Intake Manifold: Installation

All vehicles 

1. Install the intake manifold.
   • Position the intake manifold gaskets.
   • Position the intake manifold.
   • Loosely install the nine bolts.
   Fig 1: Positioning Intake Manifold Gaskets

   Courtesy of FORD MOTOR CO.
2. Install the water thermostat.
   • Install the thermostat.
   • Install a new O-ring seal.
   Fig 2: Installing Water Thermostat

   Courtesy of FORD MOTOR CO.
NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts. Do not tighten the thermostat housing bolts during thermostat installation.
3. Install the water thermostat housing and loosely install the bolts.
Fig 3: Installing Water Thermostat Bolts Loosely
Courtesy of FORD MOTOR CO.
4. Tighten the bolts in two stages, in the sequence shown.
   1. Stage 1: Tighten to 2 Nm (18 lb-in).
   2. Stage 2: Tighten to 25 Nm (18 lb-ft).
   Fig 4: Intake Manifold Bolts Tightening Sequence

   Courtesy of FORD MOTOR CO.
5. Install the heater water hose and position the clamp.
   Fig 5: Installing Heater Water Hose

   Courtesy of FORD MOTOR CO.
6. Connect the eight fuel injector electrical connectors.
   Fig 6: Connecting Eight Fuel Injector Electrical Connectors

   Courtesy of FORD MOTOR CO.
7. Install the eight ignition coils.
   Fig 7: Installing Eight Ignition Coils

   Courtesy of FORD MOTOR CO.
8. Connect the eight ignition coil electrical connectors.
   Fig 8: Connecting Ignition Coil Electrical Connectors

   Courtesy of FORD MOTOR CO.
9. Position the vacuum harness and connect the fuel pressure regulator vacuum hose.
   Fig 9: Positioning Vacuum Harness

   Courtesy of FORD MOTOR CO.
10. Connect the PCV valve tube to the intake manifold.
    Fig 10: Connecting PCV Valve Tube To Intake Manifold

    Courtesy of FORD MOTOR CO.
11. Connect the fuel tubes and install the safety clips.
    Fig 11: Connecting Fuel Tubes

    Courtesy of FORD MOTOR CO.
12. Install a new throttle body adapter gasket.
    Fig 12: Installing Throttle Body Adapter Gasket

    Courtesy of FORD MOTOR CO.
13. Install the throttle body adapter.
    • Position the throttle body adapter.
    • Install the four bolts.
    Fig 13: Installing Bolts

    Courtesy of FORD MOTOR CO.

    Vehicles with EGR system 

14. Connect the EGR valve vacuum hose.
    Fig 14: Connecting EGR Valve Vacuum Hose

    Courtesy of FORD MOTOR CO.
15. Connect the EGR vacuum regulator solenoid connections.
    Fig 15: Connecting EGR Vacuum Regulator Solenoid Connections

    Courtesy of FORD MOTOR CO.
16. Install the differential pressure feedback EGR system bracket.
    Fig 16: Installing Differential Pressure Feedback EGR System Bracket

    Courtesy of FORD MOTOR CO.
17. Connect the exhaust manifold to EGR valve tube upper fitting.
    • Tighten both fittings starting at the top in three steps.
      • Hand-tighten.
      • Tighten the upper fitting to 40-60 Nm (30-44 lb-ft).
      • Tighten the lower fitting to 40-60 Nm (30-44 lb-ft).
    Fig 17: Connecting Exhaust Manifold To EGR Valve Tube Upper Fitting

    Courtesy of FORD MOTOR CO.

    All vehicles 

18. Connect the IAC electrical connector.
    Fig 18: Connecting IAC Electrical Connector

    Courtesy of FORD MOTOR CO.
19. Connect the brake booster vacuum hose and main vacuum harness to the throttle body adapter.
    Fig 19: Connecting Brake Booster Vacuum Hose And Main Vacuum Harness To Throttle Body Adapter

    Courtesy of FORD MOTOR CO.
20. Connect the evaporative emission canister purge valve vacuum hose to the throttle body adapter.
    Fig 20: Connecting Evaporative Emission Canister Purge Valve Vacuum Hose To Throttle Body Adapter

    Courtesy of FORD MOTOR CO.
21. Install the IAC fresh air tube and insert it in the routing clip.
    Fig 21: Installing IAC Fresh Air Tube

    Courtesy of FORD MOTOR CO.
22. Connect the TP sensor electrical connector.
    Fig 22: Connecting TP Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
23. Install the accelerator cable bracket.
    • Position the accelerator cable bracket.
    • Install the bolts.
    Fig 23: Installing Bolts

    Courtesy of FORD MOTOR CO.
24. Connect the throttle body cam.
    • Connect the accelerator cable.
    • If equipped, connect speed control cable.
    • Install the return spring.
    Fig 24: Connecting Throttle Body Cam

    Courtesy of FORD MOTOR CO.
25. Install the accelerator control splash shield.
    Fig 25: Installing Accelerator Control Splash Shield

    Courtesy of FORD MOTOR CO.
26. Position the generator and install the lower mounting bolts.
    Fig 26: Installing Lower Mounting Bolts

    Courtesy of FORD MOTOR CO.
27. Install the generator upper mounting bracket stud and bolt.
    Fig 27: Installing Generator Upper Mounting Bracket Stud And Bolt

    Courtesy of FORD MOTOR CO.
28. Install the harness routing clips on the generator stud and the engine front cover.
    Fig 28: Installing Harness Routing Clips On Generator Stud And Engine Front Cover

    Courtesy of FORD MOTOR CO.

    Vehicles without A/C 

29. Rotate the belt tensioner counterclockwise and install the belt on the generator pulley.
    Fig 29: Installing Belt On Generator Pulley

    Courtesy of FORD MOTOR CO.

    Vehicles with A/C 

30. Rotate the belt tensioner clockwise and install the belt on the generator pulley.
    Fig 30: Installing Belt On Generator Pulley

    Courtesy of FORD MOTOR CO.

    All vehicles 

31. Install the upper radiator hose and reposition the clamp.
    Fig 31: Installing Upper Radiator Hose

    Courtesy of FORD MOTOR CO.
32. Position the air cleaner, air cleaner outlet housing and the air cleaner outlet pipe in the vehicle and connect the MAF sensor electrical connector.
    Fig 32: Connecting MAF Sensor Electrical Connector

    Courtesy of FORD MOTOR CO.
33. Join the air cleaner outlet housing to the air cleaner inlet housing and secure the clamp.
    Fig 33: Joining Air Cleaner Outlet Housing To Air Cleaner Inlet Housing

    Courtesy of FORD MOTOR CO.
34. Connect the air cleaner outlet pipe to the throttle body and tighten the clamp.
    Fig 34: Connecting Air Cleaner Outlet Pipe To Throttle Body

    Courtesy of FORD MOTOR CO.
35. Connect the IAC fresh air tube and crankcase ventilation tube to the air cleaner outlet pipe.
    Fig 35: Connecting IAC Fresh Air Tube And Crankcase Ventilation Tube To Air Cleaner Outlet Pipe

    Courtesy of FORD MOTOR CO.
36. Fill the cooling system. Refer to ENGINE COOLING .
37. Connect the battery ground cable.