Installation

1. Clean cylinder heads, intake manifold, valve covers and cylinder block sealing surfaces. If necessary, check cylinder head and cylinder block flatness.





2. Rotate crankshaft counter-clockwise 45 degrees.

NOTE: This step makes sure that all pistons are below top of cylinder block deck face.

3. Inspect cylinder head face surface for scratches near coolant passage and combustion chambers.
4. Rotate camshaft to a stable position where valves do not extend below cylinder head face.
5. Position new head gaskets on cylinder block.
6. Position LH cylinder head on cylinder head to block dowels.

CAUTION: Cylinder head bolts must be replaced with new bolts. They are torque-to-yield designed and cannot be re-used.

NOTE: Take care not to score the surface of the cylinder head face.

7. Apply Super Premium SAE 5W-30 Motor Oil (XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G) to all head bolt spot-faces.
8. Remove rubber band from lower rear bolt and install nine remaining bolts and hand-tighten.





9. Tighten ten LH cylinder head bolts as follows:
a. Tighten head bolts in sequence to 37 - 43 Nm (28 - 31 ft. lbs.).
b. Rotate head bolts in sequence an additional 85 - 95 degrees.
c. Loosen head bolts a minimum of one full turn (360 degrees).
d. Retighten head bolts in sequence to 37 - 43 Nm (28 - 31 ft. lbs.).
e. Rotate head bolts in sequence 85 - 95 degrees.
f. Rotate head bolts in sequence an additional 85 - 95 degrees.


10. Position RH cylinder head on cylinder head to block dowels.

11. Apply Super Premium SAE 5W30 Motor Oil (XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G) to all head bolt spot-faces.
12. Install the ten remaining bolts and hand-tighten.

13. Tighten RH cylinder head bolts as follows:
a. Tighten head bolts, in sequence, to 37 - 43 Nm (28 - 31 ft. lbs.).
b. Rotate head bolts, in sequence, 85 - 95 degrees.
c. Loosen head bolts a minimum of one full turn (360 degrees).
d. Retighten head bolts, in sequence, to 37 - 43 Nm (28 - 31 ft. lbs.).
e. Rotate head bolts, in sequence, 85 - 95 degrees.
f. Rotate head bolts, in sequence, an additional 85 - 95 degrees.


14. Position heater water tube on cylinder block and LH cylinder head and install two bolts.
Tighten lower retainer bolt to 8 - 12 Nm (71 - 106 in. lbs.) and upper retaining bolt to 20 - 30 Nm (15 - 22 ft. lbs.).

15. Rotate camshafts using flats matched at center of camshaft until both are in time. Install Cam Positioning Tool Adapters 303-413 (T92P-6256-A) and Cam Positioning Tool 303-380 (T91P-6256-A) on flats of camshafts. This will prevent the camshafts from rotating.





16. Rotate crankshaft clockwise 45 degrees.

CAUTION: Crankshaft must only be rotated in the clockwise direction and only as far as TDC.

NOTE: This will position crankshaft at TDC No 1.

17. Install timing chains.

CAUTION: Timing chain procedures must be followed exactly or damage to valves or pistons will result.

18. Inspect and replace crankshaft front seal and engine front cover gasket as necessary.





19. Apply a 8 - 12 mm (0.32 - 0.47 inch) bead of Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 in locations shown.

NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.

20. Install engine front cover on engine.





21. Install stud bolts and bolts retaining engine front cover to engine.
Tighten to 20 - 30 Nm (15 - 22 ft. lbs.).

22. Position new intake manifold gaskets on cylinder heads.

NOTE:
- Before installation, inspect intake manifold for nicks and cuts. Replace intake manifold as required.
- Make sure alignment tabs on intake manifold gaskets are aligned with holes in cylinder heads.

23. Position intake manifold on cylinder heads.





24. Install and tighten intake manifold retaining bolts 1 through 9, in sequence shown in illustration, to 20 - 30 Nm (15 - 22 ft. lbs.).

25. Install water thermostat and new O-ring, then position water hose connection and upper radiator hose and install two bolts.
Tighten to 20 - 30 Nm (15 - 22 ft. lbs.).

26. Connect heater water hose to heater water tube.
27. Connect engine control sensor extension wire to heated oxygen sensors.
28. Connect vacuum hose to throttle body adapter vacuum port.
29. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 at both places engine front cover meets cylinder head.

NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.

30. Position and, using Gasket and Trim Adhesive F3AZ-193508-B (or equivalent meeting Ford specifications ESR-M11P17A and ESE-M2G52-A), secure new valve cover gaskets into valve covers and install valve covers onto cylinder heads.
31. Install bolts and stud bolts into RH valve cover.
Tighten all bolts and stud bolts to 8 - 12 Nm (71 - 106 in. lbs.).





32. Install bolts and stud bolts into LH valve cover.
Tighten all bolts and stud bolts to 8 - 12 Nm (71 - 106 in. lbs.).

33. Install accelerator cable bracket on intake manifold and connect accelerator cable and speed control actuator cables to throttle body.
34. Raise vehicle.
35. Position starter wiring harness to RH cylinder head and install retaining bolt.
36. Remove wire and position three way catalytic converter to RH and LH exhaust manifolds.
37. Install four exhaust manifold to dual converter and pipe nuts and tighten to 27 - 41 Nm (20 - 30 ft. lbs.).

NOTE: Make sure exhaust system clears No. 3 crossmember. Adjust as necessary.

38. Connect EGR valve to exhaust manifold tube to RH exhaust manifold and tighten nut to 35 - 45 Nm (26 - 33 ft. lbs.).
39. Connect engine control sensor extension wire to the electronic variable orifice sensor and oil pressure sensor.

Crankshaft Pulley Keyway Silicone Gasket Sealant Application Locations:

40. Apply Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A6 in keyway of crankshaft pulley as shown.

NOTE: Prior to applying sealer, clean sealing surfaces with Metal Surface Cleaner F4AZ-19A536-RA (or equivalent meeting Ford specification WSE-M5B392-A) to remove all residues that may interfere with the sealer's ability to adhere.

41. Position crankshaft pulley on crankshaft. Make sure crankshaft key and keyway are aligned.





42. Using Crankshaft Damper Replacer 303-102 (T74P-6316-B), install crankshaft pulley.

43. Install crankshaft pulley bolt and crankshaft pulley retaining washer and tighten in four steps:
a. Tighten to 90 Nm (66 ft. lbs.).
b. Loosen one complete turn.
c. Tighten to 50 Nm (36 ft. lbs.).
d. Tighten an additional 90 degrees.

44. Install oil pan with new oil pan gasket.
45. Position power steering pump on engine and install four retaining bolts.
Tighten to 20 - 30 Nm (15 - 22 ft. lbs.).

46. Lower vehicle.
47. Connect fuel charging wiring to the A/C clutch, crankshaft position sensor and evaporative emission canister purge valve.
48. Position and connect 42-pin engine harness connector and 8-pin connector.
49. Position A/C line and install retaining nut.
50. Install positive crankcase ventilation valve in RH valve cover.
51. Connect front evaporative emission hose to evaporative emission canister purge valve.
52. Position generator and install two retaining bolts.
Tighten to 20 - 30 Nm (15 - 22 ft. lbs.).

53. Install two bolts retaining generator rear mounting bracket to intake manifold and tighten to 8 - 12 Nm (71 - 106 in. lbs.).

54. Install water pump pulley and tighten bolts to 20-30 Nm (15-22 ft. lbs.).

55. Position ignition coil brackets, ignition wires and ignition wire separator onto mounting stud bolts.
56. Install nuts retaining ignition coil brackets to engine front cover. Tighten to 20 - 30 Nm (15 - 22 ft. lbs.).

57. Install LH ignition coil and ignition wire assembly.
58. Connect engine control sensor extension wire to both ignition coils and camshaft position sensor.
59. Position and install power steering oil reservoir.
60. Connect ignition wires to spark plugs and install ignition wire separators onto valve cover studs.
61. Install drive belt.
62. Install windshield wiper governor.
63. Connect fuel lines.
64. Install cooling fan motor/fan blade and fan shroud assembly. Fill engine cooling system.
65. Install air cleaner outlet tube.
66. Connect battery ground cable.
67. Check and add clean engine oil Motorcraft XO-5W30-QSP meeting Ford specification WSS-M2C153-G as needed.
68. Start engine and check for leaks.