Cylinder Head Replacing Procedure for 6.0L engine?

The procedure is similar for both ford and Lincoln car models:-----

Cylinder Head
REMOVAL & INSTALLATION

F150 1/2 ton P/U 2WD/ 4WD
F250 Super Duty P/U 2WD/4WD
F350 Super Duty P/U 2WD/4WD
F450 Super Duty P/U 2WD/4WD
F550 Super Duty P/U 2WD/4WD
AND Lincoln Mark LT Models

6.0L Diesel Engine
Left Cylinder Head

1. Before servicing the vehicle, refer to the Precautions Section.
2. With the vehicle in Neutral , position it on a hoist.
3. Drain the engine oil.
4. Remove the intake manifold.
5. Remove the left cylinder block drain plug.
6. Remove the fuel injector control module mounting bracket.
7. Disconnect the glow plug connector and position aside.
8. Remove the nut and position the oil level indicator and tube aside.
   
   NOTE

   Mark the position of the valve cover bolts for valve cover bolt installation.
9. Remove the eleven bolts and the valve cover. Remove the valve cover gasket.

Early build

1. Disconnect the high-pressure oil rail supply line at the high-pressure oil rail.
2. Remove the bolts and the high-pressure oil rail.
3. Disconnect and remove the high-pressure oil supply line.
4. Remove and discard the crankcase-to-head tube assembly.
5. Remove the glow plug buss bar.

Late build

NOTE

Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.

1. Remove the bolts and the high-pressure oil rail.
   
   NOTE

   The rings on the crankcase-to-head tube are to be used to pry the tube assembly from the branch tube assembly or the oil rail assembly.
2. Remove the crankcase-to-head tube assembly.
3. Remove and discard the O-rings.
   
   WARNING

   Do not pull on the glow plug wire or damage may occur.
4. Remove the glow plug harness.

All vehicles

1. Remove the four glow plugs.
   
   WARNING

   Do not attempt to apply battery voltage to the fuel injector or damage to the fuel injector will occur.
2. Using a 19 mm socket, push the fuel injector electrical connector out of the rocker arm carrier.
3. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
   
   WARNING

   Failure to account for all snaprings or pieces prior to placing the vehicle back in service can cause engine damage. A missing snapring can be ingested into the lube oil system causing severe engine damage.
   
   
   
   WARNING

   To prevent engine damage, do not use air tools to remove the fuel injectors. The snapring that extracts the injector can dislodge and fall into the oil drain hole.
   
   
   
   NOTE

   There is no need to drain the fuel rail.
   
   
   
   NOTE

   If engine oil is found in the engine coolant or engine coolant is found in the combustion chambers, a new injector sleeve may need to be installed.
4. Remove the bolt, fuel injector hold-down and fuel injector.
   
   NOTE

   If a snapring or piece of a snapring is missing from the injector hold-down assembly, it must be located prior to removing the shop towels.
5. Remove the shop towels.
6. Remove the nuts and bolts from the turbocharger adapter pipe.
7. Remove the turbocharger adapter pipe.
   
   NOTE

   Remove and discard the O-ring.
8. Remove the oil level indicator and tube.
9. Remove the bolts and turbocharger heat shield.
10. Disconnect the exhaust backpressure tube at the exhaust manifold.
11. Remove the retaining nuts. Remove the exhaust backpressure bracket assembly.
12. Remove the retaining bolt from the fuel line bracket and position the fuel lines aside.
13. Remove the bolt and the idler pulley.
14. Disconnect the heater hose from the front cover and position aside.
15. Remove the fan shroud mounting stud.
    
    NOTE

    Remove and discard the sealing washers.
16. Remove the banjo fitting and the fuel line.
17. Remove and discard the inner cylinder head bolts.
18. Remove the eight bolts and the rocker arm assemblies.
19. Mark the eight valve bridges with a permanent marker and remove.
    
    WARNING

    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.
20. Mark the location and remove the eight push rods.
21. Remove the outer cylinder head bolts.
22. Install the special tool and the lifting crane. With the help of an assistant, remove the cylinder from the vehicle.
23. Remove and discard the cylinder head gasket and dowels.
24. Clean and inspect the gasket sealing surfaces.

To install:

All vehicles, late build

 

Fig. Rocker arm carrier installation-6.0L Diesel Engine

WARNING

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.

1. Install new D-ring seals on each end of the crankcase to head tube assemblies.
   
   NOTE

   Use care to avoid scratching the blue compound on the cylinder head gasket.
2. Install the gasket with the part number facing upward and verify the five top holes and head gasket push rod holes line up.
3. Install the dowels and the cylinder head gasket.
   
   NOTE

   Position the fuel lines in place before the cylinder head is installed.
4. Using the special tools and with the help of an assistant, install the cylinder head on the engine. Remove the special tools.
5. Install the outer cylinder head bolts finger-tight.
   
   WARNING

   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

   Higher mileage engines require push rods to be cleaned so the copper colored end of the push rod can be identified.
6. Apply clean engine oil to each end of the push rod. Insert them into their respective positions with the copper-colored end up.
   
   NOTE

   Coat the end of each valve stem with clean engine oil.
7. Install the eight valve bridges.
   
   WARNING

   Rotate the crankshaft until the damper locating dowel notch is in the six o'clock position or engine damage can occur.
   
   
   
   NOTE

   Apply clean engine oil to the top center of each valve bridge.
8. Install the rocker arm assemblies and eight bolts.
   
   WARNING

   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.
9. Install the 10 cylinder head retaining bolts finger-tight.
10. Tighten the head bolts in the following sequence.
    1. Tighten bolts 1 through 10 to 88 Nm (65 ft. lbs.).
    2. Tighten bolts 1, 3, 5, 7 and 9 to 115 Nm (85 ft. lbs.).
    3. Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
    4. Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees.
    5. Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees.
    6. Tighten bolts 11 through 15 an to 24 Nm (18 ft. lbs.).
    7. Tighten bolts 11 through 15 to 31 Nm (23 ft. lbs.).
       
       NOTE

       Install new sealing washers.
11. Install the fuel line and the banjo fitting.
12. Install the fan shroud mounting stud.
13. Position back and connect the heater hose.
14. Install the idler pulley and bolt.
15. Position the exhaust backpressure bracket assembly and install the retaining nuts.
16. Tighten the exhaust backpressure tube fitting at the exhaust manifold.
17. Position the fuel lines and install the fuel line bracket retaining bolt.
    
    NOTE

    Install a new O-ring and apply clean engine oil.
18. Install the oil level indicator and tube.
19. Install the turbocharger heat shield and bolts.
20. Position the turbocharger adapter pipe.
    
    NOTE

    Apply anti-seize lubricants to the bolt threads prior to installing the bolts.
    
    
    
    NOTE

    Do not tighten until after the turbocharger is installed.
21. Install the nuts and bolts in the adapter pipe.
22. Install the four glow plugs.
    
    WARNING

    If the fuel injector oil inlet D-ring is damaged, a new fuel injector must be installed.
    
    
    
    NOTE

    Lubricate the fuel injector and O-rings liberally with clean engine oil.
23. Install new O-rings and copper washer on the fuel injector.  
    
    WARNING

    To prevent engine damage, do not use air tools to install the fuel injectors. The snapring that extracts the injector can dislodge and fall into the oil drain hole.
24. Install the fuel injector, fuel injector hold-down and bolt. Torque to 24 ft. lbs. (33 Nm).  
    
    WARNING

    To prevent engine damage, be sure the injector wiring is clear of all moving parts.
25. Install the fuel injector electrical connector into the rocker carrier.
26. Apply engine oil to the top fuel injector O-rings.

Early build

NOTE

Install a new lower O-ring.

1. Install a new crankcase to head tube assembly. Torque to 33 ft. lbs. (45 Nm).
2. Install the high-pressure oil rail and bolts.
3. Install the high-pressure oil rail.
4. Install the bolts finger tight.
5. Tighten the bolts in the sequence shown.
   
   
   

   

   Fig. High pressure oil rail torque installation-6.0L Diesel Engine
6. Install the high-pressure oil line.
   
   NOTE

   Clean and inspect the O-rings and install new as necessary.
   
   
   
   NOTE

   Apply clean engine oil to the O-rings before installing.
7. Install the glow plug buss bar.

Late build  

WARNING

To prevent engine damage, check that the crankcase-to-head tube assemblies bottom out in the branch tube assembly. The oil rail, crankcase-to-head tube and the fuel injectors will not function correctly if the tube is not bottomed out.

NOTE

Install new O-rings and .

1. Apply clean engine oil and install the crankcase-to-head tube assembly.
   
   NOTE

   Apply clean engine oil to the top fuel injector D-ring before installing the high pressure oil rail.
2. Position the oil rail on the fuel injectors.
3. Place the oil rail on top of the carrier so that the four single ball tubes are engaging the injector lead angle.
4. Insert three guide bolts, two on the ends of the straight side of the oil rail and one in the middle of the wavy side of the oil rail. Install the guide studs six to seven turns.
5. Press the oil rail into the fuel injectors.
6. Inspect that the oil rail mounting feet are flat against the mounting surface.
7. Loosely install the six bolts.
8. Install the oil rail retaining bolts.
9. Remove the three guide bolts.
10. Loosely install the three remaining bolts.
11. Tighten the bolts in the sequence shown.
    
    NOTE

    Clean and inspect the O-rings and install new as necessary.
    
    
    
    NOTE

    Apply clean engine oil to the O-rings prior to installing.
12. Install the glow plug harness.

All vehicles  

WARNING

To prevent engine damage, do not use air powered tools when installing the valve cover.

NOTE

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

1. Position the valve cover gasket. Install the valve cover and 11 bolts.
2. Position back the oil level indicator and install the nut.
3. Connect the glow plug connector.
4. Install the fuel injector control module mounting bracket.
   
   NOTE

   Install a new oil filter.
5. Fill the crankcase with clean engine oil.
   
   NOTE

   Lightly lubricate the O-ring with clean engine oil before installing.
6. Install the cylinder block drain plug.
7. Install the intake manifold.

Right Cylinder Head

Fig. Cylinder head bolt torque sequence-6.0L Diesel Engine

1. Before servicing the vehicle, refer to the Precautions Section.

All vehicles

1. With the vehicle in Neutral , position it on a hoist.
2. Drain the engine oil.
3. Remove the intake manifold.
4. Remove the fuel injectors.
5. Remove the starter.
6. Remove the cylinder drain block.
7. Remove the nuts and bolts from the turbocharger adapter pipe.
8. Remove the turbocharger adapter pipe.

Early build

1. Remove and discard the crankcase to head tube assembly.
2. Remove the glow plug buss bar.

Late build

NOTE

The rings on the crankcase-to-head tube are to be used to pry the tube assembly from the branch tube assembly or the oil rail assembly.

1. Remove the crankcase-to-head tube assembly.
2. Remove and discard the O-rings.  
   
   WARNING

   Do not pull on the wiring to remove the glow plug connector or damage may occur.
3. Remove the glow plug harness.

All vehicles

1. Remove the four glow plugs.
2. Remove and discard the 10 inner cylinder head bolts.
3. Remove the eight bolts and the rocker arm assemblies.
4. Mark the eight valve bridges with a permanent marker and remove.  
   
   WARNING

   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.
5. Mark the location and remove the eight push rods.
6. Remove the outer cylinder head bolts.
7. Install the special tool and the lifting crane. With the help of an assistant, remove the cylinder head from the vehicle.
8. Remove and discard the cylinder head gasket and dowels.
9. Clean and inspect the gasket sealing surfaces.

To install:

All vehicles, late build  

WARNING

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.

1. Install new D-ring seals on each end of the crankcase to head tube assemblies.
   
   NOTE

   Use care to avoid scratching the blue compound on the cylinder head gasket.
2. Install a new cylinder head gasket with the part number facing up and verify the top five holes and the head gasket push rod holes line up.
3. Install the dowels and the cylinder head gasket.
4. Using the special tools and with the help of an assistant, install the cylinder head on the engine. Remove the special tools.
5. Install the outer cylinder head bolts finger-tight.  
   
   WARNING

   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

   Higher mileage engines require push rods to be cleaned so the copper colored end of the push rod can be identified.
6. Apply clean engine oil to each end of the push rod. Insert them into their respective positions with the copper colored end up.
   
   NOTE

   Coat the end of each valve stem with clean engine oil.
7. Install the eight valve bridges.  
   
   WARNING

   Rotate the crankshaft until the damper locating dowel notch is in the six o'clock position or engine damage can occur.
   
   
   
   NOTE

   Apply clean engine oil to the top center of each valve bridge.
8. Install the rocker arm assemblies and eight bolts.  
   
   WARNING

   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.
9. Install the 10 inner cylinder head retaining bolts finger-tight.
10. Tighten the head bolts in the following sequence.
    1. Tighten bolts 1 through 10 to 88 Nm (65 ft. lbs.).
    2. Tighten bolts 1, 3, 5, 7 and 9 to 115 Nm (85 ft. lbs.).
    3. Tighten bolts in sequence 1 through 10, clockwise 90 degrees.
    4. Tighten bolts in sequence 1 through 10, a second time, clockwise 90 degrees.
    5. Tighten bolts in sequence 1 through 10, a third time, clockwise 90 degrees.
    6. Tighten bolts 11 through 15 to 24 Nm (18 ft. lbs.).
    7. Tighten bolts 11 through 15 to 31 Nm (23 ft. lbs.).
11. Install the four glow plugs.

Late build

NOTE

Clean and inspect the glow plug connector O-rings and install new as necessary.

NOTE

Apply clean engine oil to the O-rings.

1. Install the glow plug harness.  
   
   WARNING

   To prevent engine damage, check that the crankcase-to-head tube assemblies bottom out in the branch tube assembly. The oil rail, crankcase-to-head tube and the fuel injectors will not function correctly if the tube is not bottomed out.
2. Apply clean engine oil and install the crankcase-to-head tube assembly.

Early build

NOTE

Clean and inspect the glow plug buss bar O-rings and install new as necessary.

NOTE

Apply clean engine oil to the O-rings before installing.

1. Install the glow plug buss bar.
   
   NOTE

   Install a new lower O-ring.
2. Install a new crankcase to head tube assembly.

All vehicles

1. Position the turbocharger adapter pipe.
   
   NOTE

   Apply anti-seize lubricants to the bolt threads prior to installing the bolts.
   
   
   
   NOTE

   Do not tighten until after the turbocharger is installed.
2. Install the nuts and bolts in the adapter pipe.
   
   NOTE

   Apply clean engine oil to the O-ring prior to installing.
3. Install the cylinder block drain plug.
4. Install the starter.
5. Install the fuel injectors.
6. Install the intake manifold.
   
   NOTE

   Install a new oil filter.
7. Fill the crankcase with clean engine oil.

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html