Ford TW-10 Service Manual page 22

- - - - - - - - - - PART 1 - ENGINE S Y S T E M - - - - - - - - - -
7. Install a new seat washer in each injector bore in
the cylinder head. Position new cork seals over
the injectors.
8. Install each injector into the cylinder head and
over the two studs, as shown in Figure 11. Install
the nut on each stud and tighten progressively to
the specified torque, page 92.
9. Using new copper washers, install the injector
leak-off line.
10. Install a new gasket and the intake manifold onto
the cylinder head. Secure the manifold with the
bolts and lock washers and tighten the bolts to
the specified torque, page 92.
11. Attach the fuel filters to the manifold with two
bolts and flat washers, and connect the fuel
lines.
12. Connect the injector lines to the injection pump
and to the injectors. Position the clamps on the
injector lines in the same position from which
they were removed.
13. Connect cold start equipment where fitted.
14. Position a new exhaust manifold gasket on the
cylinder head and install the exhaust manifold, as
shown in Figure 6. Use new lock tabs and tighten
th bolts to the specified torque, page 92. Bend
the lock tabs to retain the bolts.
TW10 and TW20:
15. Ford TW10: Bolt the muffler, with a new gasket
installed, to the exhaust manifold.
Ford TW20: Bolt the turbocharger, with a new
gasket installed, to the exhaust manifold. Install
the oil pressure and return lines to the tur-
bocharger and engine.
16. Connect the upper radiator hose to the cylinder
head.
17. Fill the radiator with coolant.
18. Install the rocker cover, installing a new gasket,
and tighten the bolts to the specified torque,
page 92. Connect the ventilating tube.
16
19. Lift the air cleaner and support assembly into
place and attach with the hardware previously
removed.
20. Ford TW10: Attach the muffler to the air cleaner
support assembly and connect the air intake tube
to the intake manifold.
Ford TW20: Connect the exhaust extension to
the turbocharger exhaust outlet and attach it to
the air cleaner support assembly. Connect the air
intake tube to the inlet side of the turbocharger
and the air cleaner.
21. Install the fuel tank assembly, Figure 10.
22. Turn on the fuel.
23. Position the wiring harness in the clips on the
support brace and connect the harness at the
alternator and air intake restrictor valve.
24. Install the top hood panel and the pre-cleaner.
25. Install both hood side panels and the radiator
grille panel(s).
26. Bleed the fuel system as described in Part 2,
"FUEL SYSTEM". Start the engine.
TW30
27. Bolt the turbocharger and new gasket to the ex-
haust manifold. Install the oil lines between the
turbocharger and the engine. Install the water
pump if removed. Use a new gasket.
28. Install the thermostat - fan hub housing. Attach
the radiator hose and heater hose, Figure 9.
29. Install the intercooler support bracket at the rear
of the engine, Figure 8.
30. Install the intercooler, Figure 7.
31. Connect the intercooler-to-turbo tube. Connect
the aspirator hoses.
32. Install the air cleaner. Connect the air cleaner-to-
turbo tube.
33. Attach the grille support, Figure 6.
34. Install the hood panel, grille and side panels,
Figure 1.