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Intake Manifold (5.4L): Installation

WARNING: This page is about a different car, the 2003 Ford Econoline. 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 any other abrasive means to clean sealing surfaces. These tools cause scratches and gouges which can cause leak paths. Use a plastic scraping tool to clean these surfaces.
  1. Clean and inspect all sealing surfaces. Position NEW intake manifold gaskets and intake manifold. Loosely install 9 bolts. Install NEW thermostat "O" ring seal and install thermostat. Loosely install thermostat housing and bolts. Thermostat housing bolts are tightened in sequence with intake manifold bolts. Tighten intake manifold and thermostat bolts in 2 steps, in proper sequence. See Figure. See TORQUE SPECIFICATIONS .
  2. Install 8 ignition coils and bolts. Tighten to specification. See TORQUE SPECIFICATIONS . Connect 8 coil-on-plug connectors and 8 fuel injector connectors.
  3. Install NEW throttle body adapter gasket. Install throttle body and adapter as an assembly. Install 4 throttle body bolts. Tighten to specification. See TORQUE SPECIFICATIONS .
  4. Install and connect PCV hose. Install exhaust manifold-to-EGR valve tube. Position EVAP canister purge valve and install 2 EVAP canister nuts.
  5. Install the following hoses:
    • Brake booster and main engine vacuum harness.
    • EGR vacuum regulator solenoid connections and EGR valve vacuum hose.
    • Fuel pressure regulator vacuum hose.
    • Evaporative Emission (EVAP) canister purge valve hose and vacuum hose.
    • Idle Air control (IAC) valve fresh air hose.
    • Auxiliary heater hoses, if equipped.
  6. Install the following brackets and supports:
    • Differential pressure feedback EGR system bracket.
    • Thermostat housing bracket and bolt.
    • Generator upper support bracket and bolts.
    • Transmission fluid filler tube support bracket and bolt.
    • Accelerator cable bracket and bolt.

    Tighten all bolts to specification. See TORQUE SPECIFICATIONS .

  7. Connect the following electrical and vacuum connections:
    • IAC valve.
    • Differential pressure feedback EGR system connector and 2 hoses.
    • TP sensor and harness routing clip.
    • ETC sensor.
  8. Connect heater hose at intake manifold. Connect upper radiator hose to thermostat housing compress and slide hose clamp into position.
  9. Connect accelerator cable, speed control actuator cable and install throttle return spring. Install accelerator cable splash shield.
  10. Install air cleaner outlet pipe, connect 2 hoses to air cleaner outlet pipe and tighten clamp at throttle body. Position air cleaner assembly to connect MAF sensor electrical connector and connect MAF sensor electrical connector. Install air cleaner assembly and 4 air cleaner assembly bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Tighten air cleaner outlet pipe clamp at air cleaner.
  11. Install engine cover. See ENGINE COVER  under MISCELLANEOUS. Install air cleaner outlet tube. Connect fuel hose spring lock couplings. See FUEL LINE CONNECTORS  under FUEL SYSTEMS. On vehicles with dual batteries, see DUAL BATTERIES  under MISCELLANEOUS. Fill and bleed the engine cooling system. See COOLING SYSTEM BLEEDING  under COOLING SYSTEM.
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