Lower

Removal
1. Drain the engine cooling system.
2. Remove both the valve covers.





3. Disconnect the hoses and the Engine Coolant Temperature (ECT) sensor.





4. Position the ignition coil aside.
- Disconnect the connector.
- Disconnect the three spark plug wires.
- Position the ignition coil aside.
- Remove the bolts.





5. Disconnect the upper radiator hose.
- Reposition the clamp.
- Disconnect the hose.

6. Remove the fuel injection supply manifold and fuel injectors as an assembly.
7. Remove the thermostat and thermostat housing.





8. Note: Identify the location of each rocker arm. Each rocker arm is to be installed in the original location to prevent premature wear.

Remove the rocker arms.
- Remove the bolts.

9. Note: Identify the location of each push rod. Each push rod is to be installed in the original location to prevent premature wear.

Remove the push rods.





10. Remove the lower intake manifold.
- Remove the bolts.
- Remove the manifold.





11. Remove the intake manifold gaskets and the end seals.

Installation





1. Clean all the sealing surfaces.





2. Install the intake manifold gaskets and seals.
- Apply a drop of Silicone Gasket and Sealant at the four cylinder block-to-cylinder head seams.
- Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4.
- Position the intake manifold gaskets.
- Position the intake manifold front and rear seals.





3. Install the intake manifold. Tighten the bolts in the sequence shown in two stages.
- Stage 1: Tighten to 15 Nm (11 ft. lbs.).
- Stage 2: Tighten to 32 Nm (24 ft. lbs.).

4. Install the push rods.





5. Install the rocker arms. Tighten the bolts in two stages.
- Stage 1: Tighten to 10 Nm (89 inch lbs.).
- Stage 2: Tighten to 32 Nm (24 ft. lbs.).

6. Install the thermostat and thermostat housing.
7. Install the fuel injectors and fuel injection supply manifold.





8. Connect the upper radiator hose.
- Connect the hose.
- Reposition the clamp.





9. Install the ignition coil.
- Connect the spark plug wires.
- Connect the ignition coil electrical connector.
- Install the bolts.





10. Connect the hoses and the coolant temperature sensor.
11. Connect the fuel line.
12. Install both valve covers.
13. Fill and bleed the engine cooling system.