Installation

1. Clean mating gasket surfaces of lower intake manifold and cylinder head. Lay a clean cloth or shop cloth in the valve tappet valley to catch any gasket material. After scraping, carefully lift cloth from valve tappet valley to prevent any particles from entering oil drain holes or cylinder head. Use a suitable solvent to remove old silicone sealant.

CAUTION: Aluminum components gouge easily which may cause gasket leaks. Always use care when scraping aluminum gasket surfaces.

NOTE: Lightly oil all retaining bolt and stud bolt threads with clean engine oil meeting Ford specification WSS-M2C153-G before installation except those specifying special sealant.

2. Lubricate valve tappets and bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.
3. Install valve tappet into bore.
4. Aligning valve tappet flats, install valve tappet guide plate. Install valve tappet guide plate with word "UP" and/or button visible.
5. Install tappet guide plate and retainer over valve tappet guide plate. Retainer orientation is not important. Loosely install two retaining bolts. Tighten bolts to 10-14 Nm (89-123 Lb-in).
6. Apply a 6 mm (1/4 inch) drop of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 to intersection of cylinder block and cylinder heads At four corners.

NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-13A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.

7. Position intake manifold gasket onto cylinder heads. Align intake manifold gasket locking tabs to provisions on head gaskets.
8. Install front and rear intake manifold end seals. Secure with retaining features.





9. Carefully lower intake manifold into position aligning intake manifold bolt holes to those in cylinder head. Use care to prevent distributing silicone sealer which can cause sealing voids.
- Install bolts No. 1,2,3, and 4 and hand-tighten.
- Install remaining bolts and tighten in sequence shown in two steps:
- Tighten in numerical sequence to 20-30 Nm (15-22 ft. lbs.).
- Then tighten again in sequence to 26-32 Nm (20-23 ft. lbs.).

10. Lubricate removed push rods and rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Move rocker arms into position with push rods and snug rocker arm seat retaining bolt. Rotate crankshaft to position camshaft lobes straight down and away from valve tappet.
- Tighten retaining bolt for rocker arm seats into cylinder head to 7-15 Nm (6-11 ft. lbs.).
- Final tighten rocker arm seat retaining bolt to 26-38 Nm (20-28 ft. lbs.) in any position.

NOTE: Rocker arm seats must be fully seated into cylinder head and push rod must be fully seated in rocker arm and valve tappet sockets prior to final tightening.

11. Install valve covers.
12. Install engine control sensor wiring to each fuel injector. Secure wire harness retainers to valve cover stud bolts.
13. Install ignition coil to rear of LH cylinder head. Tighten retaining bolts to 40-55 Nm (30-40 ft. lbs.).
14. Install ignition wire harness retainers to valve cover stud bolts and connect ignition wires to spark plugs and ignition coil.
15. Install upper intake manifold.
16. Install EGR valve to exhaust manifold tube from intake manifold to EGR valve (EGR valve).
17. Install fuel tubes.
18. Install fuel tube safety retaining clips.
19. Install upper radiator hose and heater water hoses. Tighten retaining clamps securely.
20. Connect vacuum lines to premarked locations.
21. Connect electrical connections to idle air control valve engine coolant temperature sensor throttle position sensor, EGR backpressure transducer, EGR vacuum regulator solenoid, ignition coil and water temperature indicator sender unit.
22. Fill and bleed engine cooling system.

NOTE: Engine coolant is corrosive to all engine bearing material. Replacing oil after removal of a coolant carrying component prevents damage.

23. Fill crankcase to the proper level with clean engine oil XO-5W30-QSP meeting Ford specification WSS-M2C153-G.
24. Install air cleaner outlet tube to throttle body and engine air cleaner.
25. Install crankcase ventilation tube to valve cover and air cleaner outlet tube. Install aspirator hose to air cleaner outlet tube.
26. Connect battery ground cable.
27. Start engine and check for coolant, oil, fuel and vacuum leaks.