6.0 litros cylinder head lh

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

IN-VEHICLE REPAIRMaterialCylinder Head — LH

Item Specification

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

Lifting Bracket, Cylinder Head XO-15W40-QSD or303-759 equivalent

High Temperature Nickel ESE-M12A4-AAnti-Seize LubricantXL-2 or equivalent

Metal Brake Parts Cleaner —PM-4 (Canada CPM-4)

Heavy Duty Floor CraneRemoval014-00071

All vehicles

1. With the vehicle in NEUTRAL, position it on ahoist. For additional information, refer toSection 100-02.Quick Disconnect Tool

303-6252. Drain the engine oil.

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

Disconnect Tool, Quick Release4. Remove the LH cylinder block drain plug.Coupling

303-755

Release Tool, InjectorConnector303-1115

Remover/Installer, Glow PlugConnector303-1114

Copyright 2003, Ford Motor CompanyLast updated: 6/17/2009 2004 Excursion, F-Super Duty 250-550, 12/2004


IN-VEHICLE REPAIR (Continued)

5. NOTE: Late build shown, early build similar. 8. NOTE: Late build shown, early build similar.

Remove the fuel injector control module NOTE: Mark the position of the valve covermounting bracket. bolts for valve cover bolt installation.

Remove the eleven bolts and the valve cover.Remove the valve cover gasket.

6. NOTE: Late build shown, early build similar.

Disconnect the glow plug connector andEarly buildposition aside.

9. Disconnect the high-pressure oil rail supply lineat the high-pressure oil rail.

7. Remove the nut and position the oil levelindicator and tube aside.

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

2004 Excursion, F-Super Duty 250-550, 12/2004



Two-piece head tube11. Disconnect and remove the high-pressure oilsupply line.

14. NOTE: Some engines may have been updatedwith a new two-piece crankcase-to-head tube. Ifthe crankcase-to-head tube has been updated itwill have a hex head.

If the high-pressure oil rail has a hex head,remove the crankcase-to-head tube assembly.

• Remove and discard the O-ring seals.

12. Remove and discard the crankcase-to-head tubeassembly.

Late build

15. NOTE: Do not remove the oil rail end plugs oracoustic wave attenuator port fitting. Serviceparts are not available to support thecomponents.

Remove the bolts and the high-pressure oil rail.

13. Remove the glow plug buss bar.




One-piece head tube Late build

16. NOTE: The rings on the crankcase-to-head 18. NOTICE: Do not pull on the glow plug wiretube are to be used to pry the tube assembly or damage may occur.from the branch tube assembly or the oil rail NOTE: Only one glow plug connector shown.assembly.

Using the special tool, remove the glow plugRemove the crankcase-to-head tube assembly. harness.• Remove and discard the O-rings.

All vehiclesTwo-piece head tube

19. Remove the four glow plugs.17. NOTICE: Use care not to deform the lower

crankcase-to-head tube during removal. Ifthe tube is damaged, a new tube must beinstalled.

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

If the updated crankcase-to-head tube separated,using a pair of soft jawed pliers, remove thelower crankcase-to-head tube.




20. 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.

23. 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.

24. NOTE: LH shown, RH similar.21. Prior to removing the injector assembly, insert Remove the nuts and bolts from the

clean shop towels in the oil drain holes adjacent turbocharger adapter pipe.to each glow plug.

22. NOTICE: Failure to account for all snaprings or pieces prior to placing the vehicleback in service can cause engine damage. Amissing snap ring can be ingested into thelube oil system causing 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 not any need to drain the fuelrail.

25. Remove the turbocharger adapter pipe.NOTE: If engine coolant is found in thecombustion chambers, it may be necessary toinstall a new injector sleeve. For additionalinformation, refer to Section 303-04C.

Remove the bolt, fuel injector hold down andfuel injector.




26. NOTE: Remove and discard the O-ring. 29. Remove the retaining nuts. Remove the exhaustbackpressure bracket assembly.Remove the oil level indicator and tube.

30. Remove the retaining bolt from the fuel tube27. Remove the bolts and turbocharger heat shield.bracket and position the fuel tubes aside.

28. Disconnect the exhaust backpressure tube at the31. Remove the bolt and the idler pulley.exhaust manifold.




32. Disconnect the heater hose from the front cover 35. NOTICE: Make sure the insulation blanket isand position aside. not damaged (torn, cracked or fabric

separated from the metallic skin) whenremoving the lower rear cylinder head bolt.If the insulation blanket is damaged, theentire blanket must be replaced.

NOTE: It may be necessary to slightlycompress or deform the insulation blanket togain tool clearance to remove the lower rearcylinder head bolt.

NOTE: The back two cylinder head boltscannot be removed from the head in vehicle.Raise these bolts and secure them in position sothey will clear the cylinder block deck as thehead is removed.

33. Remove the fan shroud mounting stud. Remove and discard the inner cylinder headbolts.

34. NOTE: Remove and discard the sealingwashers. 36. Remove the eight bolts and the rocker arm

assemblies.Remove the banjo bolt and the fuel tube.




37. Mark the eight valve bridges with a permanent 40. Install the special tool and the lifting crane.marker and remove. With the help of an assistant, remove the

cylinder from the vehicle.

38. NOTICE: To prevent engine damage, keepthe push rods in the order in which they 41. Check the cylinder head distortion. Forwere removed. Install all push rods back in additional information, refer to Cylinder Headtheir original positions. Distortion in this section.

Mark the location and remove the eight push42. Remove and discard the cylinder head gasketrods.

and dowels.

• Clean and inspect the gasket sealingsurfaces.

39. Remove the outer cylinder head bolts.




All vehiclesInstallation

One-piece head tube 3. NOTE: Use care to avoid scratching the bluecompound on the cylinder head gasket. Installthe gasket with the part number facing upward1. NOTICE: Install new D-ring seals on theand verify the five top holes and head gasketcrankcase-to-head tube. It requires severalpush rod holes line up.hours after installation for the D-ring seals to

relax back to their original size. If the tube Install the dowels and the cylinder head gasket.assembly is installed before the D-ring sealshave relaxed, damage to the D-ring seals 4. NOTE: Position the fuel lines in place beforecan occur. the cylinder head is installed.

Install new D-ring seals on each end of the NOTE: The back two cylinder head boltscrankcase to head tube assemblies. cannot be installed into the head in vehicle.

Lightly lubricate the threads of two newcylinder head bolts with clean engine oil.Position these bolts in the head and secure themin position so they will clear the cylinder blockdeck as the head is installed.

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

Two-piece head tube

2. NOTICE: Install new D-ring seals on thecrankcase-to-head tube. It requires severalhours after installation for the D-ring seals torelax back to their original size. If the tubeassembly is installed before the D-rings haverelaxed, damage to the D-ring seals canoccur. 5. Install the outer cylinder head bolts finger-tight.Install new D-ring seals on thecrankcase-to-head tube.




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

NOTE: Higher mileage engines require pushrods to be cleaned so the copper colored end ofthe push rod can be identified.

NOTE: If a push rod has been replaced, it maynot have a copper-colored end and can beinstalled with either end up.

Apply clean engine oil to each end of the pushrods. Insert them into their respective positions

9. NOTICE: Using too much engine oil on thewith the copper-colored end up.threads 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 thetrue torque value of the bolts.

NOTICE: Make sure the insulation blanket isnot damaged (torn, cracked or fabricseparated from the metallic skin) wheninstalling the lower rear cylinder head bolt.If the insulation blanket is damaged, theentire blanket must be replaced.

NOTE: It may be necessary to slightlycompress or deform the insulation blanket to7. NOTE: Coat the end of each valve stem withgain tool clearance to install the lower rearclean engine oil.cylinder head bolt.

Install the eight valve bridges.NOTE: Lightly lubricate the new cylinder headbolt threads and flanges with clean engine oil.

Install the 10 new cylinder head retaining boltsfinger-tight.

8. NOTICE: Rotate the crankshaft until thedamper locating dowel notch is in the sixo’clock position or engine damage can occur.

NOTE: Apply clean engine oil to the top centerof each valve bridge.

Install the rocker arm assemblies and eightbolts.




10. Tighten the head bolts in the followingsequence.

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


3 Tighten bolts in sequence 1 through 10,clockwise 90 degrees.

4 Tighten bolts in sequence 1 through 10, asecond time, clockwise 90 degrees.

5 Tighten bolts in sequence 1 through 10, athird time, clockwise 90 degrees.

6 Tighten bolts 11 through 15 an to 24 Nm(18 lb-ft).


11. NOTE: Install new sealing washers.

Install the fuel tube and the banjo bolt.

• For Viton sealing washers, tighten to 25Nm (18 lb-ft).

• For copper sealing washers, tighten to 38Nm (28 lb-ft).




12. Install the fan shroud mounting stud.

16. Tighten the exhaust backpressure tube fitting atthe exhaust manifold.

13. Position back and connect the heater hose.

17. Position the fuel tubes and install the fuel tube14. Install the idler pulley and bolt. bracket retaining bolt.

15. Position the exhaust backpressure bracketassembly and install the retaining nuts.




18. NOTE: Install a new O-ring and apply cleanengine oil.

Install the oil level indicator and tube.

22. Install the four glow plugs.

19. Install the turbocharger heat shield and bolts.

23. NOTICE: If the fuel injector oil inlet D-ringis damaged, a new fuel injector must beinstalled.

NOTE: Lubricate the fuel injector and O-rings20. Position the turbocharger adapter pipe. liberally with clean engine oil.

Install new O-rings and copper washer on thefuel injector.

21. 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.




24. NOTICE: Failure to tighten the injectorproperly 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.

Install the fuel injector, fuel injector hold-downand bolt.

Early build

27. NOTE: Install a new lower O-ring.

Install a new crankcase to head tube assembly.

25. NOTICE: Make sure the injector wiring isclear of all moving parts or engine damagecan occur.

Install the fuel injector electrical connector intothe rocker carrier.

28. Install the high-pressure oil rail and bolts.

• Install the high-pressure oil rail.

• Install the bolts finger tight.

26. Apply engine oil to the top fuel injectorO-rings.




One-piece head tube29. Tighten the bolts in the sequence shown.

32. NOTICE: To prevent engine damage, checkthat the crankcase-to-head tube assembliesbottom out in the branch tube assembly. Theoil rail, crankcase-to-head tube and the fuelinjectors will not function correctly if thetube is not bottomed out.

NOTE: Install new O-rings.

Apply clean engine oil and install thecrankcase-to-head tube assembly.

30. Install the high-pressure oil line.

31. NOTE: Clean and inspect the O-rings andinstall new as necessary.

NOTE: Apply clean engine oil to the O-ringsbefore installing.

Install the glow plug buss bar.




Late build Two-piece head tube

33. NOTE: Apply clean engine oil to the top fuel 35. NOTE: Apply clean engine oil to theinjector D-ring before installing the high crankcase-to-head tube prior to installation.pressure oil rail. If equipped with an updated crankcase-to-headPosition the oil rail on the fuel injectors. tube, install the crankcase-to-head tube

assembly.• Place the oil rail on top of the carrier sothat the four single ball tubes are engagingthe injector lead angle.

• Insert three guide bolts, two on the ends ofthe straight side of the oil rail and one inthe middle of the wavy side of the oil rail.Install the guide studs six to seven turns.

• Press the oil rail into the fuel injectors.

• Inspect that the oil rail mounting feet areflat against the mounting surface.

• Loosely install the six bolts.

Late build

36. NOTE: Clean and apply clean engine oil to theO-rings prior to installing.

Using the special tool, install the glow plugharness.

34. Install the oil rail retaining bolts.

• Remove the three guide bolts.

• Loosely install the three remaining bolts.

• Tighten the bolts in the sequence shown.




All vehicles

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

NOTE: Late build shown, early build similar.

NOTE: Clean and inspect the valve covergasket. Install a new gasket if necessary.

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


Install the fuel injector control modulemounting bracket.

38. Position back the oil level indicator and installthe nut.

41. NOTE: Install a new oil filter.

Fill the crankcase with clean engine oil.

42. NOTE: Lightly lubricate the O-ring with cleanengine oil before installing.

Install the cylinder block drain plug.


Connect the glow plug connector.




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


6.0 litros cylinder head lh

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