehicle repair

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