Installation

1. Clean sealing surfaces of intake manifold and cylinder heads.

NOTE: If a new intake manifold is being installed, transfer all necessary components onto new intake manifold.

2. Position new intake manifold gaskets on cylinder heads.
3. Position intake manifold on cylinder heads.





4. Install and tighten intake manifold retaining bolts one through nine in sequence shown to 20-30 Nm (15-22 ft. lbs.).

NOTE: Make sure alignment tabs on intake manifold gasket are aligned with holes in cylinder heads.

5. Replace O-ring seal on water hose connection. Position water hose connection and upper radiator hose and install two bolts and tighten to 20-30 Nm (15-22 ft. lbs.).
6. Connect heater water hose.
7. Connect vacuum hose to throttle body adapter vacuum port.
8. Install accelerator cable bracket on intake manifold and connect accelerator cable and speed control actuator cables to throttle body.
9. Raise and support vehicle.
10. Connect EGR valve to exhaust manifold tube to RH exhaust manifold and tighten nut to 35-45 Nm (26-33 ft. lbs.).
11. Connect the engine control sensor extension wire to the electronic variable orifice sensor and oil pressure sensor.
12. Lower vehicle.
13. Position generator and install two retaining bolts. Tighten to 20-30 Nm (15-22 ft. lbs.).
14. Install two bolts retaining generator rear mounting bracket to intake manifold and tighten to 8-12 Nm (71-106 inch lbs.).
15. Connect generator wiring harness to generator, RH front fender apron and junction block.
16. Position ignition wires and ignition wire separators on engine and install bolts retaining ignition coil to ignition coil brackets. Tighten bolts to 8-12 Nm (71-106 inch lbs.).
17. Connect all ignition wires to spark plugs.
18. Connect ignition wire separators on valve cover studs.
19. Connect the engine control sensor extension wire to both ignition coils and camshaft position sensor.
20. Install accessory drive belt.
21. Install air cleaner outlet tube.
22. Connect fuel lines.
23. Connect battery ground cable.
24. Fill and bleed engine cooling system.
25. Check and fill crankcase to specified level with clean engine oil meeting Ford specification WSS-M2G153-F.
26. Start engine and check for leaks.