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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 729 (Engine - 6.0L Diesel - F250-F550 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 F550 Super Duty, 2004 Ford F450 Super Duty, 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 

    NOTE: The locating tabs on the gaskets must be up and toward the center of the engine, or a leak will occur.
    Fig 1: Locating Intake Manifold Gasket And Front Module O-Ring Seal
    G03887125Courtesy of FORD MOTOR CO.
  1. Install the intake manifold gaskets and front module O-ring seal.

    2. Late build 

    NOTE: To keep the EGR gasket in place when installing the manifold, apply a slight amount of all purpose grease to the mating surface of the EGR tube.
    NOTE: Install the EGR cooler V-clamp loosely in place on the turbo adapter pipe.
  2. Install the intake manifold and loosely install the bolts. Tighten the intake manifold bolts in the sequence shown.
    1. Tighten bolts 9-16 to 11 N.m (8 lb-ft).
    2. Tighten all bolts to 11 N.m (8 lb-ft) in the sequence shown.
      Fig 2: Installing Intake Manifold Bolts
      G03899126Courtesy of FORD MOTOR CO.
  3. Position the EGR cooler V-clamp over the EGR tube.
  4. Install the gasket and the EGR cooler V-clamp.
    Fig 3: Installing Gasket And EGR Cooler V-Clamp
    G03899127Courtesy of FORD MOTOR CO.
  5. Install the turbocharger heat shield and the nuts.
    Fig 4: Installing Turbocharger Heat Shield Nuts
    G03899128Courtesy of FORD MOTOR CO.

    6. Early build 

  6. Install the intake manifold and bolts and tighten in the following sequence.
    1. Loosely install bolts 1-8.
    2. Tighten bolts 9-16 to 11 N.m (8 lb-ft).
    3. Tighten all bolts to 11 N.m (8 lb-ft) in the sequence shown.
      Fig 5: Bolt Tightening Sequence
      G03899129Courtesy of FORD MOTOR CO.
  7. Tighten the EGR cooler V-clamp.
    Fig 6: Tightening EGR Cooler V-Clamp
    G03899130Courtesy of FORD MOTOR CO.
  8. Install the turbocharger heat shield and the nuts.
    Fig 7: Installing Turbocharger Heat Shield Nuts
    G03899131Courtesy of FORD MOTOR CO.

    9. All vehicles 

  9. Slide the EGR cooler hose forward and rotate flat to lock.
    Fig 8: Sliding EGR Cooler Hose
    G03899132Courtesy of FORD MOTOR CO.
  10. Install the fuel line.
    • Install new sealing washers.
    • Install the fuel line.
    • Install the banjo fitting and the bolt.
      Fig 9: Installing Fuel Line
      G03899133Courtesy of FORD MOTOR CO.
  11. Install the oil filter return tube and bolt.
    • On new oil filter return tubes, tighten to 6 N.m (53 lb-in).
    • On used oil filter return tubes, tighten to 3 N.m (27 lb-in).
      Fig 10: Locating Oil Filter Return Tube Bolt
      G04519770Courtesy of FORD MOTOR CO.
  12. Install the oil filter housing and the four bolts.
    • Clean and inspect the housing O-rings. Install new O-rings if necessary.
      Fig 11: Installing Oil Filter Housing Bolts
      G03899135Courtesy of FORD MOTOR CO.
  13. Connect the fuel line fittings.
    Fig 12: Connecting Fuel Line Fittings
    G03899136Courtesy of FORD MOTOR CO.
  14. Position the fuel injector harness and install the retaining nut. Connect the eight fuel injectors electrical connectors.
    Fig 13: Installing Nut
    G03899137Courtesy of FORD MOTOR CO.
  15. Connect the retaining clip and exhaust backpressure sensor electrical connector.
    Fig 14: Connecting Retaining Clip And Exhaust Backpressure Sensor Electrical Connector
    G03899138Courtesy of FORD MOTOR CO.
  16. Connect the wiring retainer and the IAT2 sensor electrical connector.
    Fig 15: Connecting Wiring Retainer And IAT2 Sensor Electrical Connector
    G03899139Courtesy of FORD MOTOR CO.
  17. Connect the engine coolant temperature (ECT) sensor and the pin-type retainer.
    Fig 16: Identifying Pin-Type Retainer And Engine Coolant Temperature (ECT) Sensor Electrical Connector
    G03887109Courtesy of FORD MOTOR CO.
  18. Connect the EGR throttle position sensor electrical connector.
    Fig 17: Connecting EGR Throttle Position Sensor Electrical Connector
    G03899141Courtesy of FORD MOTOR CO.
  19. Connect the EGR throttle position control module electrical connector.
    Fig 18: Connecting EGR Throttle Position Control Module Electrical Connector
    G03899142Courtesy of FORD MOTOR CO.
  20. Connect the engine oil temperature (EOT) sensor electrical connector.
    Fig 19: Locating Engine Oil Temperature Sensor
    G03887108Courtesy of FORD MOTOR CO.
  21. Connect the engine oil pressure (EOP) sensor electrical connector.
    Fig 20: Locating Engine Oil Pressure Sensor Electrical Connector
    G03887107Courtesy of FORD MOTOR CO.
  22. Connect the EGR valve electrical connector.
    Fig 21: Identifying Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  23. Connect the wiring retainer, injector pressure regulator and ICP sensor (if equipped) electrical connectors.
    Fig 22: Connecting ICP Sensor Electrical Connector And Wire Retainer
    G03899146Courtesy of FORD MOTOR CO.
  24. Position back or install the heat insulating wrap.
    Fig 23: Installing Heat Insulating Wrap
    G03899147Courtesy of FORD MOTOR CO.
  25. Install the top two bolts to the injector IPR heat shield.
    Fig 24: Installing Heat Shield Bolts
    G03899148Courtesy of FORD MOTOR CO.
  26. Install the fuel injector control module. For additional information, refer to ELECTRONIC ENGINE CONTROLS - DIESEL ENGINES .
  27. Connect the engine coolant vent hose and clamp.
    Fig 25: Connecting Engine Coolant Vent Hose Clamp
    G03899149Courtesy of FORD MOTOR CO.
  28. Connect the MAP sensor hose.
    Fig 26: Connecting MAP Sensor Hose
    G03899150Courtesy of FORD MOTOR CO.
    29. NOTE: Install a new O-ring on the heater hose tube.
    Fig 27: Installing Heater Hose Tube Bolts
    G03899151Courtesy of FORD MOTOR CO.
  29. Install the heater hose tube and bolts.

    30. Early build 

    NOTE: Engine side shown, charge air cooler side similar.
    NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler duct to prevent the duct from blowing off.
    Fig 28: Installing Charge Air Cooler Duct
    G03899152Courtesy of FORD MOTOR CO.
  30. Install the charge air cooler duct and tighten the clamps.

    31. Late build 

    NOTE: Engine side shown, charge air cooler side similar.
    NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler duct to prevent the duct from blowing off.
    Fig 29: Installing Charge Air Cooler Duct
    G03899153Courtesy of FORD MOTOR CO.
  31. Install the charge air cooler duct and tighten the clamp.
  32. Install the turbocharger pedestal and turbocharger. For additional information, refer to FUEL CHARGING & CONTROLS - TURBOCHARGER .
  33. Tighten the nuts and bolts in the adapter pipe.
    Fig 30: Tightening Nuts And Bolts
    G03899154Courtesy of FORD MOTOR CO.
  34. Install the generator and the three bolts.
    Fig 31: Installing Generator Bolts
    G03899155Courtesy of FORD MOTOR CO.
  35. Connect the generator B+ wire land electrical connector and position the boot back.
    Fig 32: Connecting Generator B+ Wire Land Electrical Connector
    G03899156Courtesy of FORD MOTOR CO.

    36. Vehicles with single generator 

  36. Install the accessory drive belt.
    Fig 33: Rotating Accessory Drive Belt Tensioner
    G03906750Courtesy of FORD MOTOR CO.

    37. Vehicles with dual generators 

  37. Install the generator with mounting bracket and bolts.
    Fig 34: Locating Bolts And Generator Mounting Bracket - With Torque Specification
    G03887159Courtesy of FORD MOTOR CO.
  38. Connect the B+ wire, generator electrical connector and wire retainer.
    Fig 35: Connecting B+ Wire Generator Electrical Connector
    G03899159Courtesy of FORD MOTOR CO.
  39. Install the accessory drive belt tensioner and bolts.
    Fig 36: Primary Accessory Drive Belt Tensioner Bolts - With Torque Specification
    G03887161Courtesy of FORD MOTOR CO.
  40. Position the accessory drive belt idler pulley. Install the bracket and bolts.
    Fig 37: Secondary Accessory Drive Belt Idler Pulley Bolts - With Torque Specification
    G03887162Courtesy of FORD MOTOR CO.
  41. Install the accessory drive belt.
    Fig 38: Rotating Accessory Drive Belt Tensioner
    G03887088Courtesy of FORD MOTOR CO.
  42. Install the accessory drive belt tensioner and bolt.
    Fig 39: Secondary Accessory Drive Belt Tensioner Bolt - With Torque Specification
    G03907183Courtesy of FORD MOTOR CO.
  43. Install the accessory drive belt.
    Fig 40: Rotating Drive Belt Tensioner Clockwise
    G03887086Courtesy of FORD MOTOR CO.

    44. All vehicles 

    NOTE: Engine side shown, charge air cooler side similar.
    Fig 41: Installing Turbocharger-To-Charge Air Cooler Duct
    G03899165Courtesy of FORD MOTOR CO.
  44. Install the turbocharger-to-charge air cooler duct.
  45. Install the upper radiator hose.
    Fig 42: Installing Upper Radiator Hose
    G03899166Courtesy of FORD MOTOR CO.
  46. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  47. Install the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  48. Install the cooling fan stator - 6.0L diesel engine. For additional information, refer to ENGINE COOLING .
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