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Upper 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.
  1. Inspect the 6 upper intake manifold gaskets. Install new gaskets, if necessary.
  2. Position the upper intake manifold and install the bolts. Tighten the bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 6 N.m (53 lb-in).
    • Stage 2: Tighten to 10 N.m (89 lb-in).
    Fig 1: Tightening Upper Intake Manifold Bolts
    GF0002369Courtesy of FORD MOTOR CO.
  3. Attach the fuel charging wiring harness-to-main engine wiring harness electrical connector retainer to the rear of the upper intake manifold.
  4. Connect the PCV valve hose to the rear of the upper intake manifold.
  5. Connect the 2 heated PCV coolant hoses to the rear of the upper intake manifold and position the clamps.
  6. Connect the vacuum hose connector to the rear of the upper intake manifold.
  7. Connect the brake booster vacuum hose to the upper intake manifold and position the clamp.
  8. Connect the 5 wiring harness retainers to the upper intake manifold.
  9. Connect the fuel vapor hose to the upper intake manifold and position the clamp.
  10. Connect the electronic throttle body electrical connector.
  11. Connect the exhaust manifold-to-EGR system module tube to the EGR system module.
    • Tighten to 40 N.m (30 lb-ft).
  12. Connect the EGR system module electrical and vacuum connectors.
    13. NOTE: Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug wire boots.
    NOTE: Spark plug wires must be connected to the correct ignition coil terminals.
  13. Position the spark plug wires, connect the 2 spark plug wire retainers to the upper intake manifold and connect the 3 spark plug wires to the ignition coil.
  14. Position the heater hoses and install the bolt.
    • Tighten to 5 N.m (44 lb-in).
  15. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  16. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  17. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING article.
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