Steps 48 - 94

48. NOTE: Position 1-6-7-8-9 are stud locations.

Install and tighten the bolts in the sequence shown.





49. Install and tighten the bolts in two stages.
^ Stage 1: Tighten to 2O Nm (14 ft. lbs.).
^ Stage 2: Tighten an additional 6O degrees.





5O. Position the idler pulley and install the bolt.





51. If removed, install the drive belt tensioner.
^ Position the tensioner.
^ Install and tighten the bolt.





52. Lubricate the front cover and the front oil seal inner lip.
^ Use Motorcraft Super Premium SAE 5W-3O Motor Oil XO-5W3O-QSP or equivalent meeting Ford specification WSS-M2C153-G.





53. Use the Crankshaft Seal Replacer/Cover Aligner to install the front oil seal into the front cover.





54. Apply silicone to the woodruff key slot on the crankshaft pulley.
^ Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





55. Use Crankshaft Damper Replacer to install the crankshaft damper.





56. NOTE: Tighten the bolt in four stages.

^ Stage 1: Tighten to 9O Nm (66 ft. lbs.).
^ Stage 2: Loosen the bolt one full turn.
^ Stage 3: Tighten to 47 - 53 Nm (35 - 39 ft. lbs.).
^ Stage 4: Tighten an additional 85 - 95°.





57. Install the water pump.
^ Lubricate and install the O-ring seal.
^ Ford Premium Engine Coolant E2FZ-19549-AA (green), recycled coolant, (in Oregon, F5FZ-19544-CC, in Canada, Motorcraft CXC-1O), or equivalent that meets Ford specification ESE-M971344-A and water.
^ Position the water pump and loosely install the bolts.
^ Tighten the bolts





58. Install the water pump pulley and install the bolts.





59. Apply silicone in two places where the engine front cover meets the cylinder head.
^ Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.





6O. NOTE: Place the studs in locations 6 and 9.

Install the RH valve cover. Tighten the eight bolts and the two studs in the sequence shown.
^ Make sure to check the tower gaskets for damage.
^ Install anew valve cover gasket.





61. NOTE: Place the studs in locations 7 and 1O.

Install the LH valve cover. Tighten the eight bolts and the two studs in the sequence shown.
^ Install a new valve cover gasket.
^ Check spark plug tower (well) seals for placement.





62. Connect the knock sensor harness electrical connector to the fuel charging wiring connector.





63. Install the airflow spacers and the intake manifold assembly. Position the airflow spacers and the intake manifold assembly. Loosely install the bolts and the studs.





64. NOTE: The studs will be tightened in sequence with the intake manifold.

Tighten the fuel injection supply manifold bolts.





65. Tighten the bolts in the sequence shown:





66. Attach the high pressure power steering line to the bottom of the engine front cover.





67. Install both the exhaust manifold gaskets and the manifolds and install the nuts.
68. Install the A/C compressor.
69. Install the RH engine support insulator bracket.
^ Install the RH engine mount. Install the bolts.
^ Install the grounding strap.
7O. Attach the transmission line bracket and the starter ground to the engine insulator.





71. Lubricate the O-ring seal on the oil level indicator tube and position in the hole on the cylinder block. Use clean Motorcraft Super Premium SAE 5W-3O motor oil XO-5W3O-QSP or equivalent meeting Ford specification WSS-M2C153-G.
^ Tighten the nut.
72. Install the LH engine support insulator and install the bolts.
73. Install the bolt and nuts to the power steering.





74. Install the generator and the bolts.





75. Install the water bypass tube and install the bolts.





76. Install the generator upper support bracket and install the bolts and nuts.





77. Install the ignition coils.





78. If removed, install the EGR valve and tighten the bolts in two stages.
^ Stage 1: Tighten to 2O Nm (14 ft. lbs.).
^ Stage 2: Tighten an additional 9O°.





79. Install the differential pressure feedback EGR and bracket assembly.





8O. Connect the wiring harness connectors to the eight fuel injectors.





81. Correct the wiring harness connectors to the eight ignition coils.





82. Install the RH and LH ignition coil cover.





83. Connect the idle air control valve electrical connector.





84. Connect the generator electrical connector and the battery lead and secure to the upper generator support bracket.





85. Connect the differential pressure feedback EGR.





86. Install the EGR vacuum regulator control and bracket assembly.
1 Install the EGR vacuum regulator bracket.
2 Connect the EGR vacuum regulator control connector.
3 Connect the vacuum hoses.





87. Install the crankcase ventilation hose.





88. Connect the injector pressure sensor vacuum hose.





89. Connect the fuel injector pressure sensor connector.





9O. Connect the EGR valve vacuum hose.





91. Connect the chassis vacuum hoses to the intake manifold.





92. Install the thermostat housing to the oil filter adapter hose.
93. Install the drive belt.
94. Fill the engine with clean Motorcraft Super Premium SAE 5W-3O Motor Oil XO-5W3O-QSP or equivalent meeting Ford specification WSS-M2C153-G.