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Upper Intake Manifold: Installation

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install new gaskets in the upper intake manifold.
  2. Position the upper intake manifold and tighten the bolts in the sequence shown.
    Fig 1: Bolts Tightening Sequence
    G03429619Courtesy of FORD MOTOR CO.
  3. Connect the PSP electrical connector.
    Fig 2: Connecting PSP Electrical Connector
    G03429620Courtesy of FORD MOTOR CO.
  4. Position the transmission vent tube and bracket and install the bolt.
    Fig 3: Installing Bolt
    G03429621Courtesy of FORD MOTOR CO.
  5. Position the wire harness and install the nut.
    Fig 4: Installing Nut
    G03429622Courtesy of FORD MOTOR CO.
  6. Install the two electrical connectors on the left side of the intake manifold.
    Fig 5: Installing Two Electrical Connectors
    G03429623Courtesy of FORD MOTOR CO.
  7. Install the vapor management valve (VMV) vacuum hose.
    Fig 6: Installing Vapor Management Valve (VMV) Vacuum Hose
    G03429624Courtesy of FORD MOTOR CO.
  8. Connect the three vacuum hoses on the back of the upper intake manifold.
    1. Connect the chassis vacuum hose.
    2. Connect the engine vacuum hose.
    3. Connect the PCV hose.
    Fig 7: Connecting Chassis & Engine Vacuum Hose
    G03429625Courtesy of FORD MOTOR CO.
  9. Connect the EGR vacuum regulator solenoid electrical connector and the vacuum hose.
    Fig 8: Connecting EGR Vacuum Regulator Solenoid Electrical Connector & Vacuum Hose
    G03429626Courtesy of FORD MOTOR CO.
  10. Install the EGR valve vacuum hose and EGR tube nut.
    Fig 9: Installing EGR Valve Vacuum Hose & EGR Tube Nut
    G03429627Courtesy of FORD MOTOR CO.
  11. Connect the TP sensor and IAC electrical connectors.
    Fig 10: Connecting TP Sensor & IAC Electrical Connectors
    G03429628Courtesy of FORD MOTOR CO.
  12. Connect the throttle cables.
    1. Install the throttle cable bracket bolts.
    2. Connect the throttle cable.
    3. If equipped, connect the speed control cable.
    Fig 11: Connecting Throttle Cables
    G03429629Courtesy of FORD MOTOR CO.
  13. Install the air cleaner outlet tube.
    1. Position the air cleaner outlet tube.
    2. Install the hoses.
    3. Install the clamps.
    Fig 12: Installing Clamps
    G03429630Courtesy of FORD MOTOR CO.
  14. Install the engine appearance cover.
    Fig 13: Installing Engine Appearance Cover
    G03429631Courtesy of FORD MOTOR CO.
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