Installation

1. Place shop cloth in valve tappet valley to catch any dirt or gasket material. Clean cylinder head, intake manifold, valve cover and head gasket surfaces. If the cylinder head was removed for a head gasket replacement, check the flatness of the cylinder head and cylinder block gasket surfaces.

CAUTION: Use care when scraping aluminum surfaces to prevent gouging which may cause leak paths.

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

2. Position new head gaskets, noting UP designation on head gasket face, on cylinder block using the cylinder head to block dowel for alignment.





3. Position cylinder heads on cylinder block over cylinder head to block dowels.

NOTE: Replace cylinder head to block dowel if damaged.





4. Install new cylinder head retaining bolts.
Tighten retaining bolts in the sequence shown:
- 50 Nm (37 ft. lbs.).
- Then back off bolts 360 degrees.

CAUTION: Always use new cylinder head bolts when installing cylinder head or damage to engine may occur.

5. Tighten the cylinder head retaining bolts in three final tightening steps in the sequence shown in the above illustration:
- 30 Nm (22 ft. lbs.)
- Rotate 90 degrees
- Rotate an additional 90 degrees

NOTE: When cylinder head retaining bolts have been tightened, it is not necessary to retighten the bolts after extended engine operation.

6. Install lower intake manifold. Connect engine control sensor wiring to the engine coolant temperature sensor and to the water temperature indicator sender unit.
7. Dip each push rod end in Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Install push rods in their original position.

Rocker Arm & Valve Locations:

8. Rotate crankshaft clockwise one full turn (360 degrees). Install rocker arms, rocker arm seats and retaining bolts as specified in camshaft position A. Tighten bolts to 7-15 Nm (6-11 ft. lbs.) to position rocker arm seats. Rotate crankshaft clockwise 120 degrees to camshaft position B. Install rocker arms, rocker arm seats and retaining bolts as specified in camshaft position B. Tighten bolts to 7-15 Nm (6- 11 ft. lbs.).
9. Final tighten rocker arm seat retaining bolts to 26-38 Nm (20-28 ft. lbs.) with camshaft in any position.

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

10. Lubricate all rocker arms with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A.

NOTE: If the original valve train components are being installed, a valve clearance check is not required. If a component has been replaced, perform a valve clearance check.

11. Install lower intake manifold.
12. Install spark plugs if removed.
13. Position valve covers on the cylinder heads and install retaining bolts. Note the location of ignition wire retainer stud bolts.
14. Connect engine control sensor wiring to fuel injectors and valve cover stud bolts.
15. Install upper intake manifold and intake manifold upper gasket.
16. Install ignition coil and bracket assembly. Tighten retaining bolts to 40-55 Nm (30-40 ft. lbs.).
17. Connect ignition wires to the spark plugs and ignition wire separators to valve cover retaining stud bolts. Install camshaft position sensor.
18. Connect Intake Air Temperature Sensor (IAT sensor), throttle position sensor, idle air control valve and EGR backpressure transducer or EGR vacuum regulator solenoid electrical connectors.





19. If LH (front) cylinder head was removed, perform the following:
- Install or rotate oil level indicator tube to exhaust manifold retaining stud bolt. Tighten nut to 16-20 Nm (12-14 ft. lbs.).
- Install power steering support bracket and power steering pump assembly. Tighten retaining bolt to 40-55 Nm (30-40 ft. lbs.).
- Install drive belt tensioner.

20. If RH (rear) cylinder head was removed, install intake manifold support.
21. Install generator. Tighten long retaining bolt to 48 Nm (35 ft. lbs.) and short bolt to 37 Nm (27 ft. lbs.).
22. Install generator brace. Tighten retaining nut and bolt to 12-20 Nm (9-14 ft. lbs.).
23. Install the drive belt.
24. Connect fuel tubes.
25. Install fuel tube safety clips.
26. Connect upper radiator hose and heater water hoses. Tighten clamps securely.
27. Connect vacuum lines to premarked locations.
28. Drain and change engine oil.

CAUTION: Engine coolant is corrosive to all engine bearing material. Replace engine oil after removal of a coolant carrying component to help prevent future failure.

29. Install air cleaner outlet tube to throttle body and engine Air Cleaner (ACL)
30. Install crankcase ventilation hose to valve cover.
31. Fill and bleed engine cooling system.

CAUTION: This engine has aluminum components and requires a special corrosion inhibiting coolant to avoid cooling system damage.

32. Connect battery ground cable.
33. Start engine and check for coolant, fuel, oil, vacuum and exhaust leaks.
34. Check, and if necessary, adjust the accelerator cable and speed control actuator cable.