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Ranger 2006.5 (05.2006-)

Engine - 2.5L Duratorq-TDCi (WL) Diesel/3.0L Duratorq-TDCi (WL) Diesel - Cylinder Head Ranger 2006.5 (05/2006-)
Removal and Installation

Special Tool(s)

Oil Seal Installer

49 S010 001
WARNING:
WARNING:Fuel vapor is hazardous. It can very easily ignite, causing serious injury and damage. Always keep sparks and flames away from fuel.
WARNING:
WARNING:Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the “Fuel Line Safety Procedures”.
  1. Remove the engine cover.
  1. Disconnect the negative battery cable.
    For additional information, refer to: Battery Disconnect and Connect (414-01 Battery, Mounting and Cables, General Procedures).
  1. Drain the engine coolant.
    For additional information, refer to: Cooling System Draining, Filling and Bleeding (303-03 Engine Cooling, General Procedures).
  1. Remove the intake manifold, air intake pipe and breather chamber.
    For additional information, refer to: Intake Air System Components (303-12 Intake Air Distribution and Filtering, Removal and Installation).
  1. Remove the fuel injector.
    For additional information, refer to: Fuel Injector (303-04B Fuel Charging and Controls - 2.5L Duratorq-TDCi (WL) Diesel/3.0L Duratorq-TDCi (WL) Diesel, Removal and Installation).
  1. Remove the turbocharger.
    For additional information, refer to: Turbocharger (303-04A Fuel Charging and Controls - Turbocharger, Removal and Installation).
  1. Remove the timing belt.
    For additional information, refer to: Timing Belt (303-01 Engine - 2.5L Duratorq-TDCi (WL) Diesel/3.0L Duratorq-TDCi (WL) Diesel, Removal and Installation).

8. Remove the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Cylinder head cover
See Installation Detail
2
-
Camshaft pulley
See Removal Detail
See Installation Detail
3
-
Seal plate
See Installation Detail
4
-
Camshaft cap upper
See Removal Detail
See Installation Detail
5
-
Camshaft
See Installation Detail
6
-
Camshaft cap lower
See Installation Detail
7
-
Cylinder head
See Removal Detail
See Installation Detail
8
-
Cylinder head gasket
See Installation Detail

9. To install, reverse the removal procedure.

  1. Adjust the drive belt.
    For additional information, refer to: Accessory Drive Belt Adjustment (303-05 Accessory Drive, General Procedures).
  1. Bleed air in the fuel line.
  1. Start the engine and;
    1. Inspect for engine oil, engine coolant, and fuel leakage.
    1. Inspect the idle speed.
  1. Inspect the compression.

Removal Details

Item 2 : Camshaft pulley
  1. CAUTION:
    CAUTION:Do not move the camshaft from this position because it can cause the valve and piston to contact each other and damage them.
    Hold the camshaft by using a wrench on the cast hexagon.

Item 4 : Camshaft cap upper
  1. Loosen the camshaft cap bolts in three or four steps in the order shown.

Item 7 : Cylinder head
  1. Remove bolts A.

  1. Loosen the cylinder head bolts in two or three steps in the order shown.

Installation Details

Item 8 : Cylinder head gasket
  1. Measure the piston topping of all the cylinders.

  1. Choose the gasket according to each measured piston topping.

    Cylinder head gasket select table

    Piston topping (mm {in}) Cylinder head gasket identification mark
    0.080—0.190 {0.004—0.007} One dot
    0.135—0.255 {0.006—0.010} Nil dot
    0.200—0.310 {0.008—0.012} Two dots

  1. Apply silicone sealant to the cylinder block as shown.
    • Thickness ø2.0—3.0 mm {0.08—0.11 in}.

Item 7 : Cylinder head
  1. Measure the length of each bolt. Replace the bolt if necessary.
    • Bolt head mark W Standard length: 101.2—101.8 mm {3.985—4.007 in} Maximum length: 102.5 mm {4.035 in}.
    • Bolt head mark N Standard length: 113.2—113.8 mm {4.457—4.480 in} Maximum length: 114.5 mm {4.508 in}.
    • Bolt head mark I Standard length: 149—150 mm {5.867—5.905 in} Maximum length: 150.5 mm {5.925 in}.
  1. Apply clean engine oil to the threads and the seat face of each bolt and install them.

  1. Tighten the bolts in two or three steps in the order shown in the figure.
    • Tighten torque 29 Nm {3.0 kgf·m, 22 ft·lbf}.

  1. Retighten the bolts in the order shown in the figure until all the bolts are tightened to 29 Nm {3.0 kgf·m, 2.1 ft·lbf}.

  1. Put a paint mark on each bolt head.

  1. Using the marks as a reference, tighten the bolts by turning each 90°—105° in the sequence shown.

  1. Further tighten each bolt by turning another 90°—105°.

  1. Further tighten each bolt by turning another 90°—105°.

  1. Apply adhesive to the thread of bolt A.

  1. Tighten bolts A.
    • Tightening torque 17.6—19.6 Nm {1.80—1.99 kgf·m, 13.0—14.4 ft·lbf}.

Item 6 : Camshaft cap lower
  1. Apply silicone sealant to the cylinder head as shown in the figure.

Item 4 : Camshaft cap upper
  1. Apply adhesive to the front camshaft cap mounting surfaces as shown.

  1. CAUTION:
    CAUTION:Because there is little camshaft thrust clearance, the camshaft must be held horizontally while it is installed. Otherwise, excessive force will be applied to the thrust area, causing burr on the thrust receiving area of the cylinder head journal. To avoid this, the following procedure must be observed.
    Tighten the camshaft cap bolts gradually in three or four steps in the order shown.
  1. Apply soapy water along the perimeter of the new oil seal.
  1. Push the oil seal slightly in by hand.

  1. Tap the oil seal lightly into the cylinder head using the SST and a hammer.

  1. To ensure that the oil seal is installed correctly, measure the distance between the end of the cylinder head and the face of the oil seal.
    • Camshaft oil seal press-in amount 0.5—1.0 mm {0.02—0.03 in}.

Item 3 : Seal plate
  1. Tighten the seal plate bolts in the order indicated in the figure.

Item 2 : Camshaft pulley
  1. Install the camshaft pulleys, positioning the knock pins as shown.

  1. CAUTION:
    CAUTION:Do not move the camshaft from this position because it can cause the valve and piston to contact each other and damage them.
    Hold the camshaft using a wrench on the cast hexagon.

Item 1 : Cylinder head cover
  1. Apply silicone sealant to the cylinder head as shown.
    • Thickness ø2.0—3.0 mm {0.08—0.11 in}.

  1. Tighten the cylinder head cover bolts in the order shown.

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