Installation

INSTALLATION

NOTE: The engine should always be assembled using new cylinder head bolts.

NOTE: Head gaskets are not interchangeable, they are either right-hand or left-hand side.

1. Clean mating surfaces to ensure they are free of oil and dirt. Install cylinder head locating dowels.

Cylinder Head And Gaskets:

2. Position cylinder head gaskets on cylinder block. The installation arrows on the head gaskets must be pointing to the front of the engine. Then position the cylinder heads onto the head gaskets.

Cylinder Head Bolt Tightening Sequence:

3. Install and tighten cylinder head bolts in sequence to 30 Nm (22 ft lb).

Application Of Sealer On Lower Intake Manifold:

4. Apply Silicone Rubber F6AZ-19562-AA or equivalent meeting Ford specifications WSE-M4G323-A3 at the four corners of the cylinder block and cylinder head mating surfaces. Install the intake manifold gasket and again apply sealer to the four corner locations.

NOTE: Once applied, the silicone sealer will set up in approximately 15 minutes. The intake manifold must be installed immediately after the sealer is applied.

Lower Intake Manifold Installation:

5. Position the lower intake manifold on the cylinder heads and install the lower intake manifold bolts.

Lower Intake Manifold Bolt Tightening Sequence:

a. Tighten in sequence to 4 Nm (3 ft lb).
b. Tighten the cylinder head bolts in sequence to 70 Nm (52 ft lb).
c. Tighten the intake manifold bolts in sequence to 8 Nm (6 ft lb).
d. For the final cylinder head bolt tightening step, rotate the bolts in sequence 90 degrees (1/4 turn).
e. For the final intake manifold bolt tightening step, tighten bolts in sequence to 15 Nm (11 ft lb).

Valve Tappet Alignment:

6. Install valve tappets.
a. Lubricate each tappet and bore with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A or engine oil SAE 50 Service SG ESE-M2C39-F.
b. Install each valve tappet in the bore from which it was removed with the alignment tab in the locating groove of the bore. If new valve tappets are being installed, check for free fit in the bore.
7. Install rocker arm shaft assemblies and draw the shaft support down evenly, two turns at a time until the rocker shaft assemblies are fully down. Tighten shaft support bolts to 32 Nm (24 ft lb). Then torque again an additional 90°.
8. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to the four locations at the joint where the intake manifold and the cylinder heads meet.
9. Install valve covers.
10. Install the upper intake manifold and tighten the nuts to 20-25 Nm (15-18 ft lb).
11. Install air conditioner compressor on bracket and screw retaining air conditioner manifold tube to upper intake manifold. Tighten compressor bolts to 21-29 Nm (15-21 ft lb).
12. Install the exhaust inlet pipe, RH exhaust manifold, the EGR valve to exhaust manifold tube and LH exhaust manifold.
13. Install the spark plugs.
14. Install the ignition coil and assembled ignition coil mounting strap.
15. Install the alternator.

Drive Belt Routing:

16. Install drive belt over pulleys. Make sure that all V-grooves make proper contact with pulleys.
17. Lift tensioner and slide drive belt under drive belt tensioner. Release tensioner to rest pulley on drive belt.
18. Install the A/C compressor mounting bracket with assembled power steering pump to the cylinder heads.
19. Install the A/C compressor.
20. Fill and bleed the cooling system.
21. Connect the battery ground cable at the battery.

NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.