C.Four Barrel Carburetor and Associated Hardware Installation

Figure 20:

Figure 21:

1. Apply a 1/8 inch bead of RTV sealer (D6AZ- 19562-B or equivalent) at the extremities of the end seal mounting surface (4 places) as shown in Figure 20. Also apply a 1/16" bead of the RTV sealer to the outer end of each intake manifold end seal (2 places each end seal, E3AE-9A425-BA and E3AE-9A424-BA), as shown in Figure 21.

NOTE: This sealer sets up in 15 minutes, so it is important that assembly be completed promptly. Do not drip any sealer into the engine valley.
2. Position two intake manifold gaskets (E4TE-9439- AA) on the cylinder heads, with the trademark towards the cylinder head. Assemble the end seals with tabs interlocked with notches in the intake manifold gaskets. Press firmly in place along full length of each end seal. Be sure the holes in the gaskets are aligned with the holes in the cylinder heads.

Figure 22:

Figure 23:

3. Carefully lower the intake manifold (E4TE-9424-BA or BB) into position on the cylinder block and cylinder heads. After the intake manifold is in place, run a finger around the seal area to make sure the seals are in place. If the seals are not in place, remove the intake manifold and position the seals.
4. Be sure the holes in the intake manifold gaskets and manifold are in alignment. Reinstall the ten short intake manifold attaching bolts in positions 1 through 9 and position 11, as shown in Figures 22 and 23, and hand tighten.
5. Install the intake manifold heat control valve (E3TE- 9G464-F1C) and associated gasket (E4TE-9E486- AA), and hand tighten two attaching bolts. Reference Figure 23.
6. Tighten all bolts in sequence as shown in Figure 22 to 23-25 ft.lbs.
7. Install vacuum hose from brake booster to rear vacuum tree.
8. Install the vacuum hose that is treed from transmission and air conditioning (labeled in step 10, Section A of this procedure) to the rear vacuum tree.

Figure 24:

9. To the EGR spacer, attach the two EGR studs, gasket, EGR valve, and two nuts, as shown in Figure 24. Tighten the nuts to 12-18 ft.lbs.

Figure 25:

10. Remove the hole covering, then set the -9447- gasket and the EGR spacer assembly in place (Figure 25). Plug the carb ports with a clean rag.
11. Reinstall the PCV valve, and connect the PCV hose to the EGR spacer left nipple.
12. Attach the 381336-S20 hose to the EGR spacer right nipple, and let dangle over right front side of engine (later connected to purge system).
13. Remove the port covering, and install the gasket, heat shield, spacer, carburetor assembly, and four nuts, as shown in Figure 25. Cover the carburetor with a clean rag, then tighten the nuts to 12-15 ft.lbs.

Figure 26:

Figure 27:

14. Install new transmission kickdown rod.
15. Install the appropriate carbon canister bracket as shown in Figure 26 for 4x2 applications or Figure 27 for 4x4 applications. The canister mounting holes should already be in the frame. On 4x2 applications, use the three nuts and bolts from the kit, and tighten the nuts to 14-22 ft.lbs. On 4x4 applications, use the four self tapping bolts from kit and tighten to 100-140 in.lbs.
16. Install the carbon canister as shown in Figure 26 or 27, using the self tapping bolt from the kit. Tighten to 40-55 in.lbs.
17. Cut the rubber hose from the rear canister to the steel fuel tank vapor return tube, about 4 inches from the canister. Insert the tee (373846-S), and attach the seventeen inch length of 3/16 inch ID rubber hose from the tee to the upper canister.
18. Reinstall the thermostat and housing, using the new gasket and bolts from the kit. Remove the plug in the top of the thermostat housing and install the remaining yellow 3 port PVS from the kit, using sealer (B5A-19554-A or D7AZ-19554-B) on the threads. Tighten to 6-10 ft.lbs., then rotate clockwise only until the nipples are oriented pointing to the right.
19. Remove the existing spark plugs, and install the ASF-32-C spark plugs from the kit (Gap .042 to .046).
20. Install the new distributor, positioning such that the new rotor will be oriented to #1 TDC on the new cap. Install attaching hold down clamp, but do not tighten at this time. Attach a vacuum line from the distributor to the carburetor spark port, located underneath the front fuel bowl.

Figure 28:

Figure 29:

21. Remove the two inch length of hose that is attached to one of the solenoids in the hose and valve assembly (E4TE-9C987-GB/KA) included in the kit, and attach that two inch hose to the vapor return port on the front of the carburetor (Figures 28 and 29). Remove the three inch length of hose that is attached to the other solenoid, and attach that three inch hose to the vapor return port on the rear of the carburetor. Install the two, thermo vent valves (D8TE-9E589-BA) to these hoses, with the black side toward the carburetor. Attach the remainder of the hose and valve assembly (E4TE-9C987-GB/KA) to the carbon canisters. Cut two pieces of the 42 inch length of 7/16 hose included in the kit to the required length, (approximately 21 inches rear and 14 inches front are required), and install these hoses between the -9E589- thermo vent valves and the solenoids on the purge hose and valve assy. Route the hoses such that vapors from the front of the carburetor are vented to the upper canister, and vapors from the rear of the carburetor are vented to the newly installed lower canister. Tie down with bundling straps to the inner R fender vertical section using existing holes. Again, make sure a downward slope is maintained for the entire length of the purge system.
22. Connect the hose from the EGR spacer right nipple to the 6 inch hose on the purge hose and vacuum assembly using a connector supplied in the kit (Figure 29).

Figure 31:

23. Plumb the vacuum harness (Figure 31) by laying it next to the carburetor, on the right side of the engine with PVS connections to front of engine. Clip the 2 port PVS system into the 2 port PVS. Clip the 3 port PVS system that has a white vacuum line to the PVS on the thermostat housing. Attach the remaining 3 port PVS connector to the PVS at the heater hose outlet. At the top port of the heater hose outlet PVS is a tee with a capped short hose and a 6 inch red hose leading to another tee. To this tee, attach the pink hose from the thermactor air bypass valve.

Figure 29:

From the center port of the thermostat housing PVS is an 11 inch black hose. Remove the plug from this hose and connect to the open nipple on the purge hose and valve assembly (Figure 29).
Attach the green hose from the top of the 2 port PVS to the EGR valve. From the bottom port of the 2 port PVS is a 3 inch white hose that leads to a tee with one port capped and a 4 inch white hose at the other port. Connect this 4 inch white hose to the EGR port of the carburetor, located in upper right area of the carburetor near the choke housing.
Also from the bottom port of the 2 port PVS is a 14 inch white hose, the other end of which is capped. In the vicinity of this cap, from hoses that are taped to the 14 inch white hose, are the following: a hose with a capped straight blue connector, a tee with one nipple capped, a 6 inch orange hose, and a long red hose. Leave the 14 inch white hose capped, leave the straight blue connector capped, and leave the tee capped. Attach the 6 inch orange hose to the intake manifold heat control valve. Attach the long red hose to the rear vacuum tree.

On the vacuum harness and in the vicinity of the carburetor choke cap is a black and blue check valve with a 1-1/2 inch black hose leading to a tee. Remove the cap from this tee, and connect the pink hose from the thermactor exhaust air control valve.
24. Taped to the green EGR vacuum hose is a long orange hose. Plug this orange hose if the vehicle does not have an exhaust heat control valve. On vehicles that are equipped with an exhaust heat control valve (calibrations 1-64T-R15B and R16B), attach the orange hose to that valve.
25. Cut and remove the wires at the crankshaft position sensor (not used).
26. For air conditioned vehicles only, reinstall the previously removed (Step All) blue and red hose and connector assembly as follows: Clip the connector to the air conditioning solenoid. Connect the blue hose to the throttle kicker. Connect the long red hose to the front intake manifold tree, and plug the short red hose.
27. Cap any remaining ports on the vacuum trees and PVS valves.
28. Remove the EEC III ignition module and replace it with the D8VE-12A199-A1C Duraspark ignition module from the kit.

Figure 30:

29. Install electrical harness (Figure 30) by laying the harness across the left rocker arm cover, with the three quick disconnects toward the ignition module. Apply dielectric grease to electrical connections, and attach the three quick disconnects. Attach the coil connector to the coil, attach the condenser wire (gray connector), and attach the distributor connection. Attach the red and white striped wire to the coolant temperature sensor on top of the intake manifold. Attach the insulated wire to the oil pressure switch. Tie down with bundling straps as required to prevent chafing.
30. Fabricate a ground to the two purge solenoids, by removing existing eyelets and adding by 5" of 16GA wire to a common ground. From the hot lead to each of those solenoids, run a wire to the line on the wiring harness that has a blue connector, and splice in. Tie back the blue connector.
31. Connect the choke wire included in the kit to the choke, cap terminal, and to the gray connector on the stator lead. Follow the wire from the gray connector and splice in near the regulator located on the fender apron (for better access).
32. On air conditioned vehicles only, splice into the two wires at the air conditioning clutch and connect to the two terminals at the air conditioning kicker solenoid, located over the left rocker arm cover. This requires (2) 24 inch lengths of 16GA wire. Add spade terminals and attach to the A/C kicker solenoid.
33. Install coil assembly (suppressor) from kit.
34. Install the new distributor rotor. Install the new distributor adaptor, and distributor cap. Reinstall the coil-to-distributor wire and the spark plug wires, starting at #1 on the distributor cap going counterclockwise to the firing order 13726548. (If the number 1 spark plug wire (12286) is replaced, use E3PZ-12286-EA.)

35. Using the new accelerator control bracket from the kit, install the bracket and ground strap to the intake manifold and attach the accelerator cable to the carburetor.
36. Attach the heater hose to the intake manifold fitting and attach the upper radiator hose.
37. Close the petcock and add coolant.
38. Attach the new fuel inlet line to the fuel pump and to the carburetor.
39. Change the oil and filter, as some coolant may have gotten into the engine.
40. Reconnect the battery.

Figure 22:

41. Start the engine and check for fuel, coolant, and vacuum leaks. Warm the engine to normal operating temperature. Turn off engine, then tighten the intake manifold bolts in sequence (Figure 22) to 23-25 ft.lbs.
42. Set the timing to the 10 ~ BTDC per procedure on decal, and tighten distributor clamp.
43. Set the idle speeds per procedure on decal, 1900 RPM on hi cam and 650 RPM at curb idle.
44. Remove the duct and valve assembly from the old air cleaner and install it on the new air cleaner, with the yellow vacuum hose connected to the valve. Remove one cap from the front vacuum tree and route a 20 inch vacuum hose from that nipple to the remaining connection on the air cleaner.
45. Install the carburetor-to-air cleaner stud.
46. Install the new oil filter cap, grommet, hose, and elbows.
47. Set the air cleaner gasket in place, and install the air cleaner making the associated vacuum connections.

Figure 32:

48. Install a Ford modification decal as shown below. See Figure 31 for vacuum schematic and Figure 32 for carburetor and distributor specifications.

NOTE: A $300.00 exchange charge will be added to the kit price. All kits include a special parts return form (FPS-8467). The $300.00 exchange charge will be refunded after the return form and the parts listed below are returned to WPRC.