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Upper Intake Manifold: Installation

WARNING: This page is about a different car, the 2006 Mercury Milan, 2006 Lincoln Zephyr, and 2006 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Clean and inspect all of the sealing surfaces of the upper intake manifold.
    2. NOTE: Install new gaskets.
  2. Install the upper intake manifold, gaskets and the 8 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
      Fig 1: Identifying Tightening Sequence Of Upper Intake Manifold Bolts
      G04680642Courtesy of FORD MOTOR CO.
  3. Attach the wiring harness retainer to the front of the upper intake manifold.
  4. Connect the MAP sensor electrical connector and the pin-type retainer.
  5. Install the EGR tube-to-EGR valve nut.
    • Tighten to 40 Nm (30 lb-ft).
  6. Connect the EGR valve electrical connector.
  7. Connect the PCV tube to the intake manifold.
  8. Connect the vacuum tube to the intake manifold.
  9. Install the vacuum tube clamp bolt.
    • Tighten to 10 Nm (89 lb-in).
  10. Connect the EVAP tube to the intake manifold.
    11. NOTE: Install a new gasket. Install the gasket, throttle body and 4 bolts.
  11. Tighten to 10 Nm (89 lb-in).
  12. Connect the throttle body electrical connector.
  13. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V) .
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