Installation

1. Clean mating gasket surfaces of lower intake manifold and cylinder head. Lay a clean cloth or shop cloth in valve tappet valley to catch any gasket material. After scraping, carefully lift cloth from valve tappet valley, preventing 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.

2. If installing a new lower intake manifold, transfer engine coolant temperature sensor, water thermostat, water hose connection gasket and water hose connection heater hose elbow and water temperature indicator sender unit to new lower intake manifold.
3. If removed, install fuel injection supply manifold.
- Apply clean engine oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G lightly to fuel injector O-rings before installation.
- Install fuel injector into fuel injection supply manifold.
- Carefully align fuel injection supply manifold to intake manifold fuel injector bores.
- Push one side into place at a time until fuel injection supply manifold clicks into place.
- Install fuel injection supply manifold retaining bolts and tighten to 8-12 Nm (71-106 inch. lbs.).

4. Apply a 5-6 mm (1/4-inch) drop of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specifications WSE-M4G323-A6 to intersection of cylinder block and cylinder head at four corners as shown.

NOTE: Prior to applying sealer, clean sealing surfaces of cylinder block and cylinder head with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M6B392-A, to remove all residues that may interfere with the sealer's ability to adhere.

5. Position intake manifold gasket onto cylinder heads. Align intake manifold gasket locking tabs to provisions on head gaskets as shown.
6. Install front and rear intake manifold end seals as shown. Secure with retainers.





7. Carefully position lower intake manifold aligning intake manifold bolt holes to those in cylinder head. Use care to prevent disturbing 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.).
- Tighten again in sequence to 26-32 Nm (20-23 ft. lbs.).

8. Coat entire drive gear on COP sensor housing with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install camshaft position sensor.

CAUTION: If a new CMP sensor housing is installed, ALWAYS add the rest of the Engine Assembly Lubricant D9AZ-19579-D or equivalent (pint) meeting Ford specification ESR-M99C80-A to the engine oil by pouring it through the distributor hole onto the camshaft drive gear. Run engine at idle for five minutes prior to driving vehicle.

9. Apply clean engine oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G to cylinder No.3 intake valve, push rod and rocker arm. Install push rod. Move rocker arm into position with push rod and snug rocker arm seat retaining bolt. Rotate crankshaft to position camshaft lobe straight down and away from valve tappet.
- Tighten rocker arm seat retaining bolt to 7-15 Nm (6-11 ft. lbs.).
- Final tighten rocker arm seat retainer bolt to 26-38 Nm (20-28 ft. lbs.) in any position.

NOTE: Rocker arm seat 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.

10. Install valve covers.
11. Install engine control sensor wiring to each fuel injector. Secure retainers for engine control sensor wiring to valve cover stud bolts.
12. Install ignition coil to rear of LH cylinder head. Tighten retaining bolts to 40-55 Nm (30-40 ft. lbs.).
13. Install wire harness retainers to valve cover stud bolts and connect ignition wires to spark plugs and ignition coil.
14. Install upper intake manifold and new intake manifold upper gasket.
15. Install EGR valve to exhaust manifold tube from exhaust manifold to EGR valve.
16. Install fuel tubes.
17. Install fuel tube safety clips.
18. Install upper radiator hose and heater water hoses. Tighten retaining clamps securely.
19. Connect vacuum lines to premarked locations.
20. Connect engine control sensor wiring to camshaft position sensor, idle air control valve, throttle position sensor, engine coolant temperature sensor, EGR backpressure transducer, EGR vacuum regulator solenoid, ignition coil and water temperature indicator sender unit.
21. Fill and bleed engine cooling system.
22. Fill crankcase to proper level with clean engine oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.

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

23. Install air cleaner outlet tube to throttle body and engine air cleaner.
24. Install crankcase ventilation tube to valve cover and air cleaner outlet tube. Install aspirator hose to air cleaner outlet tube.
25. Connect battery ground cable.
26. Start engine and check for coolant, oil, fuel and vacuum leaks.