Part 2 of 2

44. On early models, install the valve tappet guide plate retainer and the valve tappet guide plate retainer bolts.





45. On late models, install the valve tappets and the valve tappet guide plates in their original positions.





46. On late models, position the valve tappet guide plate retainer and install the valve tappet guide plate retainer bolts.





47. Install the push rods in their original positions.
48. Apply engine oil to the top of the valve stems and rocker arm seats.
^ Use SAE 50 engine oil meeting Ford specification WSE-M2C908-A1.





49. Install the rocker arms and rocker arm fulcrum guides.





50. Install the eight rocker arm fulcrum.





51. Install the eight rocker arm bolts.
52. Check the valve clearance.
53. Use combustion chamber cleaner and a suitable wire brush to remove carbon buildup from the EGR passages in the upper and lower intake manifolds and cylinder head.

Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to clean the gasket surfaces of the lower intake manifold, cylinder heads and cylinder block.

NOTE: Before installing the lower intake manifold, the EGR exhaust port must be clean and free of obstructions.





54. Apply sealer in the corners where the cylinder head and block meet.
^ Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6.

NOTE: The lower intake manifold must be installed within four minutes after applying the silicone.





55. Position the four lower intake manifold gaskets.
^ Install intake manifold seal tabs to notch in the lower intake manifold gaskets.
^ Press firmly along the entire length of the intake manifold seal until the silicone sealant is visible.

56. Tighten the twelve lower intake manifold bolts in two stages.
^ Stage 1: 6-14 Nm (5-10 ft. lbs.).
^ Stage 2: 31-34 Nm (23-25 ft. lbs.).

57. Install the camshaft position sensor and camshaft synchronizer.





58. Connect the eight fuel injectors electrical connectors.





59. Install the water bypass tube.
a. Position the water bypass tube.
b. Install the two water bypass hose clamps.





60. Position the RH valve cover and install the bolts.





61. Position the LH valve cover and install the bolts.





62. Position the water heater tube fitting on the intake manifold and install the nut.





63. Install the water heater tube nut.





64. Position the engine sensor control wiring and connect the oil pressure sensor electrical connector.





65. Connect the crankshaft position sensor electrical connector.





66. Connect the engine coolant temperature electrical connector.
67. Clean and inspect all surfaces. Install new seals and gaskets.

NOTE: Before installing the upper intake manifold, the EGR exhaust port must be clean and free of obstructions. Use combustion chamber cleaner and a suitable wire brush to remove carbon buildup from the EGR passages in the upper intake manifold, intake manifold gaskets and the cylinder heads.





68. Connect the two upper intake vacuum connections.





69. Position the upper intake manifold and install the six bolts.





70. Install the upper intake manifold cover plate.





71. Connect the following connections:
a. The engine vacuum regulator (EVR) electrical connector.
b. The engine vacuum regulator (EVR) vacuum connector.





72. On early models connect the EGR vacuum connector.





73. On early models, connect the EGR electrical connector.





74. On late models, position the EGR tube and connect the lower fitting.





75. On late models, connect the upper EGR fitting.





76. On late models, connect the two pressure transducer hoses.





77. On late models equipped with the DPFE system, connect the EGR vacuum connector.





78. On early models, connect the throttle position (TP) sensor electrical connector.





79. On late models, connect the TP sensor electrical connector.





80. Connect the idle air control (IAC) bypass electrical connector.





81. Connect the crankshaft ventilation hose to the throttle body.





82. Install the snow shield and bolt.





83. Position the generator bracket and install the bolts (RH only).

CAUTION: The front end accessory drive bracket bolts require special torque values. Proper tightening is necessary to prevent excessive accessory drive vibrations.





84. Tighten the three generator bracket bolts in sequence (RH only).

NOTE: Make sure to tighten the generator bracket in two steps.





85. Tighten the last generator bracket bolt (RH only).





86. Position the drive belt tensioner and install the two bolts.