Ford E series Cylinder Head Replacing procedure?

The details to replace Cylinder head on Ford E series Vans are as follows : ------


Cylinder Head
REMOVAL & INSTALLATION procedure is shown below:----

4.6L & 5.4L Engines

Specific to:

Ford E-150 2008-2009

Ford E-250 2008-2009

Ford E-350 Super Duty 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the engine assembly. For additional information, refer to the following section, -Engine Assembly, -Removal & Installation.-
3. Lower the engine onto wooden blocks.
   
   WARNING

   Use care when lowering the engine, to prevent damage to the oil pan.
4. Remove the engine lift bracket. Install the engine lifting bracket set and mount the engine on a suitable work stand.
5. If equipped with cylinder block drain plugs, remove the 3 bolts and the right hand engine support insulator.
6. If equipped, remove the cylinder block drain plugs and drain the coolant in a suitable container.
7. Disconnect the left-hand radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.
8. Disconnect the Camshaft Position (CMP) sensor electrical connector.
9. Disconnect the right-hand radio frequency interference capacitor electrical connector.
10. Disconnect the Knock Sensor (KS) electrical connector.
11. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and wiring harness retainer.
12. Disconnect all of the harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
13. Remove the two nuts and the two radio interference capacitors.
14. Remove the oil level indicator tube support bracket nut.
15. Remove the bolt and the oil level indicator and tube and discard the O-ring seal.
    
    NOTE

    Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
16. Fully loosen the fasteners and remove the valve covers.
    
    NOTE

    The fasteners are part of the valve cover and should not be removed.
17. Remove the bolt and the CMP sensor.
18. Remove the bolt and the accessory drive belt idler pulley.
19. Remove the four bolts and the water pump pulley.
20. Remove the bolt and the Crankshaft Position (CKP) sensor.
21. Remove the crankshaft pulley bolt and washer.
22. Discard the crankshaft pulley bolt.
23. Using the Crankshaft Vibration Damper Remover, remove the crankshaft pulley.
24. Using the Crankshaft Front Oil Seal Remover, remove and discard the crankshaft front seal.
25. Remove the four front oil pan bolts.
26. Remove the 15 fasteners and remove the engine front cover from the cylinder block.
    
    NOTE

    Correct fastener location is essential for assembly procedure. Record fastener location.
27. Remove the crankshaft sensor ring from the crankshaft.
28. Remove the spark plugs.
29. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
30. Use the Valve Spring Compressor to compress the valve springs and remove the all of the camshaft roller followers.
31. Position the crankshaft with the keyway at the 12 o'clock position.
    
    NOTE

    The camshaft roller followers must be reinstalled in their original locations. Record the camshaft roller follower locations. Failure to follow these instructions may result in engine damage.
    
    
    
    NOTE

    Position the cam lobe away from the camshaft roller follower prior to removing each camshaft roller follower.
32. Remove the timing chain tensioning system from both timing chains.
33. Remove the timing chains and crankshaft sprocket.
34. Remove the applicable exhaust manifold.
35. Remove and discard the eight nuts to remove.
36. Remove and discard the two exhaust manifold gaskets.
37. Remove and discard the eight exhaust manifold-to-cylinder head studs.
38. Install the Cylinder Head Remover/Installers on both ends of the cylinder head being serviced.
39. Remove the hydraulic lash adjusters.
    
    NOTE

    The hydraulic lash adjusters must be reinstalled in their original locations. Record the hydraulic lash adjuster locations. Failure to follow these instructions may result in engine damage.
    
    
    
    WARNING

    The cylinder head must be cool before removing it from the engine. Cylinder head warpage can result if a warm or hot cylinder head is removed.
    
    
    
    NOTE

    Place clean shop towels over exposed engine cavities. Carefully remove the towels so foreign material is not dropped into the engine. Failure to follow these instructions may result in engine damage.
    
    
    
    WARNING

    The cylinder head bolts must be discarded and new bolts must be installed. They are a tighten-to-yield design and cannot be reused. Failure to follow these instructions may result in engine damage.
    
    
    
    WARNING

    Aluminum surfaces are soft and can be scratched easily. Never place the cylinder head gasket surface, unprotected, on a bench surface. Failure to follow these instructions may result in engine damage.
40. Remove the bolts and the cylinder head.
41. Discard the cylinder head gasket and cylinder head bolts.

To install:

1. Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and loosely install the new cylinder head bolts.
   
   
   

   

   Fig. Use the Cylinder Head Alignment Pins to position the cylinder head gaskets and cylinder heads -4.6L & 5.4L Engines
2. Tighten the cylinder head bolts as follows in the sequence shown:
   
   
   Step 1: Tighten to 30 ft. lbs. (40 Nm)

   Step 2: Tighten an additional 90 degrees

   Step 3: Loosen all bolts one full turn

   Step 4: Tighten to 30 ft. lbs. (40 Nm)

   Step 5: Tighten an additional 90 degrees

   Step 6: Tighten an additional 90 degrees again
   
   

   

   

   Fig. Left hand cylinder head torque sequence-4.6L Engines

   
   
   

   

   

   Fig. Right hand cylinder head torque sequence-4.6L Engines

   
   
   

   

   

   Fig. Left cylinder head torque sequence-5.4L engine

   
   
   

   

   

   Fig. Right cylinder head torque sequence-5.4L engine
3. Remove the cylinder head remover/installer from the cylinder head.
4. Lubricate the hydraulic lash adjusters with clean engine oil and install in their original locations.
5. Install new exhaust manifold-to-cylinder head studs and tighten to 106 inch lbs. (12 Nm).
6. Install the exhaust manifold. For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
   
   WARNING

   Timing chain procedures must be followed exactly or damage to valves and pistons will result.
7. Compress the tensioner plunger, using a vise.
8. Install a retaining clip on the tensioner to hold the plunger in during installation.
   
   
   

   

   Fig. Plunger held by a retaining clip-4.6L & 5.4L Engines
9. Remove the tensioner from the vise. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks.
   
   
   

   

   Fig. If the copper links are not visible, mark one link on one end and one link on the other end, and use as timing marks-4.6L & 5.4L Engines
10. Install the crankshaft sprocket, making sure the flange faces forward.
    
    
    

    

    Fig. Install the crankshaft sprocket, making sure the flange faces forward-4.6L & 5.4L Engines
11. Position the left timing chain guide.
    
    
    

    

    Fig. Timing chain guide installation-4.6L & 5.4L Engines
12. Install and tighten the left bolts.
13. Position the right timing chain guide.
14. Install and tighten the right bolts.
15. Rotate the right camshaft sprocket until the timing mark is approximately at the 11 o'clock position. Rotate the left camshaft sprocket until the timing mark is approximately at the 12 o'clock position.
    
    NOTE

    The number one cylinder is at top dead center (TDC) when the stud on the engine block fits into the slot in the handle of the special tool.
    
    
    
    
    

    

    Fig. Crankshaft alignment tool installed-4.6L & 5.4L Engines
16. Position the crankshaft so the number one cylinder is at TDC with the special tool.
17. Remove the Crankshaft Holding Tool.
18. Position the left (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    
    
    

    

    Fig. Position the left (inner) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket-4.6L & 5.4L Engines
19. Install the left timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    
    NOTE

    The left timing chain tensioner arm has a bump near the dowel hole for identification.
    
    
    
    
    

    

    Fig. Install the left timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket-4.6L & 5.4L Engines
20. Position the left timing chain tensioner arm on the dowel pin and install the left timing chain tensioner.
21. Remove the retaining clip from the left timing chain tensioner. Tighten to 18 ft. lbs. (25 Nm).
22. Position the right (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket.
    
    
    

    

    Fig. Position the right (outer) timing chain on the crankshaft sprocket, aligning the copper (marked) link with the timing mark on the sprocket-4.6L & 5.4L Engines
23. Install the right timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket.
    
    
    

    

    Fig. Install the right timing chain on the camshaft sprocket, aligning the copper (marked) link with the timing marks on the sprocket-4.6L & 5.4L Engines
24. Position the right timing chain tensioner arm on the dowel pin and install the right timing chain tensioner. Torque to 18 ft. lbs. (25 Nm).
25. Remove the retaining clip from the right timing chain tensioner. Make sure that the copper (marked) chain links are lined up with the dots on the crankshaft sprockets and the camshaft sprocket.
26. Install the crankshaft sensor ring on the crankshaft.
27. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage
28. Use the Valve Spring Compressor to compress the valve springs, and install the camshaft roller follower.
29. Install the spark plugs.
30. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown.
    
    
    

    

    Fig. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface, at the locations shown-4.6L & 5.4L Engines
31. Install a new engine front cover gasket on the engine front cover. Position the engine front cover. Install the fasteners finger-tight. Then tighten the bolts in sequence to 18 ft. lbs. (25 Nm).
    
    
    

    

    Fig. Front cover fastener tightening sequence-4.6L & 5.4L Engines
32. Install the front four oil pan bolts and tighten the bolts in sequence as follows:
    
    
    Step 1: Tighten to 15 ft. lbs. (20 Nm)

    Step 2: Tighten an additional 60 degrees
    
    

    

    

    Fig. Front oil pan bolt torque sequence-4.6L & 5.4L Engines
33. Install the valve cover. For additional information, refer to the following section, -Valve Covers, Removal & Installation.-
34. Install the accessory drive belt idler pulley and tighten the bolt to 18 ft. lbs. (25 Nm).
35. The remainder of the installation is the reverse order of removal.
36. Refill the engine with oil to the correct level.
37. Refill the cooling system to the correct level.

6.0L Engine

Specific to:

Ford E-350 Super Duty 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the engine assembly. For additional information, refer to the following section, -Engine Assembly, -Removal & Installation.-
3. Remove the flexplate. For additional information, refer to the following section, -Flexplate, Removal & Installation.-
4. Mount the engine on a suitable engine stand.
5. Unplug the glow plug harnesses and remove the glow plugs.
   
   NOTE

   Prior to removing the exhaust manifolds, inspect the exhaust manifold for warpage with a feeler gauge between the manifold and cylinder head. Record the measurement and compare with the specification.
6. Remove the exhaust manifolds.
7. Remove the cylinder head banjo fitting and fuel line, left side only.
8. Remove the three bolts and turbocharger heat shield, left side only.
9. Remove the protective cover from the cylinder, left side only.
10. Remove the valve cover, right side only.
11. Remove the high pressure oil rail-to-valve cover gasket, right side only.
12. Disconnect the fuel injector electrical connectors.
13. Remove the crankcase-to-head tube(s).
    
    WARNING

    Do not remove the oil rail end plugs or acoustic wave attenuator port fitting. Service parts are not available to support the components.
14. Remove the 18 bolts and the high-pressure oil rails.
15. If the crankcase-to-head tube separated, using the High Pressure Supply Tube Remover, remove the lower crankcase-to-head tube.
16. Using the Injector Connector Release Tool, push the fuel injector electrical connectors out of the rocker arm carrier.
17. Prior to removing the injector assembly, insert clean shop towels in the oil drain holes adjacent to each glow plug.
18. Loosen the bolt and remove the bolt and fuel injector hold-down assembly and the fuel injector. Remove and discard the O-ring seals and copper washer.
19. Remove the shop towels.
20. Remove and discard the inner cylinder head bolts.
21. Remove the bolts and rocker arm assemblies.
22. Remove the bolts and rocker arm carriers. Remove and discard the press-in-place gaskets.
23. Matchmark the 16 valve bridges and remove the pushrods.
    
    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. The push rods are directional and the copper-coated end must be installed in the upward position where it will contact the rocker arm.
24. Matchmark the pushrods and remove the pushrods.
25. Remove the ten outer cylinder head bolts.
26. Install the cylinder head lifting bracket, and remove the cylinder head.
    
    
    

    

    Fig. Install the cylinder head lifting bracket to remove the cylinder head-6.0L Engine

To install:

NOTE

Use care to avoid scratching the blue compound on the cylinder head gasket. Install a new cylinder head gasket with the part number facing upward and verify the top 5 holes and the head gasket push rod holes line up.

1. Install new dowels and the cylinder head gaskets.
2. Using the cylinder head lifting bracket, install the cylinder head on the engine.
3. Install the ten outer cylinder head bolts finger tight.
4. Apply clean engine oil to each end of the push rods and insert them into their respective positions.
5. Install the 16 valve bridges.
6. Install new press-in-place gaskets, the rocker arm carries and tighten the four bolts to 46 ft. lbs. (62 Nm).
7. Rotate the crankshaft until the damper locating dowel notch is in the 6 o'clock position.
8. Apply clean engine oil to the top center of each valve bridge. Install the rocker arm assemblies and tighten the bolts to 23 ft. lbs. (31 Nm).
   
   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.
9. Lightly lubricate the cylinder head bolt threads with clean engine oil. Install the inner cylinder head bolts finger tight.
   
   
   

   

   Fig. Cylinder head bolt torque sequence-6.0L engine
10. Tighten the inner cylinder head bolts as follows:
    1. Tighten bolts 1-10 to 65 ft. lbs. (88 Nm).
    2. Tighten bolts 1-10 to 85 ft. lbs. (115 Nm).
    3. Tighten bolts 1-10 an additional 90°.
    4. Tighten bolts 1-10 90° a second time.
    5. Tighten bolts 1-10 90° a third time.
    6. Tighten bolts 11-15 to 18 ft. lbs. (24 Nm).
    7. Tighten bolts 11-15 to 23 ft. lbs. (31 Nm).
11. Install new O-ring seals and a copper washer on the fuel injectors.
    
    NOTE

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

    Lubricate the fuel injector and O-ring seals with clean engine oil.
12. Assemble the fuel injector hold down and bolt on the fuel injector and install the assembly. Tighten the bolt to 26 ft. lbs. (35 Nm).
13. Install the fuel injector electrical connector into the rocker carrier.
    
    NOTE

    Make sure the injector wiring is clear of all moving parts or engine damage can occur.
14. Apply clean engine oil to the top fuel injector O-ring seals.
    
    WARNING

    Using the bolts to push the high pressure oil rail into the fuel injectors can damage the fuel injectors and high pressure oil rail.
15. Place the high-pressure oil rail on top of the carrier so that the four single ball tubes are engaging the fuel injector lead angle.
16. Insert three guide bolts, two on the ends of the straight side of the high-pressure oil rail and one in the middle of the wavy side of the high-pressure rail. Install the guide studs 6 to 7 turns.
17. Manually press the high-pressure oil rail into the fuel injectors.
18. Inspect that the high-pressure oil rail mounting feet are flat against the mounting surface.
19. Loosely install the six bolts.
20. Remove the three guide bolts, and install the remaining bolts and tighten the nine bolts to 115 inch lbs. (13 Nm) in the sequence shown.
    
    
    

    

    Fig. High pressure oil rail torque sequence-6.0L engine
21. Apply clean engine oil to the D-ring seals and reassemble the crankcase-to-head tube if necessary. Install the crankcase-to-head tube(s) and tighten to 60 ft. lbs. (82 Nm).
22. Connect the fuel injector electrical connectors.
23. Install the high-pressure oil rail-to-valve cover gasket, right cylinder head only.
24. Position the right hand valve cover gasket, right hand valve cover, and tighten the six stud bolts and five bolts to 80 inch lbs. (9 Nm).
25. Install the right hand exhaust manifold, 8 spacers and tighten the eight new bolts to 28 ft. lbs. (38 Nm). For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
26. Cover the left hand cylinder head with an appropriate covering.
27. Install the turbocharger heat shield. For additional information, refer to the following section, -Turbocharger, Removal & Installation.-
28. Install the left-hand cylinder head fuel line and tighten to 28 ft. lbs. (38 Nm).
29. Install the left hand exhaust manifold, spacers and tighten the eight new bolts to 28 ft. lbs. (38 Nm). For additional information, refer to the following section, -Exhaust Manifold, Removal & Installation.-
30. Install the glow plugs and tighten to 14 ft. lbs. (19 Nm).
31. Using the Glow Plug Connector Installer tool, install the glow plug harnesses.
32. The remainder of the installation is the reverse order of removal.
33. Install the engine assembly. For additional information, refer to the following section, -Engine Assembly, Removal & Installation.-

6.8L Engine

Specific to:

Ford E-350 Super Duty 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the engine assembly. For additional information, refer to the following section, -Engine Assembly, -Removal & Installation.-
3. Remove the flexplate. For additional information, refer to the following section, -Flexplate, Removal & Installation.-
4. Lower the engine onto wooden blocks and remove the engine lifting bracket.
5. Install the engine lifting brackets from the engine lifting bracket set.
6. Mount the engine on a suitable work stand.
7. If equipped with cylinder block drain plugs, remove the 4 bolts and the right hand engine support insulator.
8. If equipped, remove the cylinder block drain plugs and drain the coolant into a suitable container.
9. Disconnect the left hand radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.
10. Disconnect the Camshaft Position (CMP) electrical connector.
11. Remove the bolt and the CMP sensor.
12. Disconnect the right hand radio frequency interference capacitor electrical connector.
13. Disconnect the Knock Sensor (KS) electrical connector, if equipped.
14. Disconnect the Crankshaft Position (CKP) sensor electrical connector.
15. Remove the bolt and the CKP sensor.
16. Disconnect the Engine Oil Pressure (EOP) switch electrical connector.
17. Disconnect all of the engine control sensor wiring harness routing clips and connector retainers. Remove the engine control sensor wiring harness.
18. Remove the two nuts and the two radio frequency interference capacitors.
19. Remove the nut attaching the oil level indicator tube to the front of the engine.
20. Remove the bolt attaching the oil level indicator tube to the left hand cylinder head.
21. Position the oil level indicator tube aside.
22. Remove the valve cover. For additional information, refer to the following section, -Valve Covers, Removal & Installation.-
23. Remove the idler pulley.
24. Remove the four bolts and remove the water pump pulley.
25. Remove the crankshaft pulley. For additional information, refer to the following section, -Crankshaft Pulley, Removal & Installation.-
26. Remove the crankshaft front seal. For additional information, refer to the following section, -Crankshaft Front Seal, Removal & Installation.-
27. Remove the three bolts and the power steering pump.
28. Remove the four front oil pan bolts.
29. Remove the engine front cover bolts and remove the engine front cover.
    
    NOTE

    The front cover bolts are different sizes. Keep them in order for reinstallation.
30. Remove the crankshaft sensor ring from the crankshaft.
31. Remove the six bolts and remove the balance shaft bearing caps and remove the balance shaft.
32. Remove the spark plugs.
33. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
34. Position the crankshaft with the keyway at the 12 o'clock position.
35. Remove the 4 bolts and remove the two timing chain tensioners.
36. Remove the 2 timing chain tensioner arms.
37. Remove the 2 timing chains and the crankshaft sprocket.
38. Remove the mounting bolts and remove the timing chain guides.
39. Remove the cylinder head insert, if removing the left cylinder head.
40. Remove the exhaust manifold.
41. Remove and discard the exhaust manifold studs.
42. Install the Cylinder Head Remover/Installer on both ends of the cylinder head being removed.
    
    
    

    

    Fig. Install the Cylinder Head Remover/Installer on both ends of the cylinder head being removed-6.8L Engine
43. Remove the hydraulic last adjusters.
44. Remove the cylinder head mounting bolts.
45. Remove the cylinder head.
46. Discard the bolts and the cylinder head gasket.

To install:

NOTE

Make sure all coolant residue and foreign material is cleaned from the block surface and the cylinder bore.

NOTE

The use of sealing aids is not permitted. The gasket must be installed dry.

NOTE

The new gasket has a film coating which is crucial to the gasket's ability to seal properly. Do not scratch the gasket.

1. Using the Cylinder Head Alignment Pins, position the cylinder head gaskets and cylinder heads over the dowels and install the cylinder head bolts loosely.
2. Tighten the bolts in sequence as follows:
   
   
   Tighten to 30 ft. lbs. (40 Nm)

   Tighten an additional 90 degrees

   Tighten another 90 degrees
   
   

   

   

   Fig. Left cylinder head torque sequence-6.8L Engines

   
   
   

   

   

   Fig. Right cylinder head torque sequence-6.8L Engines
3. Lubricate the hydraulic lash adjusters with clean engine oil. Install the 20 hydraulic lash adjusters in their original locations.
4. Install new exhaust manifold studs and tighten to 106 inch lbs. (12 Nm).
5. Install the insert into cylinder head, left cylinder only.
6. Using a new gasket, install the exhaust manifold and tighten the new nuts to 18 ft. lbs. (25 Nm).
   
   NOTE

   Timing chain procedures must be followed exactly or damage to valves and pistons will result.
   
   
   
   NOTE

   Prior to installation, inspect the tensioner-sealing bead for seal integrity. If cracks, tears, separation from the tensioner body or permanent compression of the seal bead is observed, install a new tensioner or engine damage may occur.
7. Compress the tensioner plunger, using a vise.
8. Install a retaining clip on the tensioner to hold the plunger in during installation.
   
   NOTE

   There are 61 links in each timing chain.
9. If copper links are not visible, mark 2 links on one end and one link on the other end, and use as timing marks.
10. Install the timing chain guides and tighten the four bolts to 89 inch lbs. (10 Nm).
11. Preposition the left hand camshaft until the timing mark is approximately at 12 o'clock and preposition the right hand camshaft until the timing mark is approximately at 11 o'clock.
12. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool.
    
    
    

    

    Fig. Position the crankshaft with the Crankshaft Holding Tool, then remove the tool-6.8L Engine
13. Install the crankshaft sprocket, making sure the flange faces forward.
14. Install the lower end of the left hand timing chain, aligning the timing marks.
    
    NOTE

    Be sure the upper half of the timing chain is below the tensioner guide dowel.
15. Install the left hand timing chain on the camshaft sprocket with the 2 chain (marked) links and the timing marks aligned.
    
    NOTE

    The left hand timing chain tensioner arm has a bump near the dowel hole for identification.
16. Position the left hand timing chain tensioner arm on the dowel pin and install the left hand timing chain tensioner and tighten the two bolts to 18 ft. lbs. (25 Nm).
    
    NOTE

    Be sure the chain link and crankshaft sprocket timing marks are aligned.
    
    
    
    NOTE

    The lower half of the timing chain must be positioned above the dowel.
17. Install the right hand (outer) timing chain on the crankshaft sprocket.
18. Position the timing chain on the camshaft sprocket. Make sure the 2 copper-colored (marked) links align with the camshaft sprocket timing mark.
19. Position the right hand timing chain tensioner arm on the dowel pin and install the right hand timing chain tensioner and tighten the two bolts to 18 ft. lbs. (25 Nm).
20. Remove the retaining clips from the right hand and left hand timing chain tensioners.
21. Check for correct alignment of all timing marks.
22. Install the crankshaft sensor ring on the crankshaft.
23. Lubricate the balance shaft journals with clean engine oil.
24. Using the index mark on the balance shaft, mark the corresponding teeth on the gear with chalk.
25. Position the balance shaft on the journals.
26. Align the chalk mark on the balance shaft with the camshaft timing mark as shown.
27. Install the balance shaft bearing caps in their original locations and tighten the 6 bolts in the sequence shown.
    
    
    

    

    Fig. Balance shaft bearing cap torque sequence-6.8L Engines
28. Install the Valve Spring Compressor Spacer between the valve spring coils to prevent valve stem seal damage.
    
    NOTE

    The camshaft roller followers must be installed in their original locations. Failure to follow these instructions may result in engine damage.
    
    
    
    NOTE

    Do not allow the valve keepers to fall off the valve or the valve may drop into the cylinder. If a valve drops into the cylinder, the cylinder head must be removed. For additional information, refer to Cylinder Head in this section.
    
    
    
    NOTE

    It may be necessary to push the valve down while compressing the spring.
    
    
    
    NOTE

    Position the cam lobe away from the camshaft roller follower prior to installing each camshaft roller follower.
    
    
    
    NOTE

    Lubricate the camshaft roller follower with clean engine oil prior to installation.
29. Use the Valve Spring Compressor to compress the valve springs, and install each of the camshaft roller followers.
30. Install the spark plugs. For additional information, refer to the following section, -Spark Plugs, Removal & Installation.-
31. Apply a bead of silicone gasket and sealant along the cylinder head-to-cylinder block surface and the oil pan-to-cylinder block surface.
32. Install a new front cover gasket on the engine front cover. Position the engine front cover.
33. Install the front cover fasteners in sequence in two stages as follows:
    
    
    Step 1: Fasteners 1-5 to 18 ft. lbs. (25 Nm)

    Step 2: Fasteners 6-15 to 35 ft. lbs. (48 Nm)
    
    

    

    

    Fig. Front cover fastener torque sequence-6.8L Engine
34. Loosely install the four front oil pan bolts, then tighten the bolts in two stages, in the sequence shown:
    
    
    Stage 1: Tighten the 15 ft. lbs. (20 Nm)

    Stage 2: Tighten an additional 60 degrees
    
    

    

    

    Fig. Front oil pan bolt torque-6.8L Engines
35. Apply instant gel adhesive completely around the gasket groove in the valve covers. Install the new valve cover gaskets.
36. Apply silicone gasket and sealant in two places where the engine front cover meets the cylinder head.
37. Position the valve covers and tighten the 14 fasteners to 89 inch lbs. (10 Nm) for each valve cover in the sequence shown.
    
    
    

    

    Fig. Valve cover torque sequence-6.8L Engines
38. Position the accessory drive belt idler pulley and tighten the bolt to 18 ft. lbs. (25 Nm).
39. Lubricate the engine front cover and the crankshaft front seal inner lip with clean engine oil.
40. Install a new crankshaft front seal. For additional information, refer to the following section, -Crankshaft Front Seal, Removal & Installation.-
41. Install the crankshaft pulley. For additional information, refer to the following section, -Crankshaft Damper, Removal & Installation.-
42. Put the power steering pump back into position and tighten the three mounting bolts to 18 ft. lbs. (25 Nm).
43. Position the oil level indicator tube and tighten bolt to the left cylinder head to 89 inch lbs. (10 Nm). Tighten the bracket support nut to 18 ft. lbs. (25 Nm).
44. The remainder of the installation is the reverse order of removal.
45. Install the engine into the vehicle. For additional information, refer to the following , -Engine Assembly, Removal & Installation.-

This details will help.

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Car repair guide?

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