Intake Manifold: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Install the intake manifold.
- Position the intake manifold gaskets and the intake manifold, and loosely install the bolts.
  
  Fig 1: Installing Intake Manifold
  Courtesy of FORD MOTOR CO.
Install the thermostat housing.
1. Install the thermostat.
2. Install a new O-ring seal.
  
  Fig 2: Installing New O-Ring Seal
  Courtesy of FORD MOTOR CO.

NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.

Fig 3: Installing Thermostat Housing Bolts

Courtesy of FORD MOTOR CO.

Install the thermostat housing and loosely install the bolts.
Tighten the bolts in the sequence shown in two stages.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).
  
  Fig 4: Tightening Bolts In Sequence
  Courtesy of FORD MOTOR CO.
Connect the pushpin retainer to the intake manifold bracket.

Fig 5: Connecting Pushpin Retainer To Intake Manifold Bracket
Courtesy of FORD MOTOR CO.
Install the screws and the 10 coils.

Fig 6: Installing Screws Coils
Courtesy of FORD MOTOR CO.
Position back the LH fuel charge wiring harness and install the bolts.

Fig 7: Installing Bolts
Courtesy of FORD MOTOR CO.
Position back the RH fuel charging wiring harness and install the stud bolts.

Fig 8: Installing Stud Bolts
Courtesy of FORD MOTOR CO.
Position back the transmission fluid level indicator tube and install the retaining nut.

Fig 9: Positioning Transmission Fluid Level Indicator Tube
Courtesy of FORD MOTOR CO.
Install the retaining nut on the transmission fluid indicator and tube.

Fig 10: Installing Retaining Nut
Courtesy of FORD MOTOR CO.
Connect the 10 ignition coil electrical connectors.

Fig 11: Identifying Ignition Coil Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the 10 fuel injector electrical connectors.

Fig 12: Identifying Fuel Injector Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the fuel rail pressure (FRP) sensor electrical connector.

Fig 13: Connecting Fuel Rail Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the vacuum connector.

Fig 14: Connecting Vacuum Connector
Courtesy of FORD MOTOR CO.
Connect the coolant hose.

Fig 15: Identifying Heater Hose
Courtesy of FORD MOTOR CO.
Install the throttle body adapter gasket and the throttle body and adapter as an assembly.
Tighten the bolts in two stages.
- Stage 1: Tighten the bolts to 9 Nm (80 lb-in).
- Stage 2: Tighten the bolts an additional 90 degrees (1/4 turn).
  
  Fig 16: Tightening Bolts
  Courtesy of FORD MOTOR CO.
Connect the brake booster and evaporative emission hose.

Fig 17: Connecting Brake Booster And Evaporative Emission Hose
Courtesy of FORD MOTOR CO.
Connect the positive crankcase ventilation (PCV) coolant hose.

Fig 18: Connecting Positive Crankcase Ventilation Coolant Hose
Courtesy of FORD MOTOR CO.
Connect the heated PCV tube and engine vacuum harness.

Fig 19: Connecting Heated Tube And Engine Vacuum Harness
Courtesy of FORD MOTOR CO.
Connect the throttle position (TP) sensor electrical connector.
- Push in the red clip.
  
  Fig 20: Connecting Throttle Position Sensor Electrical Connector
  Courtesy of FORD MOTOR CO.
Connect the electronic throttle body (TB) electrical connector.
- Push in the red clip.
  
  Fig 21: Identifying Electronic Throttle Body (TB) Electrical Connector
  Courtesy of FORD MOTOR CO.
Install the upper radiator hose.

Fig 22: Installing Upper Radiator Hose
Courtesy of FORD MOTOR CO.
Connect the fuel hose spring lock couplings. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Install the generator. For additional information, refer to GENERATOR AND REGULATOR .
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
Install the air cleaner assembly and tubes. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
Fill the cooling system. For additional information, refer to ENGINE COOLING .