Part 2 of 2

67. Using special tool to install the water pump drive pulley.





68. Coat the mating faces of the cylinder heads with sealer.
^ Use Black silicone rubber or equivalent meeting Ford specification WSE-M4G323-A6.





69. Install the LH spark plugs.





70. Install the RH spark plugs.





71. NOTE: Install the bolts in the indicated sequence.

Install the cylinder head covers.
^ Install new gaskets.





72. Install the fuel charging wiring bracket to the cylinder head cover.





73. Install the LH engine lifting eye.





74. Coat the mating faces with sealer.
^ Use Black silicone rubber or equivalent meeting Ford specification WSE-M4G323-A6.
^ Apply a 10 mm diameter dot of sealer onto cylinder block at the indicated areas.





75. NOTE: Note the locations of the studs.

NOTE: Install the bolts and studs in the indicated sequence.

NOTE: Install the oil pan and tighten the bolts within six minutes of applying sealer.

Install the oil pan.
^ Install anew gasket.





76. Position and install the oil pan heat shields.





77. Install the oil pressure switch.





78. NOTE: If studs were removed, install short end of studs into cylinder head.

NOTE: Install the nuts in the indicated sequence.

Install the LH exhaust manifold with the Three-way Catalytic Converter (TWC).
^ Install a new gasket.





79. Install the oil filter.





80. NOTE: Install the nuts in the indicated sequence.

Position the RH exhaust manifold and install the nuts.





81. Install the generator bracket.





82. Install the generator.
1 Install the generator bolts.
2 Install the bracket bolt.





83. NOTE: Alternate bolt tightening to correctly seat the crankshaft rear oil seal until it is flush with the cylinder block.

Using special tools, install the crankshaft rear oil seal.
^ Lubricate the outer ring and sealing lip with Ford super premium engine oil SAE 5W-30.





84. NOTE: Use a suitable strap wrench to hold the crankshaft pulley.

Install the flywheel.
1 Install the backing plate.
2 Install the flywheel and tighten the bolts working diagonally.





85. Install the water pump.
1 Position the pump.
2 Install new bolts and tighten them in two stages.
^ Stage 1: 10 Nm
^ Stage 2: 90 degrees





86. Connect the water pump coolant hoses.
1 Connect the coolant hose to the oil filter adapter.
2 Connect the coolant hose to the cylinder block.





87. Install the water bypass.
^ Use new O-ring seals and lubricate them with coolant.
^ Use Premium cooling system fluid or equivalent meeting Ford specification ESE-M971344-A.





88. Install the PCV valve and hoses.
1 Connect the PCV valve and hoses.
2 Install the nut.





89. Install the water pump drive belt.
^ Rotate the belt tensioner clockwise to relieve tension on the belt.





90. Install the LH engine lifting eye.
1 Position the lifting eye.
2 Install the bolt.





91. NOTE: Install the O-ring seal on the oil level indicator tube prior to installation.

Install the oil level indicator.
1 Position the oil level indicator tube using a twisting motion.
2 Install the bolt.





92. Install the coolant distribution tube and bolts.





93. Install the thermostat housing with the coolant hoses.





94. NOTE: Install new gaskets with the locating lugs facing downwards.

NOTE: Tighten the bolts in the indicated sequence.

Install the lower part of the intake manifold.





95. Install the fuel injection system wiring harness.
1 Connect the fuel injector electrical connectors beginning at the front of the engine.
2 Connect the ECT sensor electrical connector.
3 Connect the DPFE sensor electrical connector.





96. Connect the CKP sensor electrical connector.
1 Connect the harness clip.
2 Connect the CKP sensor electrical connector.





97. Connect the CMP sensor electrical connector.
1 Connect the harness clip.
2 Connect the CMP sensor electrical connector.





98. Connect the oil pressure switch electrical connector.





99. Connect the H02S electrical connector.





100. NOTE: Install new gaskets with the locating lugs pointing downwards.

NOTE: Tighten the bolts in the indicated sequence.

Install the upper part of the intake manifold.





101. Connect the Throttle Position (TP) sensor electrical connector.





102. Connect the PCV hose to the throttle body.





103. Connect the Idle Air Control (IAC) valve electrical connector.





104. Position the vacuum harness and connect the vacuum lines.
1 Position the vacuum harness and connect the two vacuum supply hoses to the intake manifold.
2 Connect the Electronic Vacuum Regulator (EGR) solenoid vacuum hoses.
3 Connect the fuel pressure regulator vacuum hose.
4 Connect the DPFE vacuum hoses.
5 Connect the EGR valve vacuum hoses.





105. Install the ignition coil.
1 Position the coil.
2 Position the capacitor.
3 Position the ground cable.
4 Install the bolts.
5 Connect the ignition coil electrical connector.





106. Install the IMRC control unit.
1 Install the bolts.
2 Connect the IMRC electrical connector.





107. Connect the IMRC cable.
1 Connect the cable to the retainer.
2 Connect the cable end.

108. Position the wiring harness.





109. Connect the Engine Coolant Temperature (ECT) sensor electrical connector.





110. Connect the EGR vacuum regulator solenoid electrical connector.





111. Connect the DPFE sensor electrical connector.





112. Connect the generator electrical connections.
1 Install the battery cable.
2 Install the field cable.
3 Position the battery cable cover.





113. Install the connecting shaft bracket to the cylinder block.