Part 2 of 2

66. Tighten the bolts in the sequence shown.





67. Position the belt idler pulley and install the bolt.





68. If removed, install the drive belt tensioner.
a. Position the drive belt tensioner.
b. Install and tighten the bolts.





69. Lubricate the crankshaft front seal and the front oil seal inner lip. Use engine oil meeting Ford specification WSS-M2C153-F.





70. Use the Crankshaft Seal Replacer/Aligner to install the front oil seal into the engine front cover.





71. Apply silicone to the woodruff key slot on the crankshaft pulley.





72. Use Crankshaft Damper Replacer to install the crankshaft pulley.

NOTE: Make sure to tighten the bolt in four steps.





73. Tighten the bolt.





74. Loosen the bolt.





75. Tighten the bolt.





76. Tighten the bolt.





77. Install the water pump.
a. Lubricate and install the O-ring seal (1). Use Premium Cooling System Fluid E2FZ-19549-AA or -B (in Oregon, FSFZ-19549-CC) or equivalent meeting Ford specification ESE-M97B44-A
b. Position the water pump and loosely install the bolts (2).





78. Tighten the bolts.





79. Install the water pump pulley and install the bolts.





80. Apply silicone in two places where the engine front cover meets the cylinder head.





81. Install the RH valve cover. Tighten the bolts in the sequence shown.
- Make sure to check the tower gaskets for damage.
- Install a new valve cover gasket.





82. Install the LH valve cover. Tighten the bolts in the sequence shown.
- Install a new valve cover.
- Check spark plug tower (well) seals for placement.





83. Connect the knock sensor harness to knock sensors.





84. Install the noise shield.

NOTE: The lower intake manifold runner control gaskets are housed within grooves located in the bottom surface of the intake manifold runner control (IMRC) units.





85. Place the IMRC units, upper gaskets and new lower gaskets under the lower intake manifold.








86. Install the lower intake manifold with IMRC units and tighten the bolts.





87. Install the fuel injection supply manifold and the fuel injectors. Install the bolts.





88. Attach the wiring harness to the bottom of the engine front cover.





89. Install the secondary air injection diverter valve and the bracket nuts.





90. Install the two LH exhaust manifold gasket and the manifold assembly. Install the nuts.





91. Install the RH exhaust manifold gasket and the exhaust manifold. Install the nuts.





92. Connect the secondary air injection manifold tube and the secondary air injection manifold tube.
a. Connect the tubes (1) to the exhaust manifold.
b. Attach the tube (2) to the bracket.
c. Connect the tubes (3) together and to the valve.





93. Install the A/C compressor and install the A/C compressor bolts.





94. Install the RH front engine support insulator.
a. Install the RH front engine support insulator. Install the bolts (1).
b. Install the grounding strap (2).





95. Attach the transmission line bracket and the starter ground to the engine insulator.





96. Lubricate the O-ring seal on the oil level indicator tube and position in the hole on the cylinder block. Use clean engine oil meeting Ford specification WSS-M2C153-F.





97. Install the oil level indicator tube and tighten nut.





98. Install the LH front engine support insulator and install the bolts.





99. Install the grounding strap to the bolt.





100. Install the intake manifold upper to lower gaskets.





101. Install the upper intake manifold and install the bolts.





102. Install the bolt and nuts to the power steering reservoir bracket.





103. Install the generator and the bolts.





104. Install the water bypass tube and install the nuts.





105. Install the generator mounting bracket and install the bolts and nuts.





106. Install the ignition coil assemblies.





107. If removed, install the idle air control valve and install the bolts.





108. If removed, install the EGR valve and install the bolts.





109. Install the Delta PFE and Bracket Assy intake manifold runner control actuator and install the retaining bolts.





110. Install the IMRC actuator cables.
a. Connect the IMRC actuator cables (1) to the brackets.
b. Attach the nail head clips to the levers (2).





111. Connect the wiring harness connectors to the eight fuel injectors.





112. Connect the wiring harness connectors to the eight ignition coils.





113. Install the RH and LH ignition coil cover. Install the bolts.





114. Connect the idle air control valve connector.





115. Connect the generator connector and attach the grounding wire to the generator bracket.





116. Connect the LH oxygen sensor connector.





117. Connect the EGR pressure transducer and the IMRC actuator connectors.





118. Install the heater water tube and install the bolts and nut.





119. Install the EGR vacuum regulator control and bracket assembly and install the nuts to the camshaft cover.





120. Install the crankcase ventilation hose.





121. Connect the EGR vacuum regulator control connector and vacuum hoses.





122. Connect the fuel pressure regulator vacuum hose.





123. Connect the fuel pulse damper connector.





124. Connect the EGR valve vacuum hose.





125. Connect the chassis vacuum hoses to the lower intake manifold.





126. Install vacuum hose to the diverter valve





127. Install the thermostat housing to oil filter adaptor hose.





128. Install the RH radio ignition interference capacitor and connect the connectors.
129. Install the accessory drive belt.
130. Fill the engine with clean engine oil meeting Ford specification WSS-M2C153-F.