Installation

WARNING: DO NOT SMOKE OR CARRY LIGHTED TOBACCO OR OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENTS. HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED, RESULTING IN POSSIBLE PERSONAL INJURY.

1. Clean all gasket material from the mating surfaces on the cylinder head and cylinder block. Clean out the bolt holes in the cylinder block. Inspect the cylinder head for flatness.

CAUTION: Do not use abrasive grinding discs to remove gasket material; use only plastic manual scrapers. Do not scratch or gouge aluminum sealing surfaces.

2. Install a new head gasket on the cylinder block.
3. Install the cylinder head assembly and tighten the cylinder head bolts in the following sequence.
1 Tighten all the bolts in a single sequence to 40-60 Nm (30-44 ft. lbs.).
2 Back the bolts off 1/2 turn.
3 Tighten the bolts in the sequence shown to 40-60 Nm (30-44 ft. lbs.).
4 Rotate all the bolts in a single sequence an additional 180 degrees in two steps of 90 degrees each.

CAUTION:
- Do not attempt to install the cylinder head assembly without assistance. Installation of the cylinder head assembly requires two people.
- Always use new cylinder head bolts.

NOTE: Lubricate the cylinder head bolts with Super Premium 5W30 SAE XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G prior to installation.





4. Install the uppermost front engine accessory drive bracket bolt.





5. Install the A/C line bracket on the front engine accessory drive bracket.





6. Install the valve cover gasket and valve cover.
7. Raise and support the vehicle.
8. Tighten the four front engine accessory drive bracket bolts and one nut.





9. Remove the wire support and install the A/C compressor and four bolts.
10. Close the radiator petcock.





11. Install the RH splash shield assembly.





12. Install the oil level indicator tube.
13. Lower the vehicle.





14. Install the heater hose.





15. Install the upper radiator hose.
16. Install the timing belt.





17. Install the generator.





18. Install the power steering pressure hose to the front engine accessory drive bracket.





19. Connect the crankshaft position sensor electrical connector.





20. Connect the two main engine/fuel charging wiring electrical connectors.





21. Install the bolt.





22. Install the EGR valve manifold tube at the EGR valve.





23. Install the EGR valve manifold tube to the exhaust manifold.





24. Connect the fuel supply line to the fuel injection supply manifold.





25. Install a new gasket and the four exhaust manifold-to-TWC nuts.





26. Install the exhaust manifold heat shield.





27. Install the speed control cable bracket.





28. Connect the (1) speed control cable and the (2) accelerator cable to the throttle control lever.





29. Install the vacuum hoses at the (1) EGR valve, the (2) positive crankcase ventilation (PCV) valve, the (3) throttle body, the (4) fuel pressure sensor, and the (5) intake manifold.
30. Install the outlet half of the engine air cleaner and the air cleaner intake tube.
31. Fill engine with coolant.
32. Connect the battery ground cable.