ford Workshop Repair Guides

Ford Ranger Workshop Service and Auto Repair Manuals - 20065 onwards

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Assembly > < Cylinder Block

Removing and Installing Cylinder Head

Engine - 2.5L Duratorq-TDCi (WL) Diesel/3.0L Duratorq-TDCi (WL) Diesel - Cylinder Head Ranger 2006.5 (05/2006-)
Disassembly and Assembly of Subassemblies

Special Tool(s)

Valve Spring Lifter Arm

49 0636 100B

Pivot

49 B012 0A2

Valve Guide Remover and Installer

49 B012 015

Valve Seal Installer

49 B012 016

Oil Seal Installer

49 S010 001

Valve Seal Remover

49 S120 170

1. Disassemble the components in the order indicated in the following illustration(s) and table(s).

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

 
Item
Part Number
Description
9
-
Rocker arm
10
-
Pivot
11
-
Valve cap
12
-
Valve keeper
See Disassembly Detail
13
-
Upper valve spring seat
14
-
Valve spring
15
-
Valve
16
-
Valve seal
See Disassembly Detail
17
-
Lower valve spring seat
18
-
Water outlet pipe

2. Assemble the components in the order indicated in the following illustration(s) and table(s).

 
Item
Part Number
Description
1
-
Water outlet pipe
2
-
Lower valve spring seat
3
-
Valve seal
See Assembly Detail
4
-
Valve
5
-
Valve spring
6
-
Upper valve spring seat
7
-
Valve keeper
See Assembly Detail
8
-
Valve cap
9
-
Pivot
See Assembly Detail
10
-
Rocker arm
See Assembly Detail

 
Item
Part Number
Description
11
-
Cylinder head gasket
See Assembly Detail
12
-
Cylinder head
See Assembly Detail
13
-
ECT sensor
14
-
Camshaft cap lower
See Assembly Detail
15
-
Camshaft
16
-
Camshaft cap upper
See Assembly Detail
17
-
Seal plate
See Assembly Detail
18
-
Camshaft pulley
See Assembly Detail

Disassembly Details

Item 1 : Camshaft pulley

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.
  1. Hold the camshaft using a wrench on the cast hexagon.

Item 3 : Camshaft cap upper
  1. Loosen the camshaft cap bolts in three or four steps in the order shown in the figure.

Item 4 : Camshaft

  1. Before removing the camshaft, inspect the camshaft oil clearance.
    For additional information, refer to: Camshaft Bearing Journal Clearance - Plastigage Method (303-00 Engine System - General Information, General Procedures).

Item 7 : Cylinder head
  1. Remove bolts A.
  1. Loosen the cylinder head bolts in two or three steps in the order shown in the figure.

Item 12 : Valve keeper
  1. Remove the valve keeper using the SST.

Item 16 : Valve seal
  1. Remove the valve seal using the SST.

Assembly Details

Item 3 : Valve seal
  1. Tap the SST using a plastic hammer.

Item 7 : Valve keeper
  1. Install the valve keeper using the SST.

Item 9 : Pivot

  1. Apply adhesive to the thread of the pivot.

Item 10 : Rocker arm
  1. If a new rocker arm is used, set dimension A as follows.
    1. Dimension A0.0—4.0 mm {0.0—0.115 in}.

Item 11 : Cylinder head gasket
  1. Measure the piston topping of all the cylinders.

  1. Choose the gasket according to each measured piston topping.
    Piston topping (mm {in}) Cylinder head gasket Cylinder head gasket identification mark
    0.080—0.190 {0.004—0.007} one dot
    0.135—0.255 {0.006—0.010} zero dots
    0.200—0.310 {0.008—0.012} two dots

  1. Apply silicone sealant to the cylinder block as shown in the figure.
    1. Thickness ø 2.0—3.0 mm {0.08—0.11 in}.

Item 12 : Cylinder head
  1. Before installing the cylinder head bolts, inspect their length.
    • Measure the length of each bolt. Replace the bolt if necessary.
    • Cylinder head bolt mark W: Standard length: 101.2—101.8 mm {3.985—4.007 in} Maximum length: 102.5 mm {4.035 in}.
    • Cylinder head bolt mark N: Standard length: 113.2—113.8 mm {4.457—4.480 in} Maximum length: 114.5 mm {4.508 in}.
    • Cylinder head bolt mark I: Standard length: 149.0—150.0 mm {5.866—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.
    1. Tighten torque 29 Nm {3.0 kgf·m, 21 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.
    1. Tighten torque17.6—19.6 Nm {1.8—1.9 kgf·m, 13—14 ft·lbf}.

Item 14 : Camshaft cap lower
  1. Apply silicone sealant to the cylinder head as shown in the figure.

Item 16 : Camshaft cap upper

  1. Apply adhesive to the front camshaft cap mounting surfaces as shown in the figure.
  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 burrs 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 in the figure.
  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.
    1. Camshaft oil seal press-in amount 0.5—1.0 mm {0.020—0.039 in}.

Item 17 : Seal plate
  1. Tighten the seal plate bolts in the order indicated in the figure.

Item 18 : Camshaft pulley
  1. Install the camshaft pulleys, positioning the knock pins as shown in the figure.

  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.

Assembly > < Cylinder Block