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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 653 (Engine - 5.4L (2V) - Excursion & F250-F350 Super Duty) >> In-Vehicle Repair >> Intake Manifold >> Installation

Intake Manifold: Installation

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

All vehicles 

  1. Install the intake manifold.
    • Position the intake manifold gaskets.
    • Position the intake manifold.
    • Loosely install the nine bolts.
      Fig 1: Installing Intake Manifold
      G02770461Courtesy of FORD MOTOR CO.
  2. Install the water thermostat.
    • Install the thermostat.
    • Install a new O-ring seal.
      Fig 2: Installing Water Thermostat
      G02770462Courtesy of FORD MOTOR CO.
      Fig 3: Tightening Thermostat Housing Bolts
      G02770463Courtesy of FORD MOTOR CO.
    3. 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.
  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: Tightening Bolts In Sequence
      G02770464Courtesy of FORD MOTOR CO.
  5. Install the heater water hose and position the clamp.
    Fig 5: Installing Heater Water Hose
    G02770465Courtesy of FORD MOTOR CO.
  6. Connect the eight fuel injector electrical connectors.
    Fig 6: Connecting Fuel Injector Electrical Connectors
    G02770466Courtesy of FORD MOTOR CO.
  7. Install the eight ignition coils.
    Fig 7: Installing Ignition Coils
    G02770467Courtesy of FORD MOTOR CO.
  8. Connect the eight ignition coil electrical connectors.
    Fig 8: Connecting Ignition Coil Electrical Connectors
    G02770468Courtesy of FORD MOTOR CO.
  9. Position the vacuum harness and connect the fuel pressure regulator vacuum hose.
    Fig 9: Connecting Fuel Pressure Regulator Vacuum Hose
    G02770469Courtesy of FORD MOTOR CO.
  10. Connect the PCV valve tube to the intake manifold.
    Fig 10: Connecting PCV Valve Tube To Intake Manifold
    G02770470Courtesy of FORD MOTOR CO.
  11. Connect the fuel tubes and install the safety clips.
    Fig 11: Installing Safety Clips
    G02770471Courtesy of FORD MOTOR CO.
  12. Install a new throttle body adapter gasket.
    Fig 12: Installing Throttle Body Adapter Gasket
    G02770472Courtesy of FORD MOTOR CO.
  13. Install the throttle body adapter.
    • Position the throttle body adapter.
    • Install the four bolts.
      Fig 13: Installing Throttle Body Adapter
      G02770473Courtesy of FORD MOTOR CO.

    Vehicles with EGR system 

  14. Connect the EGR valve vacuum hose.
    Fig 14: Connecting EGR Valve Vacuum Hose
    G02770474Courtesy of FORD MOTOR CO.
  15. Connect the EGR vacuum regulator solenoid connections.
    Fig 15: Connecting EGR Vacuum Regulator Solenoid Connections
    G02770475Courtesy of FORD MOTOR CO.
  16. Install the differential pressure feedback EGR system bracket.
    Fig 16: Installing Differential Pressure Feedback EGR System Bracket
    G02770476Courtesy 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
        G02770477Courtesy of FORD MOTOR CO.

    All vehicles 

  18. Connect the IAC electrical connector.
    Fig 18: Connecting IAC Electrical Connector
    G02770478Courtesy 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
    G02770479Courtesy 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
    G02770480Courtesy 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
    G02770481Courtesy of FORD MOTOR CO.
  22. Connect the TP sensor electrical connector.
    Fig 22: Connecting TP Sensor Electrical Connector
    G02770482Courtesy of FORD MOTOR CO.
  23. Install the accelerator cable bracket.
    • Position the accelerator cable bracket.
    • Install the bolts.
      Fig 23: Installing Accelerator Cable Bracket
      G02770483Courtesy 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
      G02770484Courtesy of FORD MOTOR CO.
  25. Install the accelerator control splash shield.
    Fig 25: Installing Accelerator Control Splash Shield
    G02770485Courtesy of FORD MOTOR CO.
  26. Position the generator and install the lower mounting bolts.
    Fig 26: Installing Lower Mounting Bolts
    G02770486Courtesy of FORD MOTOR CO.
  27. Install the generator upper mounting bracket stud and bolt.
    Fig 27: Installing Generator Upper Mounting Bracket Stud And Bolt
    G02770487Courtesy 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
    G02770488Courtesy 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
    G02770489Courtesy 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
    G02770490Courtesy of FORD MOTOR CO.

    All vehicles 

  31. Install the upper radiator hose and reposition the clamp.
    Fig 31: Installing Upper Radiator Hose
    G02770491Courtesy 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
    G02770492Courtesy 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
    G02770493Courtesy 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
    G02770494Courtesy 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
    G02770495Courtesy of FORD MOTOR CO.
  36. Fill the cooling system. Refer to ENGINE COOLING .
  37. Connect the battery ground cable.
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