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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1805 (Engine - 4.6L (2V) - F-150) >> In-Vehicle Servicing >> Intake Manifold >> Installation

Intake Manifold: Installation

WARNING: This page is about a different car, the 2007 Ford Pickup. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  1. Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep and silicone gasket remover. Follow the directions on the packaging.
  2. Install the intake manifold.
    1. Position the new intake manifold gaskets.
    2. Position the intake manifold.
    3. Loosely install the 9 intake manifold bolts.
  3. Tighten the intake manifold bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    4. Fig 1: Identifying Intake Manifold Bolts
    GF0002588Courtesy of FORD MOTOR CO.
  4. Install the thermostat.
  5. Install the thermostat housing and a new thermostat housing O-ring seal.
  6. Install the 2 thermostat housing bolts.
    • Tighten to 25 Nm (18 lb-ft).
  7. Connect the fuel hose spring lock coupling. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  8. Connect the vacuum hose.
    9. Fig 2: Identifying Vacuum Hose
    GF0002587Courtesy of FORD MOTOR CO.
  9. Install the power steering reservoir support bracket and the 3 bolts.
    • Tighten the 2 bracket-to-power steering reservoir bolts to 17 Nm (13 lb-ft).
    • Tighten the power steering reservoir bracket-to-thermostat housing bolt to 11 Nm (8 lb-ft).
    10. Fig 3: Locating Power Steering Reservoir Support Bracket Bolts
    GF0002586Courtesy of FORD MOTOR CO.
  10. Connect the heater coolant hose.
    11. Fig 4: Locating Heater Coolant Hose
    GF0002585Courtesy of FORD MOTOR CO.
  11. Connect the upper radiator coolant hose.
    12. Fig 5: Locating Upper Radiator Coolant Hose
    GF0002584Courtesy of FORD MOTOR CO.
  12. Connect the electronic throttle control electrical connector.
  13. Connect the fuel rail pressure and temperature sensor electrical connector.
  14. Connect the fuel rail pressure and temperature sensor vacuum connector.
  15. Connect the 8 fuel injector electrical connectors.
  16. Connect the vacuum and coolant hose.
    17. Fig 6: Locating Vacuum And Coolant Hose
    GF0002582Courtesy of FORD MOTOR CO.
  17. Connect the brake booster vacuum hose and the EVAP hose quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
    18. Fig 7: Locating Brake Booster Vacuum Hose And EVAP Hose
    GF0002583Courtesy of FORD MOTOR CO.
  18. Install the EGR system module tube.
    • Tighten to 40 Nm (30 lb-ft).
  19. Connect the EGR system module electrical connector.
  20. Position the PCV tube and connect the quick connect couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  21. Install the ignition coils. For additional information, refer to ENGINE IGNITION - 4.6L (2V) article.
  22. Install the generator. For additional information, refer to GENERATOR AND REGULATOR article.
  23. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  24. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  25. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING article.
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