Upper Intake Manifold: Installation

WARNING: This page is about a different car, the 2006 Mercury Mariner and 2006 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: Clean and inspect all sealing surfaces. Install new gaskets.

NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

1.
Position the upper intake manifold and install the bolts.
- Tighten in the sequence shown below to 10 Nm (89 lb-in).

Fig 1: Upper Intake Manifold Bolts Tightening Sequence

Courtesy of FORD MOTOR CO.

2.

Connect the 2 throttle body coolant hoses.

3.

Attach the main engine wiring harness electrical connectors to the upper intake manifold.

4.

Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold.

5.

Attach the wiring retainer to the EGR vacuum regulator stud bolt and install the nut.
- Tighten to 6 Nm (53 lb-in).

6.

Connect the EGR vacuum regulator electrical connector.

7.

Connect the IAC valve electrical connector.

8.

Connect the vacuum harness tube fittings to the EGR valve and the EGR vacuum regulator.

9.

Attach the transaxle vent tube to the throttle body stud bolt.

10.

Connect the TP sensor electrical connector and attach the wiring retainer.

11.

Connect the fuel vapor tube to the upper intake manifold.

12.

Connect the EGR tube fitting to the EGR valve.
- Tighten to 40 Nm (30 lb-ft).

13.

Position the accelerator/speed control cables and brackets and install the 3 bolts.
- Tighten to 10 Nm (89 lb-in).

14.

Attach the speed control and accelerator cables to the throttle body.

15.

Install the accelerator cable snow shield and the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

16.

Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION SYSTEM & FILTERING SYSTEM - 3.0L (4V) .

17.

Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .

18.

Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING - (EXCEPT HYBRID) .