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Intake Manifold: Installation

    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges, which make leak paths. Use a plastic scraping tool to clean the surfaces.
  1. Clean the gasket sealing surfaces.
  2. Install new gaskets, the intake manifold, the 7 bolts and the 3 studs in the sequence shown.
    • Tighten to 20 Nm (15 lb-ft).
      Fig 1: Identifying Intake Manifold Bolts And Studs Tightening Sequence
      G04690246Courtesy of FORD MOTOR CO.
  3. Connect the 2 throttle body coolant tubes.
  4. Install the radio interference ignition capacitors and nuts.
    • Tighten to 10 Nm (89 lb-in).
  5. Install the engine wiring harness retainer and the 2 nuts.
    • Tighten to 10 Nm (89 lb-in).
      Fig 2: Locating Engine Wiring Harness Retainer And Nuts
      G04690247Courtesy of FORD MOTOR CO.
  6. Connect the 8 fuel injectors and the radio interference ignition capacitor electrical connectors.
    Fig 3: Locating Fuel Injector And Radio Interference Capacitor Electrical Connectors
    G04690248Courtesy of FORD MOTOR CO.
  7. Install the 2 engine appearance cover brackets and the 4 nuts.
    • Tighten to 6 Nm (53 lb-in).
  8. Attach the engine wiring harness to the engine appearance cover brackets.
  9. Attach the vacuum harness retainers to the LH engine appearance cover bracket.
  10. Connect the vacuum supply tube.
    Fig 4: Locating Vacuum Supply Tube
    G04690249Courtesy of FORD MOTOR CO.
  11. Install the crankcase ventilation tube.
  12. Connect the EGR system module-to-exhaust manifold tube to the EGR system module.
    • Tighten to 40 Nm (30 lb-ft).
  13. Connect the EGR system module electrical connector and the vacuum harness to the EGR system module.
  14. Connect the fuel rail temperature sensor electrical connector.
  15. Connect the EVAP hose to the intake manifold.
  16. Connect the throttle body electrical connector.
  17. Connect the fuel pressure sensor electrical connector and vacuum hose.
  18. Connect the TP sensor electrical connector.
  19. Install the 6 bolts and the cross-vehicle brace.
    • Tighten to 20 Nm (15 lb-ft).
  20. Connect the fuel supply tube spring lock coupling to the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  21. Install the cowl panel grille. For additional information, refer to FRONT END BODY PANELS .
  22. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
    23. CAUTION: The engine appearance cover is equipped with a noise suppressor. If the noise suppressor becomes separated from the engine appearance cover it must be positioned on the intake manifold prior to installing the engine appearance cover.
    Fig 5: Locating Noise Suppressor And Engine Appearance Cover
    G04690250Courtesy of FORD MOTOR CO.
  23. Install the noise suppressor (if detached) and the engine appearance cover.
  24. Connect the battery ground cable. For additional information, refer to BATTERY MOUNTING AND CABLES .
  25. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
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