Installation

2. Install the throttle body.
^ Position the throttle body gasket.
^ Position the throttle body.
^ Install the bolts and tighten to 9 Nm (80 inch lbs.) and rotate an additional 90°.

3. Install the idle air control valve.
^ Install a new idle air control gasket.
^ Install the idle air control valve.
^ Tighten the bolt to 9 Nm (80 inch lbs.) and rotate an additional 90°.

4. Install the EGR valve. Install the EGR valve gasket. Position the EGR valve. Tighten the bolt in two stages.
^ Stage 1: Tighten to 20 Nm (14 ft. lbs.).
^ Stage 2: Tighten an additional 90°.

5. Install the intake manifold assembly.
^ Position the intake manifold assembly.
^ Loosely install the bolts and the studs.

6. NOTE: Fuel injectors should be properly oriented when installed, orientation clips will not allow movement.

Tighten the studs.

7. Tighten the bolts in the sequence shown.

8. Position the engine control sensor wiring holders on the studs.

9. Connect the vacuum line to the EGR valve.

10. Connect the EGR tube to the EGR valve.

11. Connect the engine control sensor wiring to:
^ the idle air control valve.
^ the throttle position sensor.

12. Connect the engine control sensor wiring to the eight fuel injectors.

13. Install the engine control sensor wiring covers.

14. Connect the electrical connector and the vacuum lines to the EGR vacuum regulator.

15. Connect the heater water hose.

16. Connect the main emission hose.

17. Connect the vacuum line and the electrical connector to the fuel injection pressure sensor.

18. Connect the chassis vacuum supply tube, the positive crankcase ventilation tube and the engine vacuum supply line.

19. Install the accelerator cable bracket.

20. Connect the accelerator cable and the speed control actuator cable.

21. Position the snow shield and install the bolt and the pushpin.

22. Connect then attach the mass air flow sensor to the snow shield.

23. Replace the O-ring seals.

24. CAUTION: Do not cut O-ring seal during tube installation into cylinder heads or engine coolant leakage may occur.

Clean O-ring sealing surface on cylinder heads and coat water bypass tube sealing O-rings with Premium Engine Coolant E2FZ-19549-AA (green), recycled coolant, (in Oregon, F5FZ-19544-CC, in Canada, Motorcraft CXC-10), or equivalent that meets Ford specification ESE-M971344-A and water. Insert water bypass tube support braces over intake manifold inner studs and install water bypass tube into position.

25. Install the bypass tube and the two nuts.

26. Install the generator mounting bracket.
^ Position the generator mounting bracket.
^ Install the bolts and nuts.

27. Connect the generator electrical connector.

28. Position the generator battery lead and install the nut and the bolt.

29. Connect the engine control sensor wiring electrical connector to the engine coolant temperature sensor.

30. Connect the hoses to the bypass tube.

31. Install the two nuts retaining the engine control sensor wiring to the valve cover.
32. Connect the fuel line.
33. Install the air cleaner outlet tube.
34. Connect the battery ground cable.
35. Connect the starter.
36. Connect the ignition coils.
37. Fill and bleed the cooling system.