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Upper Intake Manifold: Installation

WARNING: This page is about a different car, the 2011 Mercury Milan and 2011 Ford Fusion. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.
  1. Clean and inspect all of the sealing surfaces of the upper intake manifold.
    2. NOTE: Install new upper intake manifold gaskets.
    Fig 1: Identifying Upper Intake Manifold Bolts Tightening Sequence
    G07781246Courtesy of FORD MOTOR CO.
  2. Position the upper intake manifold and install the 7 bolts.
    • Tighten the bolts in 2 stages in the sequence shown in the illustration.
    • Stage 1: Tighten to 10 Nm (89 lb-in).
    • Stage 2: Tighten an additional 45 degrees.
  3. Install the 2 upper intake manifold support bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
  4. Connect the MAP sensor electrical connector and attach the wiring retainer.
  5. Connect the PCV tube to the upper intake manifold.
  6. Attach the engine control wiring harness retainer to the upper intake manifold.
  7. Connect the EVAP tube-to-EVAP canister purge valve quick connect coupling and the brake booster vacuum tube to the upper intake manifold.
    • Attach the fuel tube and EVAP tube-to-EVAP canister purge valve tube retainer to the upper intake manifold.
  8. Connect the EGR valve electrical connector and attach the wiring retainer.
  9. Connect the EVAP canister purge valve electrical connector.
  10. Connect the electronic throttle control electrical connector.
  11. Install the EGR tube fitting to the EGR valve.
    • Tighten to 40 Nm (30 lb-ft).
  12. Install the battery. For additional information, refer to BATTERY, MOUNTING & CABLES -- FUSION, MILAN & MKZ article.
  13. Install the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING - 3.0L (4V) -- FUSION & MILAN article.
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