Installation

INSTALLATION

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

1. Clean sealing surfaces of intake manifold and cylinder heads.
2. Position new intake manifold gaskets on cylinder heads.
3. Position intake manifold on cylinder heads.

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

Torque Sequence:

4. Install and tighten nine bolts in sequence shown to 20-30 Nm (15-22 ft. lbs.).
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 fuel charging wiring and transmission to bracket at rear of LH cylinder head.
7. Install fuel charging wire retainers on valve cover stud bolts.
8. Connect fuel charging wiring to 42-pin connector and eight-pin transmission harness connector at power brake booster.
9. Connect accelerator cable and speed control actuator cable.
10. Install heater water hoses.
11. Connect fuel pressure regulator coolant hoses to T-fittings on heater water hoses.
12. Connect vacuum hose to throttle body adapter vacuum port.
13. Install positive crankcase ventilation valve to valve cover.
14. Install generator. Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.).
15. Install two bolts retaining generator bracket to generator. Tighten bolts to 8-12 Nm (71-106 inch lbs.).
16. Connect fuel charging wiring to generator.
17. Connect generator wiring harness eyelet on generator stud. Tighten retaining nut to 7-9 Nm (62-80 inch lbs.).
18. Connect generator wiring harness to junction box at front fender apron.
19. Connect fuel charging wiring to ignition coil, radio ignition interference capacitor (18801) and camshaft position sensor.
20. Position ignition wire and bracket (12280) on engine.





21. Connect eight ignition wires to ignition coils as illustrated.

NOTE: Spark plug wire boot must be positioned 90° from centerline of crankshaft to make sure boot seal is fully seated against cylinder head.

22. Connect ignition wire and bracket to spark plug.
23. Connect ignition wire retainers to valve cover studs. Install ignition wire separators to generator.
24. Raise and support vehicle.
25. Connect fuel charging wiring to heated oxygen sensors.
26. Connect EGR valve to exhaust manifold tube to EGR valve tube to manifold connector (9F485). Tighten fitting to 35-45 Nm (26-33 inch lbs.).
27. Connect EGR transducer hoses to EGR valve to exhaust manifold tube.
28. Connect fuel charging wiring to oil pressure sensor, power steering pump and oil filter adapter bracket.
29. Install oil bypass filter.
30. Connect fuel charging wiring to both crankshaft position sensor and A/C clutch.
31. Lower vehicle.
32. Install accessory drive belt.
33. Install EGR valve to exhaust manifold tube to EGR valve. Tighten fitting to 35-45 Nm (26-33 ft. lbs.).
34. Install windshield wiper governor.
35. Connect fuel lines. See Powertrain Management.
36. Install air cleaner outlet tube. See Powertrain Management.
37. Install fan blade and fan clutch, as an assembly and fan shroud. See Cooling System.
38. Connect battery ground cable.
39. Fill and bleed engine cooling system. See Cooling System.
40. Check and fill crankcase to specified level with clean engine oil meeting Ford specification WSS-M2C153-F.
41. Start engine and check for leaks.