Part 2 of 2

41. Install the cylinder head on the head gasket and install the ten new bolts in three steps.
- Step 1: Tighten to 34-47 Nm (25-35 ft. lbs.).
- Step 2: Tighten to 61-75 Nm (45-55 ft. lbs.).
- Step 3: Rotate an additional 85-90 degrees.

42. Lubricate the valve tappet bores before installing the valve tappets.
- Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





43. Install the valve tappets and the valve tappet guide plates in their original positions.





44. Position the valve tappet guide plate retainer and install the bolts.





45. Install the push rods in their original positions.
46. Apply engine oil to the top of the valve stems and rocker arm seats.
- Use Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.





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





48. Install the eight rocker arm fulcrums.





49. Install the bolts.
50. Check the valve clearance.





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

NOTE:
- Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-MSB392-A to clean the gasket surfaces of the lower intake manifold, cylinder heads and cylinder block.
- The lower intake manifold must be installed within four minutes after applying the silicone.





52. 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.





53. Tighten the twelve bolts in two steps.
- Step 1: 6-14 Nm (5-10 ft. lbs.).
- Step 2: 31-34 Nm (23-25 ft. lbs.).

54. Install the camshaft position sensor (CMP sensor) and camshaft synchronizer.





55. Connect the eight fuel injector electrical connectors.





56. Install the water bypass tube.
1 Position the water bypass tube.
2 Install the clamps.





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





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





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





60. Install the nut.





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





62. Connect the crankshaft position sensor electrical connector.





63. Connect the engine coolant temperature electrical connector.
64. Clean and inspect all surfaces. Install new seals and intake manifold gaskets.





65. Connect the two upper intake vacuum connections and the two PCV heater hoses.





66. Position the upper intake manifold and install the bolts.





67. Install the upper intake manifold cover plate.





68. Connect the following connections:
- The engine vacuum regulator (EVR) electrical connector.
- The engine vacuum regulator (EVR) vacuum connector.





69. Position the EGR valve to exhaust manifold tube and connect the lower fitting.





70. Connect the upper EGR valve-to-exhaust manifold tube fitting.





71. Connect the two pressure transducer hoses.





72. Connect the EGR valve vacuum connector.





73. Connect the TP sensor electrical connector.





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





75. Connect the crankcase ventilation hose to the throttle body.





76. Install the accelerator control splash shield and bolt.





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

CAUTION: These bolts require special torque values. Proper tightening is necessary to prevent excessive accessory drive vibrations.





78. Tighten the bolts in sequence (RH only).

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





79. Tighten the last bolt (RH only).





80. Position the drive belt tensioner and install the bolts.