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Intake Manifold: Installation

WARNING: This page is about a different car, the 2006 Mercury Grand Marquis and 2006 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Align the gasket locator tabs with the slots in the cylinder head.
    Fig 1: Installing Intake Manifold Gaskets
    G04583410Courtesy of FORD MOTOR CO.
  1. Install new intake manifold gaskets.
  2. Install the intake manifold and hand-tighten the 8 bolts.
  3. Install the 8 ignition coil-on-plugs. For additional information, refer to ENGINE IGNITION .
  4. Position the intake manifold crash bracket and loosely install the bolt and stud bolt.
  5. Tighten the bolts in the sequence shown.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 2: Tightening Bolts In Sequence
      G04583411Courtesy of FORD MOTOR CO.
  6. Tighten the intake manifold crash bracket bolt.
    • Tighten to 25 Nm (18 lb-ft).
  7. Install the exhaust gas recirculation (EGR) system module tube. For additional information, refer to ENGINE EMISSION CONTROL .
  8. Install the intake manifold shield and the 2 bolts.
    • Tighten to 12 Nm (9 lb-ft).
  9. Connect the throttle control and the TP sensor electrical connectors.
  10. Install the coolant thermostat. For additional information, refer to ENGINE COOLING .
  11. Install the generator bracket and the 4 bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
  12. Connect the generator electrical connector.
  13. Connect the evaporative emission (EVAP) canister purge valve hoses to the TB and the EVAP canister purge valve. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  14. Connect the intake manifold vacuum hose to the TB spacer.
  15. Connect the EGR system module vacuum and electrical connectors.
  16. Connect the PCV tube quick connect coupling to the TB spacer. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  17. Connect the brake booster vacuum hose to the intake manifold.
  18. Install the heater hose and spring clamp.
  19. Connect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
  20. Connect the 8 fuel injector electrical connectors.
  21. Install the wire harness retainer to the rear of the intake manifold.
  22. Attach the wire harness retainer to the LH front fuel rail stud.
  23. If equipped, attach the wire harness retainer to the intake manifold crash bracket.
  24. Connect the ground connector to the RH rear fuel rail stud bolt.
  25. Install the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS AND WASHERS .
  26. Connect the fuel spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  27. Install the air cleaner and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  28. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  29. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
    30. WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .
  30. If equipped with fire suppression system, repower the system.
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