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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 320 (Engine - 4.6L & 5.4L) >> In-Vehicle Repair >> Intake Manifold - 4.6L >> Installation

Intake Manifold - 4.6L: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not use metal scrapers, power abrasive discs or any abrasive means to clean the sealing surfaces, these tools cause scratches and gouges that make leak paths. Use a plastic scraper only.
  1. Clean all the sealing surfaces.
  2. Install the upper intake manifold.
    1. Position the new intake manifold gaskets.
    2. Position the upper intake manifold.
    3. Loosely install nine bolts.
    Fig 1: Installing Upper Intake Manifold
    G01536158Courtesy of FORD MOTOR CO.
  3. Connect the intake manifold tuning valve electrical connector.
    Fig 2: Connecting Intake Manifold Tuning Valve Electrical Connector
    G01536159Courtesy of FORD MOTOR CO.
  4. Install the thermostat.
    1. Install the thermostat.
    2. Install a new O-ring seal.
    Fig 3: Installing Thermostat
    G01536160Courtesy of FORD MOTOR CO.
    5. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.
    Fig 4: Installing Thermostat Housing Bolts
    G01536161Courtesy of FORD MOTOR CO.
  5. Install the thermostat housing and loosely install the bolts.
  6. Tighten the 11 bolts in two stages in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    Fig 5: Intake Manifold Bolt Tightening Sequence
    G01536162Courtesy of FORD MOTOR CO.
  7. Install the heater hose and position the clamp.
    Fig 6: Installing Heater Hose
    G01536163Courtesy of FORD MOTOR CO.
  8. Install the generator upper support bracket.
    Fig 7: Installing Generator Upper Support Bracket
    G01536164Courtesy of FORD MOTOR CO.
    9. NOTE: LH shown, RH similar.
    Fig 8: Installing Ignition Coils
    G01536165Courtesy of FORD MOTOR CO.
  9. Install the eight ignition coils and bolts.
    10. NOTE: LH shown, RH similar.
    Fig 9: Connecting Fuel Injector Electrical Connectors
    G01536166Courtesy of FORD MOTOR CO.
  10. Connect the eight fuel injector electrical connectors.
    11. NOTE: LH shown, RH similar.
    Fig 10: Connecting Coil-On-Plug Electrical Connectors
    G01536167Courtesy of FORD MOTOR CO.
  11. Connect the eight coil-on-plug electrical connectors.
  12. Position a new throttle body adapter gasket and install the throttle body adapter assembly.
    Fig 11: Installing Throttle Body Adapter Assembly
    G01536168Courtesy of FORD MOTOR CO.
  13. Connect the following vacuum connections:
    1. EGR valve vacuum connector.
    2. Engine vacuum supply vacuum connector.
    3. EGR vacuum regulator solenoid vacuum connector.
    4. Fuel pressure regulator vacuum connector.
    5. Evaporative emission canister purge valve vacuum connector.
    Fig 12: Connecting EGR Vacuum Regulator Solenoid Vacuum Connector
    G01536169Courtesy of FORD MOTOR CO.
  14. Connect the IAC electrical connector.
    Fig 13: Connecting IAC Electrical Connector
    G01536170Courtesy of FORD MOTOR CO.
  15. Install the evaporative emission canister purge valve and bracket.
    Fig 14: Installing Evaporative Emission Canister Purge Valve And Bracket
    G01536171Courtesy of FORD MOTOR CO.
  16. Connect the following vacuum hoses:
    • The brake booster hose.
    • The positive crankcase ventilation (PCV) valve tube.
    Fig 15: Connecting Vacuum Hoses
    G01536172Courtesy of FORD MOTOR CO.
  17. Connect the EGR vacuum regulator solenoid electrical connector.
    Fig 16: Connecting EGR Vacuum Regulator Solenoid Electrical Connector
    G01536173Courtesy of FORD MOTOR CO.
  18. Install the exhaust manifold to EGR valve tube.
    • Hand-tighten the upper and lower fittings.
    • Tighten the fittings to 35-45 Nm (26-33 lb-ft).
    Fig 17: Installing Exhaust Manifold To EGR Valve Tube
    G01536174Courtesy of FORD MOTOR CO.
  19. Install the differential pressure feedback EGR system.
    • Install the system and hoses on the exhaust manifold to EGR valve tube.
    • Connect the electrical connector.
    Fig 18: Connecting Differential Pressure Feedback EGR System Electrical Connector
    G01536175Courtesy of FORD MOTOR CO.
  20. Connect the fuel hose spring lock couplings. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL or FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS .
    21. NOTE: Typical is shown.
    Fig 19: Connecting TP Sensor Electrical Connector
    G01536176Courtesy of FORD MOTOR CO.
  21. Connect the TP sensor electrical connector.
    22. NOTE: Typical is shown.
    Fig 20: Positioning Accelerator Cable Bracket
    G01536177Courtesy of FORD MOTOR CO.
  22. Position the accelerator cable bracket and install the bolts.
    23. NOTE: Typical is shown.
    Fig 21: Connecting Throttle Control Return Spring
    G01536178Courtesy of FORD MOTOR CO.
  23. Connect the throttle body control linkage.
    1. Connect the accelerator cable.
    2. Connect the speed control actuator cable.
    3. Connect the throttle control return spring.
  24. Install the accelerator cable snow shield.
    Fig 22: Installing Accelerator Cable Snow Shield
    G01536179Courtesy of FORD MOTOR CO.
  25. Install the upper radiator hose and position the clamp.
    Fig 23: Installing Upper Radiator Hose
    G01536180Courtesy of FORD MOTOR CO.
  26. Install the air cleaner outlet pipe and tighten the clamp.
    Fig 24: Installing Air Cleaner Outlet Pipe
    G01536181Courtesy of FORD MOTOR CO.
  27. Connect the two hoses to the air cleaner outlet pipe.
    Fig 25: Connecting Hoses To Air Cleaner Outlet Pipe
    G01536182Courtesy of FORD MOTOR CO.
  28. Connect the MAF sensor and position the ACL.
    Fig 26: Connecting MAF Sensor
    G01536183Courtesy of FORD MOTOR CO.
  29. Install the ACL.
    • Install the four bolts.
    • Tighten the clamp.
    Fig 27: Installing ACL Securing Bolts
    G01536184Courtesy of FORD MOTOR CO.
  30. Install the interior engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  31. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  32. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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