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Engine - 3.9L: Assembly: Engine: Material

MATERIAL SPECIFICATION

Item Specification
Motorcraft Premium Gold Engine Coolant
VC-7-A Or Equivalent		 WSE-M97B51-A1
Motorcraft Premium Engine Coolant
VC-4-A Or Equivalent		 ESE-M97B44-A
Super Premium SAE 5W-20
XO-5W20-QSP Or Equivalent		 WSS-M2C153-H
Silicone Gasket & Sealant
F7AZ-19554-EA (In Canada CXC-111-A) Or Equivalent		 WSE-M4G323-A4
Metal Surface Cleaner
F4AZ-19A536-RA Or Equivalent		 WSE-M5B392-A
    CAUTION: The plastic sleeve that comes with the new crankshaft rear oil seal protects the seal while in transit and is also used as an installation tool to prevent lip seal roll when carrying out the repair. The sleeve must be used to prevent future seal concerns.
    NOTE: Lubricate the cylinder block bore and the crankshaft with clean engine oil before installing seal.
    Fig 1: Positioning Rear Oil Seal
    G03421810Courtesy of FORD MOTOR CO.
  1. Position the rear oil seal with the protective installer onto the end of the crankshaft.
    2. NOTE: Lubricate the outer lips and the inner seal on the crankshaft rear oil seal with clean engine oil.
    Fig 2: Installing Rear Main Seal
    G03421811Courtesy of FORD MOTOR CO.
  2. Using the special tools, install the rear main seal.
    3. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs, or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
    NOTE: If the sump is not secured within four minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 3: Applying Silicone Gasket & Sealant
    G03421812Courtesy of FORD MOTOR CO.
  3. Apply three continuous beads of sealer of silicone gasket and sealant.
  4. Install the oil sump. Using a straightedge, align the sump to the lower cylinder block. Tighten the bolts in sequence in two stages.
    • Tighten the bolts to 15 N.m (11 lb-ft).
    • Tighten the bolts to 25 N.m (18 lb-ft).
    Fig 4: Oil Sump Bolt Tightening Sequence
    G03421813Courtesy of FORD MOTOR CO.
  5. Install the flexplate and tighten the bolts in two stages in the sequence shown.
    • Stage 1: Tighten to 15 N.m (11 lb-ft).
    • Stage 2: Tighten to 110 N.m (81 lb-ft).
    Fig 5: Flexplate Bolt Tightening Sequence
    G03421814Courtesy of FORD MOTOR CO.
    6. NOTE: There is one window on the ignition pulse wheel that is unique to accept the special tool.
    Fig 6: Installing Special Tool
    G03421815Courtesy of FORD MOTOR CO.
  6. Install the special tool.
    • Turn the crankshaft to 45 degrees ATDC. The crankshaft keyway will be in the 6 o'clock position.
    • Install the special tool.
  7. Install a new gasket, the oil pump and the bolts.
    Fig 7: Installing Oil Pump
    G03421816Courtesy of FORD MOTOR CO.
  8. Verify the retaining washers are in place.
    Fig 8: Identifying Retaining Washers
    G03421817Courtesy of FORD MOTOR CO.
    9. NOTE: Inspect the O-ring. Install a new O-ring if necessary. Lubricate the O-ring with clean engine oil.
    Fig 9: Installing Oil Pump Screen Cover & Tube
    G03421818Courtesy of FORD MOTOR CO.
  9. Install the oil pump screen cover and tube.
    10. NOTE: Inspect and install a new oil pan gasket if necessary.
    Fig 10: Installing Oil Pan
    G03421819Courtesy of FORD MOTOR CO.
  10. Install the oil pan.
  11. Tighten the bolts in the sequence shown in two stages.
    • Stage 1: Tighten to 5 N.m (44 lb-in).
    • Stage 2: Tighten to 12 N.m (9 lb-ft).
    Fig 11: Oil Pan Bolt Tightening Sequence
    G03421820Courtesy of FORD MOTOR CO.
  12. Install the throttle body heater return hose.
    Fig 12: Installing Throttle Body Heater Return Hose
    G03421821Courtesy of FORD MOTOR CO.
  13. Install the knock sensors.
    Fig 13: Installing Knock Sensors
    G03421822Courtesy of FORD MOTOR CO.
  14. Position the cylinder heads.
    • Install new gaskets.
    Fig 14: Positioning Cylinder Heads
    G03421823Courtesy of FORD MOTOR CO.
    15. NOTE: The cylinder head bolts are a torque-to-yield design and must not be reused. Always use new bolts.
    Fig 15: RH Cylinder Head Bolt Tightening Sequence
    G03421824Courtesy of FORD MOTOR CO.
  15. Install and tighten the RH head bolts in four stages in the sequence shown.
    • Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft).
    • Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft).
    • Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees.
    • Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
  16. Install and tighten the bolts in two stages.
    1. Tighten to 20 N.m (15 lb-ft).
    2. Tighten an additional 90 degrees.
    Fig 16: Tightening Bolts
    G03421825Courtesy of FORD MOTOR CO.
  17. Install and tighten the LH head bolts in four stages in the sequence shown.
    • Stage 1: Tighten bolts 1 through 10 to 20 N.m (15 lb-ft).
    • Stage 2: Tighten bolts 1 through 10 to 35 N.m (26 lb-ft).
    • Stage 3: Tighten bolts 1 through 10 to 45 N.m (33 lb-ft) and an additional 90 degrees.
    • Stage 4: Tighten bolts 1 through 10 an additional 90 degrees.
    Fig 17: LH Cylinder Head Bolt Tightening Sequence
    G03421826Courtesy of FORD MOTOR CO.
  18. Install and tighten the bolts in two stages.
    1. Tighten to 20 N.m (15 lb-ft).
    2. Tighten an additional 90 degrees.
    Fig 18: Tightening Bolts
    G03421827Courtesy of FORD MOTOR CO.
    19. CAUTION: The shim and tappets are location-specific. They must be installed in their original locations or shims will have to be reselected during installation.
    CAUTION: Do not use any means of marking the shims other than a permanent type marker. Any scratches or paint on the shims can result in incorrect lash adjustments and severe engine damage.
    Fig 19: Installing Tappets & Shims
    G03421828Courtesy of FORD MOTOR CO.
  19. If removed, install the tappets and shims. If new tappets and shims are to be installed or if they cannot be identified, refer to VALVE CLEARANCE ADJUSTMENT .
    20. NOTE: Apply clean engine oil to the camshaft journals, the camshaft caps and the camshaft lobes prior to installing the camshafts.
    Fig 20: Positioning LH Camshafts On Camshaft Journals
    G03421829Courtesy of FORD MOTOR CO.
  20. Position the LH camshafts on the camshaft journals.
    21. CAUTION: Install the camshaft bearing cap locations. The camshaft bearing caps are positional and must be installed in their original locations and orientation or engine damage can occur.
    Fig 21: LH Camshaft Bearing Cap Bolt Tightening Sequence
    G03421830Courtesy of FORD MOTOR CO.
  21. Install the LH camshaft bearing caps.
    • Position the bearing caps.
    • Install the bolts. Tighten the bolts in three stages in the sequence shown.
      • Stage 1: Hand-tighten.
      • Stage 2: Tighten to 6 N.m (53 lb-in).
      • Stage 3: Tighten an additional 90 degrees.
    22. NOTE: Apply clean engine oil to the camshaft journals, the camshaft caps and the camshaft lobes prior to installing the camshafts.
    Fig 22: Installing RH Camshafts
    G03421831Courtesy of FORD MOTOR CO.
  22. Position the RH camshafts on the camshaft journals.
    23. CAUTION: Install the camshaft bearing caps in their original locations. The camshaft bearing caps are positional and must be installed in their original locations and orientations or engine damage can occur.
    Fig 23: Camshaft Bearing Cap Tightening Sequence
    G03421832Courtesy of FORD MOTOR CO.
  23. Install the RH camshaft bearing caps.
    • Position the bearing caps.
    • Install the bolts. Tighten the bolts in three stages in the sequence shown.
      • Stage 1: Hand-tighten.
      • Stage 2: Tighten to 6 N.m (53 lb-in).
      • Stage 3: Tighten an additional 90 degrees.
    24. NOTE: The crankshaft must be at 45 degrees ATDC with crankshaft position tool installed.
    Fig 24: Checking Bucket Tappet & Shim Clearances
    G03421833Courtesy of FORD MOTOR CO.
  24. Using a feeler gauge, confirm that the bucket tappet and shim clearances are within specification.
    25. NOTE: LH shown; RH similar.
    Fig 25: Installing Special Tool On LH Head
    G03421834Courtesy of FORD MOTOR CO.
  25. Install the special tool on the LH head.
  26. Collapse the tensioners.
    1. Insert a thin wire into the check valve and apply hand pressure until the tensioner is fully collapsed.
    2. Install a wire in the side to retain the tensioner.
    Fig 26: Collapsing Tensioners
    G03421835Courtesy of FORD MOTOR CO.
  27. Position the tensioner.
    Fig 27: Positioning Tensioner
    G03421836Courtesy of FORD MOTOR CO.
  28. Install the secondary timing chain tensioner bolts.
    Fig 28: Installing Secondary Timing Chain Tensioner Bolts
    G03421837Courtesy of FORD MOTOR CO.
  29. Position the intake sprocket, chain and exhaust sprocket on the camshaft as an assembly.
    Fig 29: Positioning Intake Sprocket, Chain & Exhaust Sprocket
    G03421838Courtesy of FORD MOTOR CO.
  30. Loosely install the intake and exhaust sprocket bolts.
    Fig 30: Installing Intake & Exhaust Sprocket Bolts
    G03421839Courtesy of FORD MOTOR CO.
  31. Reset the timing chain tensioner.
    1. Hold the lever toward the tensioner piston.
    2. Using finger pressure, compress the tensioner.
    3. Push the lever down and install a drill rod to lock the piston.
    Fig 31: Resetting Timing Chain Tensioner
    G03421840Courtesy of FORD MOTOR CO.
    32. NOTE: The special tool should still be installed on the LH cylinder head.
    Fig 32: Positioning LH Timing Chain & Crankshaft Gear
    G03421841Courtesy of FORD MOTOR CO.
  32. Position the LH timing chain and crankshaft gear.
    • Position the timing chain over the LH intake camshaft sprocket.
    • Position the crankshaft gear in the timing chain.
    • Position the timing chain and crankshaft gear over the crankshaft as an assembly.
  33. Install the LH timing chain guide.
    Fig 33: Installing LH Timing Chain Guide
    G03421842Courtesy of FORD MOTOR CO.
  34. Install the LH timing chain tensioner arm.
    Fig 34: Installing LH Timing Chain Tensioner Arm
    G03421843Courtesy of FORD MOTOR CO.
  35. Install the LH timing chain tensioner.
    1. Install the timing chain tensioner and bolts.
    2. Remove the drill rod.
    Fig 35: Installing LH Timing Chain Tensioner
    G03421844Courtesy of FORD MOTOR CO.
  36. Install a tie strap to take up the slack in the timing chain.
    Fig 36: Installing Tie Strap To Take Up Slack In Timing Chain
    G03421845Courtesy of FORD MOTOR CO.
    37. NOTE: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.
    Fig 37: Tightening LH Exhaust Camshaft Sprocket Bolts
    G03421846Courtesy of FORD MOTOR CO.
  37. Using the special tool, apply 10 N.m (89 lb-in) counterclockwise to the LH exhaust camshaft sprocket and tighten the camshaft sprocket bolts in two stages.
    • Stage 1: Tighten to 20 N.m (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  38. Remove the special tool.
  39. Install the special tool on the right cylinder head.
    Fig 38: Installing Special Tool On RH Cylinder Head
    G03421847Courtesy of FORD MOTOR CO.
  40. Position the RH timing chain over the RH intake camshaft sprocket and over the crankshaft gear.
    Fig 39: Installing RH Timing Chain
    G03421848Courtesy of FORD MOTOR CO.
  41. Install the RH timing chain guide.
    Fig 40: Installing RH Timing Chain Guide
    G03421849Courtesy of FORD MOTOR CO.
  42. Install the RH timing chain tensioner arm.
    Fig 41: Installing RH Timing Chain Tensioner Arm
    G03421850Courtesy of FORD MOTOR CO.
  43. Install the RH timing chain tensioner.
    1. Install the timing chain tensioner and bolts.
    2. Remove the drill rod.
    Fig 42: Removing Drill Rod
    G03421851Courtesy of FORD MOTOR CO.
  44. Install a tie strap to take up the slack in the timing chain.
    Fig 43: Installing Tie Strap To Take Up Slack In Timing Chain
    G03421852Courtesy of FORD MOTOR CO.
    45. NOTE: The exhaust camshaft sprocket bolt must be fully tightened before tightening the intake camshaft sprocket bolt.
    Fig 44: Installing RH Camshaft Sprocket Bolts
    G03421853Courtesy of FORD MOTOR CO.
  45. Using the special tool, apply 10 N.m (89 lb-in) counterclockwise to the RH camshaft sprockets and tighten the bolts in two stages.
    • Stage 1: Tighten to 20 N.m (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
  46. Remove the special tool and the two tie straps.
    47. NOTE: If the front cover is not secured within four minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 45: Silicone Gasket & Sealant Application Locations
    G03421854Courtesy of FORD MOTOR CO.
  47. Apply silicone gasket and sealant in eight places.
  48. Install the engine front cover.
    • Install new gaskets.
    • Position the engine front cover on the cylinder block.
    • Loosely install the bolts.
    • Tighten the bolts in two stages in the sequence shown.
      • Stage 1: Tighten to 5 N.m (44 lb-in).
      • Stage 2: Tighten to 10 N.m (89 lb-in).
      Fig 46: Engine Front Cover Bolt Tightening Sequence
      G03421855Courtesy of FORD MOTOR CO.
  49. Using the special tool, install the front crankshaft seal.
    Fig 47: Installing Front Crankshaft Seal
    G03421856Courtesy of FORD MOTOR CO.
    50. NOTE: If the crankshaft pulley is not secured within four minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 48: Applying Silicone Gasket & Sealant To Crankshaft Pulley Keyway
    G03421857Courtesy of FORD MOTOR CO.
  50. Apply silicone gasket and sealant to the crankshaft pulley keyway.
  51. Using the special tool, install the crankshaft pulley.
    Fig 49: Installing Crankshaft Pulley
    G03421858Courtesy of FORD MOTOR CO.
  52. Install the washer and a new bolt and tighten in two stages.
    • Stage 1: Tighten to 80 N.m (59 lb-ft).
    • Stage 2: Tighten an additional 80 degrees.
    • Remove the flexplate holding tool.
  53. Install a new seal and the oil filter adapter.
    Fig 50: Installing Oil Filter Adapter
    G03421859Courtesy of FORD MOTOR CO.
  54. Install the oil filter.
    • Install the oil filter until the seal makes contact.
    • Tighten an additional 270 degrees.
    Fig 51: Installing Oil Filter
    G03421860Courtesy of FORD MOTOR CO.
    55. NOTE: The gaskets are marked top to aid in installation.
    NOTE: LH shown; RH similar.
    Fig 52: Installing Exhaust Manifolds
    G03421861Courtesy of FORD MOTOR CO.
  55. Install the new exhaust manifold gaskets, the exhaust manifolds and the new bolts.
  56. Install the starter motor.
    Fig 53: Installing Starter Motor
    G03421862Courtesy of FORD MOTOR CO.
    57. NOTE: Lubricate the water pump O-ring seal with engine coolant. Use the same coolant that was drained from the engine.
  57. Install the water pump.
    • Inspect the O-ring seal and install a new O-ring seal as necessary.
    • Position a new water pump gasket.
    • Position the water pump.
    • Install the bolts and tighten in two stages.
      • Stage 1: Tighten to 8 N.m (71 lb-in).
      • Stage 2: Tighten an additional 90 degrees.
      Fig 54: Identifying Water Pump
      G03421863Courtesy of FORD MOTOR CO.
    58. NOTE: RH shown; LH similar.
    Fig 55: Installing Gaskets
    G03421864Courtesy of FORD MOTOR CO.
  58. Inspect and install new gaskets as necessary.
    59. NOTE: RH shown; LH similar.
    NOTE: If the valve covers are not secured within four minutes of sealant application the sealant must be removed and the sealing area cleaned with metal surface cleaner. Allow to dry until there is no sign of wetness, or four minutes, whichever is longer. Failure to follow this procedure can cause future oil leakage.
    Fig 56: Silicone Gasket Application Locations
    G03421865Courtesy of FORD MOTOR CO.
  59. Apply four beads of silicone gasket and sealant as shown.
    60. NOTE: RH shown; LH similar.
    Fig 57: Valve Cover Bolt Tightening Sequence
    G03421866Courtesy of FORD MOTOR CO.
  60. Install the valve covers.
    • Tighten the bolts in the sequence shown.
    61. NOTE: Lubricate the O-ring with clean engine oil.
    Fig 58: Installing Oil Level Indicator & Tube
    G03421867Courtesy of FORD MOTOR CO.
  61. Install the oil level indicator and tube. Install the nut.
  62. Install the eight ignition coils.
    Fig 59: Installing Ignition Coils
    G03421868Courtesy of FORD MOTOR CO.
  63. Install the four bolts and the thermostat housing.
    Fig 60: Installing Thermostat Housing
    G03421869Courtesy of FORD MOTOR CO.
  64. Install the intake manifold and tighten the bolts and stud bolt (2) in the sequence shown.
    • Inspect and install a new gasket if necessary.
    Fig 61: Intake Manifold Bolts & Stud Bolt Tightening Sequence
    G03421870Courtesy of FORD MOTOR CO.
  65. Position the wiring harness and install the nuts.
    Fig 62: Installing Wiring Harness
    G03421871Courtesy of FORD MOTOR CO.
  66. Install the bracket.
    Fig 63: Installing Bracket
    G03421872Courtesy of FORD MOTOR CO.
  67. Install the exhaust manifold to Exhaust Gas Recirculation (EGR) valve tube. Finger-tighten both fittings. Tighten the upper fitting.
    Fig 64: Installing Exhaust Manifold-To-EGR Valve Tube
    G03421873Courtesy of FORD MOTOR CO.
  68. Tighten the lower fitting.
    Fig 65: Tightening Lower Fitting
    G03421874Courtesy of FORD MOTOR CO.
  69. Connect the fuel injector connectors and position the engine wiring harness.
    Fig 66: Installing Engine Wiring Harness
    G03421875Courtesy of FORD MOTOR CO.
  70. Install the bracket and the two nuts.
    Fig 67: Installing Bracket & Nuts
    G03421876Courtesy of FORD MOTOR CO.
  71. Install the water outlet pipe.
    • Inspect and install a new gasket if necessary.
    • Install the four bolts.
    • Connect the hoses.
    Fig 68: Installing Water Outlet Pipe
    G03421877Courtesy of FORD MOTOR CO.
  72. Connect the knock sensor connector and install onto the bracket.
    Fig 69: Connecting Knock Sensor Connector
    G03421878Courtesy of FORD MOTOR CO.
  73. Install the CHT sensor and KS electrical connectors on the bracket.
    Fig 70: Connecting CHT Sensor & KS Electrical Connectors
    G03421879Courtesy of FORD MOTOR CO.
  74. Connect the fuel pressure sensor electrical connector.
    Fig 71: Connecting Fuel Pressure Sensor Electrical Connector
    G03421880Courtesy of FORD MOTOR CO.
  75. Connect the HO2S connectors to the brackets.
    Fig 72: Connecting HO2S Connectors
    G03421881Courtesy of FORD MOTOR CO.
  76. Remove the special tool, install the CKP sensor.
    Fig 73: Installing CKP Sensor
    G03421882Courtesy of FORD MOTOR CO.
  77. Connect the CKP sensor connector.
    Fig 74: Connecting CKP Sensor Connector
    G03421883Courtesy of FORD MOTOR CO.
  78. Connect the two pin-type retainers.
    Fig 75: Connecting Pin-Type Retainers
    G03421884Courtesy of FORD MOTOR CO.
  79. Install the wiring harness to the front cover on the LH side.
    Fig 76: Installing Wiring Harness To Front Cover On LH Side
    G03421885Courtesy of FORD MOTOR CO.
  80. Install the wiring harness to the front cover on the RH side.
    Fig 77: Installing Wiring Harness To Front Cover On RH Side
    G03421886Courtesy of FORD MOTOR CO.
  81. Install the power steering pump bracket.
    Fig 78: Installing Power Steering Pump Bracket
    G03421887Courtesy of FORD MOTOR CO.
  82. Install the power steering pump.
    Fig 79: Installing Power Steering Pump
    G03421888Courtesy of FORD MOTOR CO.
  83. Connect the Power Steering Pressure (PSP) switch.
    Fig 80: Connecting PSP Switch
    G03421889Courtesy of FORD MOTOR CO.
  84. Install the hydraulic cooling fan pump bracket.
    Fig 81: Installing Hydraulic Cooling Fan Pump Bracket
    G03421890Courtesy of FORD MOTOR CO.
  85. Install the hydraulic cooling fan pump.
    Fig 82: Installing Hydraulic Cooling Fan Pump
    G03421891Courtesy of FORD MOTOR CO.
  86. Connect the electrical connector.
    Fig 83: Connecting Electrical Connector
    G03421892Courtesy of FORD MOTOR CO.
  87. Install the A/C compressor.
    Fig 84: Installing A/C Compressor
    G03421893Courtesy of FORD MOTOR CO.
  88. Connect the electrical connector and the retaining clip.
    Fig 85: Connecting Electrical Connector
    G03421894Courtesy of FORD MOTOR CO.
    89. CAUTION: The generator must be installed in the order shown or damage to the drive belt can occur.
  89. Position the generator and loosely install the bolts and nut.
    • Tighten the upper bolt and nut.
      Fig 86: Installing Generator
      G03421895Courtesy of FORD MOTOR CO.
  90. Tighten the lower expanding bushing and bolt in two stages.
    • Stage 1: Tighten to 20 N.m (15 lb-ft).
    • Stage 2: Tighten an additional 90 degrees.
    Fig 87: Tightening Lower Expanding Bushing & Bolt
    G03421896Courtesy of FORD MOTOR CO.
  91. Tighten the bolt.
    Fig 88: Tightening Bolt
    G03421897Courtesy of FORD MOTOR CO.
  92. Connect the electrical connector.
    Fig 89: Connecting Generator Electrical Connector
    G03421898Courtesy of FORD MOTOR CO.
  93. Install the two idler pulleys.
    Fig 90: Installing Idler Pulleys
    G03421899Courtesy of FORD MOTOR CO.
  94. Position the water pump pulley and loosely install new bolts.
  95. Install the drive belt tensioner. For additional information, refer to SPECIFICATIONS & DRIVE BELT ROUTING .
  96. Tighten the water pump pulley bolts in two stages.
    • Stage 1: Tighten to 10 N.m (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
    Fig 91: Tightening Water Pump Pulley Bolts
    G03421900Courtesy of FORD MOTOR CO.
  97. Install the inlet tube support bracket.
    Fig 92: Installing Inlet Tube Support Bracket
    G03421901Courtesy of FORD MOTOR CO.
  98. Install the six wiring harness retainers.
    Fig 93: Installing Wiring Harness Retainers
    G03421902Courtesy of FORD MOTOR CO.
  99. Connect the fuel injector connectors and position the engine wiring harness.
    Fig 94: Installing Engine Wiring Harness
    G03421903Courtesy of FORD MOTOR CO.
  100. Connect the eight ignition coil connectors.
    Fig 95: Connecting Ignition Coil Connectors
    G03421904Courtesy of FORD MOTOR CO.
    101. CAUTION: Make sure that the wiring harness inlet seals are seated in the valve covers or damage to the wiring harness can occur.
    Fig 96: Installing Ignition Coil Covers
    G03421905Courtesy of FORD MOTOR CO.
  101. Install the ignition coil covers.
    102. NOTE: Clean and inspect the gasket. Install a new gasket if necessary.
    Fig 97: Installing Throttle Body
    G03421906Courtesy of FORD MOTOR CO.
  102. Install the throttle body.
  103. Connect the hoses (1) and install the hose in the clip (2).
    Fig 98: Connecting Hoses
    G03421907Courtesy of FORD MOTOR CO.
  104. Connect the Positive Crankcase Ventilation (PCV) line.
    Fig 99: Connecting PCV Line
    G03421908Courtesy of FORD MOTOR CO.
  105. Connect the Idle Air Control (IAC) and Throttle Position Sensor (TPS) electrical connectors.
    Fig 100: Connecting IAC & TPS Electrical Connectors
    G03421909Courtesy of FORD MOTOR CO.
  106. Connect the air assist valve hose.
    Fig 101: Connecting Air Assist Valve Hose
    G03421910Courtesy of FORD MOTOR CO.
  107. Connect the EGR and vacuum regulator solenoid electrical connections.
    Fig 102: Connecting EGR & Vacuum Regulator Solenoid Electrical Connectors
    G03421911Courtesy of FORD MOTOR CO.
  108. Connect the CMP sensor connector and connect the connector locator.
    Fig 103: Connecting CMP Sensor Connector
    G03421912Courtesy of FORD MOTOR CO.
  109. Connect the exhaust manifold to EGR valve tube.
    Fig 104: Connecting Exhaust Manifold-To-EGR Valve Tube
    G03421913Courtesy of FORD MOTOR CO.
  110. Connect the vacuum hose.
    Fig 105: Connecting Vacuum Hose
    G03421914Courtesy of FORD MOTOR CO.
  111. Connect the vacuum harness.
    Fig 106: Connecting Vacuum Harness
    G03421915Courtesy of FORD MOTOR CO.
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