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Upper Intake Manifold: Installation

  1. Install new intake manifold gaskets and the intake manifold.
  2. Install the 8 intake manifold bolts and tighten the upper intake manifold bolts in 2 stages in the sequence shown in illustration.
    • Stage 1: Tighten to 6 Nm (53 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
    Fig 1: Installing Intake Manifold Gaskets And Intake Manifold Bolts
    G04003892Courtesy of FORD MOTOR CO.
  3. Connect the 2 engine harness pin-type retainers.
    Fig 2: Connecting Engine Harness Pin-Type Retainers (1 Of 2)
    G04003891Courtesy of FORD MOTOR CO.
  4. Connect the 4 engine harness pin-type retainers.
    Fig 3: Connecting Engine Harness Pin-Type Retainers (2 Of 2)
    G04003890Courtesy of FORD MOTOR CO.
  5. Connect the coolant outlet hose to the intake manifold.
  6. Connect the coolant inlet hose to the intake manifold.
  7. Connect the vacuum tube connector to the upper intake manifold.
    8. CAUTION: Make sure the spark plug boots are positioned so the spark plug wires do not contact the exhaust manifold.
    NOTE: Apply dielectric grease to the inside of the spark plug wire boots before attaching to the spark plugs and the ignition coil.
  8. Install the spark plug wires and pin-type retainers as an assembly.
  9. Connect the crankcase vent hose to the intake manifold.
  10. Connect the TP sensor electrical connector.
  11. Connect the IAC electrical connector.
  12. Connect the EGR system module electrical connector.
  13. Connect the EGR system module vacuum connector.
  14. Position the EGR system module tube and connect the upper and lower module tube fittings.
    • Tighten to 40 Nm (30 lb-ft).
  15. Connect the brake booster vacuum hose and clamp to the intake manifold.
  16. Connect the EVAP emission return tube to the intake manifold.
  17. Position the accelerator cable bracket and install the 2 stud bolts.
    • Tighten to 10 Nm (89 lb-in).
  18. Install the engine harness retainer to the accelerator cable stud bolt.
  19. Connect the speed control cable to the throttle body.
  20. Connect the throttle return spring to the accelerator cable bracket.
  21. Connect the accelerator cable to the throttle body.
  22. Install the engine air cleaner outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  23. Install the wiper motor and pivot assembly. For additional information, refer to WIPERS AND WASHERS .
  24. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  25. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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