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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 - 5.4L >> Installation

Intake Manifold - 5.4L: 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, wire brushes, power abrasive discs or any 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 these surfaces.
  1. Clean and inspect all sealing surfaces.
  2. Position the intake manifold gaskets and the intake manifold.
    Fig 1: Positioning Intake Manifold Gaskets And Intake Manifold
    G01536219Courtesy of FORD MOTOR CO.
  3. Loosely install the nine bolts.
    Fig 2: Installing Nine Bolts
    G01536220Courtesy of FORD MOTOR CO.
  4. Install the thermostat.
    1. Install the thermostat.
    2. Install a new O-ring seal.
    Fig 3: Installing Thermostat
    G01536221Courtesy of FORD MOTOR CO.
    5. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.
    Fig 4: Installing Thermostat Housing And Bolts
    G01536222Courtesy of FORD MOTOR CO.
  5. Loosely install the thermostat housing and bolts.
  6. Tighten the 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
    G01536223Courtesy of FORD MOTOR CO.
    7. NOTE: LH shown, RH similar.
    Fig 6: Installing Ignition Coils And Bolts
    G01536224Courtesy of FORD MOTOR CO.
  7. Install the eight ignition coils and bolts.
    8. NOTE: LH shown, RH similar.
    Fig 7: Connecting Fuel Injector Electrical Connectors
    G01536225Courtesy of FORD MOTOR CO.
  8. Connect the eight fuel injector electrical connectors.
    9. NOTE: LH shown, RH similar.
    Fig 8: Connecting Coil-On-Plug Electrical Connectors
    G01536226Courtesy of FORD MOTOR CO.
  9. Connect the eight coil-on-plug electrical connectors.
  10. Install the PCV hose and valve.
    Fig 9: Installing PCV Hose And Valve
    G01536227Courtesy of FORD MOTOR CO.
  11. Install the new throttle body adapter gasket.
    Fig 10: Installing Throttle Body Adapter Gasket
    G01536228Courtesy of FORD MOTOR CO.
  12. Install the throttle body and adapter assembly.
    Fig 11: Installing Throttle Body And Adapter Assembly
    G01536229Courtesy of FORD MOTOR CO.
  13. Install the exhaust manifold-to-EGR valve tube and tighten the fitting in two stages.
    • Hand-tighten the fittings.
    • Tighten the fittings to 40-60 Nm (30-44 lb-ft).
    Fig 12: Installing Exhaust Manifold-To-EGR Valve Tube
    G01536230Courtesy of FORD MOTOR CO.
  14. Connect the brake booster and the main engine vacuum harnesses.
    Fig 13: Connecting Brake Booster
    G01536231Courtesy of FORD MOTOR CO.
  15. Connect the IAC electrical connector.
    Fig 14: Connecting IAC Electrical Connector
    G01536232Courtesy of FORD MOTOR CO.
  16. Connect the EGR vacuum hose.
    Fig 15: Connecting EGR Vacuum Hose
    G01536233Courtesy of FORD MOTOR CO.
  17. Connect the EGR vacuum regulator solenoid connections.
    Fig 16: Connecting EGR Vacuum Regulator Solenoid Connections
    G01536234Courtesy of FORD MOTOR CO.
  18. Connect the fuel pressure regulator vacuum hose.
    Fig 17: Connecting Fuel Pressure Regulator Vacuum Hose
    G01536235Courtesy of FORD MOTOR CO.
  19. Install the evaporative emission canister purge valve and bracket.
    Fig 18: Installing Evaporative Emission Canister Purge Valve
    G01536236Courtesy of FORD MOTOR CO.
  20. Connect the evaporative emission canister purge valve hoses.
    Fig 19: Connecting Evaporative Emission Canister Purge Valve Hoses
    G01536237Courtesy of FORD MOTOR CO.
  21. Connect the IAC fresh air hose.
    Fig 20: Connecting IAC Fresh Air Hose
    G01536238Courtesy of FORD MOTOR CO.
  22. If equipped, connect the auxiliary heater hoses. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 21: Connecting Auxiliary Heater Hoses
    G01536239Courtesy of FORD MOTOR CO.
  23. 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 .
  24. Install the accelerator cable bracket.
    Fig 22: Installing Accelerator Cable Bracket
    G01536240Courtesy of FORD MOTOR CO.
  25. Install the transmission fluid filler tube bracket and bolt.
    Fig 23: Installing Transmission Fluid Filler Tube Bracket
    G01536241Courtesy of FORD MOTOR CO.
  26. Install the generator upper support bracket.
    Fig 24: Installing Generator Upper Support Bracket
    G01536242Courtesy of FORD MOTOR CO.
  27. Install the accelerator cable routing bracket.
    Fig 25: Installing Accelerator Cable Routing Bracket
    G01536243Courtesy of FORD MOTOR CO.
  28. Install the differential pressure feedback EGR system bracket.
    Fig 26: Installing Differential Pressure Feedback EGR System Bracket
    G01536244Courtesy of FORD MOTOR CO.
  29. Connect the differential pressure feedback EGR system.
    1. Connect the electrical connector.
    2. Connect the two hoses.
    Fig 27: Connecting Differential Pressure Feedback EGR System
    G01536245Courtesy of FORD MOTOR CO.
  30. Connect the TP sensor.
    1. Connect the electrical connector.
    2. Attach the harness routing clip.
    Fig 28: Connecting Electrical Connector
    G01536246Courtesy of FORD MOTOR CO.
  31. Connect the water temperature sensor electrical connector.
    Fig 29: Connecting Water Temperature Sensor Electrical Connector
    G01536247Courtesy of FORD MOTOR CO.
  32. Connect the heater hose.
    Fig 30: Connecting Heater Hose
    G01536248Courtesy of FORD MOTOR CO.
  33. Connect the upper radiator hose.
    Fig 31: Connecting Upper Radiator Hose
    G01536249Courtesy of FORD MOTOR CO.
    34. NOTE: Typical is shown.
    Fig 32: Connecting Speed Control Actuator Cable
    G01536250Courtesy of FORD MOTOR CO.
  34. Connect the throttle controls.
    1. Connect the accelerator cable.
    2. Connect the speed control actuator cable.
    3. Install the throttle return spring.
  35. Install the accelerator cable snow shield.
    Fig 33: Installing Accelerator Cable Snow Shield
    G01536251Courtesy of FORD MOTOR CO.
  36. Install the air cleaner outlet pipe and tighten the clamp.
    Fig 34: Installing Air Cleaner Outlet Pipe
    G01536252Courtesy of FORD MOTOR CO.
  1. Connect the two hoses to the air cleaner outlet pipe.
    Fig 35: Connecting Two Hoses To Air Cleaner Outlet Pipe
    G01536253Courtesy of FORD MOTOR CO.
  2. Connect the MAF sensor and position the ACL.
    Fig 36: Connecting MAF Sensor
    G01536254Courtesy of FORD MOTOR CO.
  3. Install the ACL.
    • Install the four bolts.
    • Tighten the clamp.
    Fig 37: Installing Four Bolts
    G01536255Courtesy of FORD MOTOR CO.
  4. Install the interior engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  5. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  6. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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