First clean all sealing surfaces of the 5.4L engine using a plastic scraper tool to prevent leaks from developing because of scratches. Install the intake manifold gaskets and the intake manifold before starting to run the nine bolts without full torque. The installation of the
Thermostat demands placement of a new O-ring before attaching the thermostat housing while its bolts need loose installation but require a systematic tightening process starting with 2 Nm (18 inch lbs.) then reaching 25 Nm (18 ft. lbs.). Follow this sequence with the intake manifold bolts. The next step involves mounting the eight
Ignition Coils followed by their bolt installation then connecting the eight fuel injector electrical connectors and eight ignition coil electrical connectors lastly. Start by setting the
Throttle Body assembly and adapter component before placing the new gasket and attaching the adapter to the body. Follow these two steps when attaching the exhaust manifold-to-EGR valve tube: Begin by hand-tightening then progress to tightening the fittings to 50 Nm (37 ft. lbs.). Install the differential pressure EGR sensor hoses on the EGR valve tube while also connecting
Brake Booster and main engine vacuum harnesses, the IAC electrical connector, the EGR vacuum hose and EGR vacuum regulator solenoid connections. Connect the fuel pressure sensor vacuum hose along with its electrical connector and after that mount the evaporative emission
Canister Purge Valve with its bracket and attach all its purge valve hoses and IAC fresh air hose. Install all fittings for auxiliary heater hoses while also hooking up fuel hose spring lock couplings if they apply. The next sequence of installation includes the differential pressure feedback EGR system bracket followed by the
Accelerator Cable routing bracket and the generator upper support bracket, the transmission fluid filler tube bracket and bolt. Connect the EGR sensor through electrical connector attachment followed by hose installation and connect the TP sensor through installation of its electrical connector and routing strap. After connecting the coolant hoses with the upper radiator hose you must install all throttle controls that include the accelerator cable with speed control actuator cable and the throttle return spring together with the accelerator cable snow shield. The air cleaner outlet pipe installation requires tightening the clamp before connecting the two hoses to it, which also includes installation of MAF sensor and ACL placement followed by bolt fixation and clamp tightening. To finish the task you should place the interior engine cover in place while connecting the battery ground cable and filling and bleeding the engine cooling system.