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Home >> Ford >> 2000 >> Contour SE, 2.0 3, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 799 (Engine - 6.0L Diesel -- E350 & E450) >> In-Vehicle Repair >> Intake Manifold >> Installation

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.

    All vehicles 

    NOTE: The locating tabs on the gaskets must be positioned upward and toward the center of the engine, or a leak will occur.
    Fig 1: Installing Intake Manifold Gaskets
    G03887125Courtesy of FORD MOTOR CO.
  1. Install the intake manifold gaskets and front module O-ring seal.
  2. Install the intake manifold and bolts and tighten in the following sequence, in three stages:
    • Stage 1: Loosely install bolts 1-8.
    • Stage 2: Tighten bolts 9-16 to 11 Nm (8 lb-ft).
    • Stage 3: Tighten all bolts to 11 Nm (8 lb-ft).
      Fig 2: Tightening Sequence
      G03887127Courtesy of FORD MOTOR CO.
  3. Slide the EGR cooler hose forward and rotate the flat to lock.
    Fig 3: Sliding EGR Cooler Hose
    G03887128Courtesy of FORD MOTOR CO.
  4. If equipped, install the turbocharger heat shield and nuts.
    Fig 4: Installing Turbocharger Heat Shield Nuts
    G03887129Courtesy of FORD MOTOR CO.
  5. Install the secondary fuel filter assembly and bolts.
    Fig 5: Installing Secondary Fuel Filter Assembly Bolts
    G03887130Courtesy of FORD MOTOR CO.
    6. NOTE: Install new copper sealing washers.
    Fig 6: Installing RH Fuel Line And Banjo Bolt
    G03887131Courtesy of FORD MOTOR CO.
  6. Install the RH fuel line and banjo bolt.
  7. Install the retaining nut and connect the fuel tube at the fuel filter assembly.
    Fig 7: Installing Retaining Nut
    G03887132Courtesy of FORD MOTOR CO.
    8. NOTE: Install new copper sealing washers on the banjo fitting.
    Fig 8: Connecting Fuel Tubes
    G03887133Courtesy of FORD MOTOR CO.
  8. Reposition and connect the fuel tubes at the fuel filter housing.
  9. Install the secondary fuel filter and cover.
    Fig 9: Installing Secondary Fuel Filter And Cover
    G03887134Courtesy of FORD MOTOR CO.
  10. Connect the engine coolant vent hose.
    Fig 10: Connecting Engine Coolant Vent Hose
    G03887116Courtesy of FORD MOTOR CO.
  11. Connect the MAP sensor hose.
    Fig 11: Connecting MAP Sensor Hose
    G03887115Courtesy of FORD MOTOR CO.
  12. Position back the engine wiring harness as needed. Connect the harness retainers.
    Fig 12: Connecting Harness Retainers
    G03887114Courtesy of FORD MOTOR CO.
    13. NOTE: Only one injector shown, others similar.
    Fig 13: Identifying Fuel Injector Electrical Connector & Retainer Clip
    G03887113Courtesy of FORD MOTOR CO.
  13. Connect the eight fuel injector electrical connectors.
  14. Remove the plug or cap. Install the IAT2 sensor.
    Fig 14: Installing IAT2 Sensor
    G03887139Courtesy of FORD MOTOR CO.
  15. Connect the IAT2 sensor electrical connector.
    Fig 15: Connecting IAT2 Sensor Electrical Connector
    G03887111Courtesy of FORD MOTOR CO.
  16. Remove the plug or cap. Install the ECT sensor.
    Fig 16: Removing Plug
    G03887141Courtesy of FORD MOTOR CO.
  17. Connect the ECT sensor electrical connector and the pin-type retainer.
    Fig 17: Connecting ECT Sensor Electrical Connector
    G03887109Courtesy of FORD MOTOR CO.
  18. Connect the EOT sensor electrical connector.
    Fig 18: Locating Engine Oil Temperature Sensor
    G03887108Courtesy of FORD MOTOR CO.
  19. Connect the EOP sensor electrical connector.
    Fig 19: Locating Engine Oil Pressure Sensor Electrical Connector
    G03887107Courtesy of FORD MOTOR CO.
  20. Connect the EGR valve electrical connector.
    Fig 20: Locating EGR Valve Assembly Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  21. Connect the injector pressure regulator valve electrical connector and position back the heat insulating wrap. Install the wiring retainer and retaining nut.
    Fig 21: Connecting Injector Pressure Regulator Valve Electrical Connector
    G03887105Courtesy of FORD MOTOR CO.
    22. NOTE: Install a new O-ring seal and apply clean engine coolant.
    Fig 22: Installing Heater Tube And Bolts
    G03887147Courtesy of FORD MOTOR CO.
  22. Install the heater tube and bolts.
  23. Install the generator, ground wire and the three bolts.
    Fig 23: Installing Bolts
    G03887148Courtesy of FORD MOTOR CO.
  24. Position back the transmission fluid indicator and tube and install the retaining nut. Connect the pushpin retainer.
    Fig 24: Connecting Pushpin Retainer
    G03887149Courtesy of FORD MOTOR CO.
  25. Install the retaining nut for the transmission fluid indicator and tube.
    Fig 25: Installing Retaining Nut
    G03887150Courtesy of FORD MOTOR CO.
  26. Connect the generator B+ wire and electrical connector. Position back the boot. Connect the wiring pushpin.
    Fig 26: Connecting Wiring Pushpin
    G03887151Courtesy of FORD MOTOR CO.
    27. NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler tube to prevent the tube from blowing off.
    Fig 27: Locating Bracket Retaining Nuts
    G03887099Courtesy of FORD MOTOR CO.
  27. Position the charge-air-cooler tube, oil fill tube and bracket. Install the retaining nuts.
  28. Connect the oil fill tube at the valve cover.
    Fig 28: Identifying Oil Fill Tube At Valve Cover
    G03887098Courtesy of FORD MOTOR CO.
  29. Install the bolts for the charge-air-cooler tube and oil fill tube.
    Fig 29: Locating CAC Tube And Oil Fill Tube Bolts
    G03887097Courtesy of FORD MOTOR CO.
  30. Position the conduit and install the bolts.
    Fig 30: Installing Bolts
    G03887096Courtesy of FORD MOTOR CO.
  31. Connect the push pin. Position back the MAP sensor assembly and install the bolt.
    Fig 31: Connecting Push Pin
    G03887095Courtesy of FORD MOTOR CO.
  32. Connect the electrical connector pushpin. Position back the ground wire and install the bolt.
    Fig 32: Connecting Electrical Connector Pushpin
    G03887094Courtesy of FORD MOTOR CO.

    33. Vehicles with single generator 

  33. Install the accessory drive belt.
    Fig 33: Rotating Accessory Drive Belt Tensioner Clockwise
    G03887093Courtesy of FORD MOTOR CO.

    34. Vehicles with dual generator 

  34. Install the generator with mounting bracket and bolts.
    Fig 34: Locating Bolts And Generator Mounting Bracket - With Torque Specification
    G03887159Courtesy of FORD MOTOR CO.
  35. Connect the generator B+ wire and electrical connector. Position the boot.
    Fig 35: Connecting Generator Wire And Electrical Connector
    G03887160Courtesy of FORD MOTOR CO.
  36. Install the accessory drive belt tensioner and bolts.
    Fig 36: Primary Accessory Drive Belt Tensioner Bolts - With Torque Specification
    G03887161Courtesy of FORD MOTOR CO.
  37. 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.
  38. Install the accessory drive belt.
    Fig 38: Rotating Accessory Drive Belt Tensioner Clockwise
    G03887088Courtesy of FORD MOTOR CO.
  39. Install the accessory drive belt tensioner and bolt.
    Fig 39: Secondary Accessory Drive Belt Tensioner Bolt - With Torque Specification
    G03907183Courtesy of FORD MOTOR CO.
  40. Install the accessory drive belt.
    Fig 40: Rotating Drive Belt Tensioner Clockwise
    G03887086Courtesy of FORD MOTOR CO.

    41. All vehicles 

  41. Install the turbocharger pedestal and turbocharger. For additional information, refer to FUEL CHARGING & CONTROLS - TURBOCHARGER .
  42. Install the cooling fan stator. For additional information, refer to ENGINE COOLING .
  43. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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