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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 2237 (Engine - 4.6L And 5.4L) >> In-Vehicle Servicing >> Intake Manifold - 4.6L >> Installation

Intake Manifold - 4.6L: Installation

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. 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 can cause leak paths. Use a plastic scraping tool to clean sealing surfaces.
  1. Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  2. Position the new intake manifold gaskets, the intake manifold and loosely install the 9 bolts.
  3. Using a new O-ring seal, install the thermostat.
    4. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.
  4. Install the thermostat housing and loosely install the 2 bolts.
  5. Tighten the 11 bolts in 2 stages in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    6. Fig 1: Intake Manifold Bolts Torque Sequence
    GF0011604Courtesy of FORD MOTOR CO.
  6. Connect the 2 electrical connector position retainers to the support bracket.
    7. Fig 2: Electrical Connector Position Retainers
    GF0011603Courtesy of FORD MOTOR CO.
  7. Position the heater outlet tube and install the stud bolt.
    • Tighten to 25 Nm (18 lb-ft).
    8. Fig 3: Heater Outlet Tube & Stud Bolt
    GF0011602Courtesy of FORD MOTOR CO.
  8. Connect the coolant hose to the heater outlet tube.
    9. Fig 4: Heater Outlet Tube Coolant Hose & Clamp
    GF0011601Courtesy of FORD MOTOR CO.
  9. Connect the wiring harness retainer to the rear of the RH cylinder head.
    10. Fig 5: Wiring Harness Retainer
    GF0011600Courtesy of FORD MOTOR CO.
  10. Connect the 8 fuel injector electrical connectors.
  11. Connect the PCV coolant hose to the TB adapter.
  12. Connect the vacuum harness connector to the intake manifold.
  13. Connect the EVAP system vapor tube quick connect coupling to the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  14. Connect the fuel pressure and temperature sensor electrical connector.
  15. Using a new gasket, position the EGR system module and install the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  16. Position the exhaust manifold-to-EGR system module tube and connect the upper and lower fittings.
    • Tighten to 42 Nm (31 lb-ft).
  17. Connect the EGR system module vacuum hose and electrical connector.
  18. Connect the crankcase vent tube quick connect coupling to the LH valve cover. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  19. Install the transmission fluid level indicator and tube bolt.
    • To install, tighten to 28 Nm (21 lb-ft).
    20. Fig 6: Transmission Fluid Level Indicator Tube & Bolt
    GF0011597Courtesy of FORD MOTOR CO.
  20. Install the transmission fluid level indicator and tube nut.
    • Tighten to 10 Nm (89 lb-in).
    21. Fig 7: Transmission Fluid Level Indicator Tube & Bolt
    GF0011598Courtesy of FORD MOTOR CO.
  21. Connect the vacuum harness connector.
    22. Fig 8: Vacuum Harness Connector
    GF0011599Courtesy of FORD MOTOR CO.
  22. Position the generator support bracket and install the 3 bolts.
  23. Connect the generator wiring harness retainer.
    24. Fig 9: Generator Wiring Harness Retainer
    GF0011596Courtesy of FORD MOTOR CO.
  24. Rotate the tensioner clockwise and install the accessory drive belt onto the generator pulley.
    25. Fig 10: Rotating Tensioner Clockwise
    GF0000336Courtesy of FORD MOTOR CO.
  25. Connect the heater coolant hose.
    26. Fig 11: Heater Coolant Hose & Clamp
    GF0011595Courtesy of FORD MOTOR CO.
  26. If equipped, connect the auxiliary heater hoses. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
    27. Fig 12: Identifying Auxiliary Heater Hoses
    G03885101Courtesy of FORD MOTOR CO.
  27. Connect the upper radiator hose.
  28. Connect the fuel supply tube spring lock coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  29. Install the 8 ignition coils. For additional information, refer to ENGINE IGNITION - 4.6L (2V) AND 5.4L (2V) article.
  30. Install the throttle body (TB). For additional information, refer to FUEL CHARGING AND CONTROLS - 4.6L (2V) AND 5.4L (2V) article.
  31. Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
  32. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  33. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING article.
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