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Upper Intake Manifold: Installation

  1. Install new intake manifold gaskets and position the intake manifold.
  2. Install the 8 intake manifold bolts and tighten the upper intake manifold bolts in 2 stages in the sequence shown.
    • Stage 1: Tighten to 6 Nm (53 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
      Fig 1: Identifying Tightening Sequence Of Intake Manifold Bolts
      G04660272Courtesy of FORD MOTOR CO.
  3. Connect the 2 engine harness pin-type retainers.
    Fig 2: Locating Engine Harness Pin-Type Retainers
    G04660273Courtesy of FORD MOTOR CO.
  4. Connect the 4 engine harness pin-type retainers.
    Fig 3: Locating Engine Harness Pin-Type Retainers
    G04660274Courtesy 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 valve 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 to the intake manifold.
  16. Connect the EVAP 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. Attach the engine harness retainers to the accelerator cable bracket stud bolt and the TP sensor 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 pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  23. Install the cowl top panel and the bolts.
    • Tighten to 6 Nm (53 lb-in).
      Fig 4: Locating Cowl Top Panel Bolts
      G04004019Courtesy of FORD MOTOR CO.
  24. Connect the windshield wiper motor electrical connector.
    Fig 5: Locating Windshield Wiper Motor Electrical Connector
    G04004018Courtesy of FORD MOTOR CO.
  25. Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
  26. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
  27. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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