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Intake Manifold: Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the intake manifold gaskets and the intake manifold. Install the bolts finger tight.
  2. Tighten the bolts in the sequence shown in Fig 1 to 25 Nm (18 lb-ft).
    Fig 1: Tighten Bolts In Sequence Shown
    G03947565Courtesy of FORD MOTOR CO.
    3. NOTE: Apply dielectric compound to the inside of the coil boots.
  3. Install all 8 ignition coils and the bolts.
    • Tighten to 6 Nm (53 lb-in).
      Fig 2: Installing Ignition Coils And Bolts
      G03947564Courtesy of FORD MOTOR CO.
  4. Attach the wire harness locators and the KS electrical connector to the back of the intake manifold.
    Fig 3: Attaching Wire Harness Locators And KS Electrical Connector
    G03947567Courtesy of FORD MOTOR CO.
  5. Connect the LH fuel injector and coil pack electrical connectors and the fuel charging wiring harness retainers.
    Fig 4: Connecting LH Fuel Injector And Coil Pack Electrical Connectors
    G03947562Courtesy of FORD MOTOR CO.
  6. Connect the RH fuel injector, coil pack electrical connectors and the wiring harness retainers.
    Fig 5: Connecting RH Fuel Injector, Coil Pack Electrical Connectors
    G03947561Courtesy of FORD MOTOR CO.
  7. Connect the ground wire.
    Fig 6: Connecting Ground Wire
    G03947560Courtesy of FORD MOTOR CO.
  8. Connect the EGR system module electrical connector.
  9. Install the coolant outlet hose anchor to the fuel rail stud.
    Fig 7: Installing Coolant Outlet Hose Anchor To Fuel Rail Stud
    G03947559Courtesy of FORD MOTOR CO.
  10. Connect the heated PCV coolant outlet hose and position the clamp.
  11. Connect the heated PCV coolant inlet hose and position the clamp.
  12. Connect the EVAP hose to the throttle body adapter.
  13. Connect the fuel pressure sensor electrical connector.
  14. Connect the TP sensor and the electronic throttle body electrical connectors.
  15. Install the thermostat.
    16. NOTE: Inspect the thermostat O-ring seal and install a new seal if necessary.
  16. Install the thermostat O-ring seal, the thermostat housing cover and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  17. Install the PCV valve tube.
  18. Position the vacuum harness and connect the fuel pressure sensor and EGR system module vacuum fittings.
    Fig 8: Installing PCV Valve Tube
    G03947558Courtesy of FORD MOTOR CO.
  19. Connect the vacuum tube to the throttle body adapter.
    Fig 9: Connecting Vacuum Tube To Throttle Body Adapter
    G03947557Courtesy of FORD MOTOR CO.
  20. Connect the heater control vacuum hose fitting.
    Fig 10: Connecting Heater Control Vacuum Hose Fitting
    G03947556Courtesy of FORD MOTOR CO.
  21. Position the crankcase breather tube and connect it to the valve cover.
  22. Connect the heater hose and position the clamp
  23. Position the brake booster vacuum tube and connect it to the throttle body adapter. Install the brake booster vacuum tube bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
  24. Connect the upper radiator hose to the thermostat housing and position the clamp.
  25. Connect the fuel tube spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  26. Install the generator. For additional information, refer to GENERATOR AND REGULATOR .
  27. Install the EGR tube. For additional information, refer to ENGINE EMISSION CONTROL .
  28. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  29. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  30. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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