LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 200 (Engine Controls - Removal & Installation - Gasoline) >> Air Induction Systems >> Intake Manifold (6.8L) >> Installation

Intake Manifold (6.8L): 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.
  1. Clean and inspect all sealing surfaces. If lower intake manifold was removed, position lower intake manifold, with NEW gasket, to upper intake manifold and loosely install 10 bolts. Tighten lower intake manifold bolts in 2 steps, in the proper sequence. See Fig 2. See TORQUE SPECIFICATIONS .
  2. Position NEW intake manifold gaskets and intake manifold. Loosely install 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 Fig 3. See TORQUE SPECIFICATIONS .
  3. Apply dielectric compound to inside of coil boots. Install the 10 coils and screws. Tighten coil screws to specification. See TORQUE SPECIFICATIONS . Connect CHT sensor electrical connector. Connect the 10 fuel injector and ignition coil electrical connectors.
  4. Install NEW throttle body gasket and install throttle body with adapter as an assembly. Install 4 throttle body bolts. Tighten throttle body bolts in 2 steps. See TORQUE SPECIFICATIONS .
  5. Install PCV hose and connect brake booster hose. Install exhaust manifold-to-EGR valve tube, if equipped. Tighten exhaust tube nuts to specification. See TORQUE SPECIFICATIONS .
  6. Install engine vacuum harness by connecting the following:
    • EGR valve, if equipped.
    • EGR vacuum regulator solenoid, if equipped.
    • Vacuum source.
    • Fuel pressure regulator.
    See Fig 1.
  7. Connect EGR vacuum regulator solenoid connector, if equipped.
  8. Connect IAC valve electrical connector and install IAC valve fresh air hose.
  9. Install EVAP canister purge valve and bracket. Install 2 EVAP canister purge valve retaining screws. Tighten screws to specification. See TORQUE SPECIFICATIONS . Connect evaporative emission hose and vacuum hose.
  10. If equipped connect auxiliary heater hoses. Install fuel charging wiring harness to fuel injection supply manifold. Install 4 fuel charging wiring harness retaining nuts. Install transmission fluid level indicator tube brackets into position and install retaining nuts. Tighten harness and bracket nuts to specification. See TORQUE SPECIFICATIONS .
  11. Install accelerator cable bracket and bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Connect accelerator cable, speed control actuator cable and install throttle return spring. Connect TP sensor electrical connector and attach harness routing clip.
  12. Install heater hoses at intake manifold. Install generator upper support bracket and bolts. Tighten bolts to specification. See TORQUE SPECIFICATIONS . Connect ECT electrical connector. Install upper radiator hose to thermostat housing, compress and slide upper radiator hose clamp in position.
  13. 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.
  14. 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.
Fig 1: Identifying Engine Vacuum Harness Connections (6.8L)
G00242012Courtesy of FORD MOTOR CO.
Fig 2: Lower Intake Manifold Tightening Sequence (6.8L)
G00132439Courtesy of FORD MOTOR CO.
Fig 3: Upper Intake Manifold Tightening Sequence (6.8L)
G00132440Courtesy of FORD MOTOR CO.
scientia non olet · About LEMON Manuals