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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 589 (Engine 4.6 & 5.4L) >> In-Vehicle Repair >> Intake Manifold - 4.6L >> Installation

Intake Manifold - 4.6L: Installation

WARNING: This page is about a different car, the 2004 Ford Econoline. 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
    G02762657Courtesy of FORD MOTOR CO.
  3. Connect the intake manifold tuning valve electrical connector.
    Fig 2: Connecting Intake Manifold Tuning Valve Electrical Connector
    G02762658Courtesy of FORD MOTOR CO.
  4. Install the thermostat.
    1. Install the thermostat.
    2. Install a new O-ring seal.
    Fig 3: Installing Thermostat
    G02762659Courtesy of FORD MOTOR CO.
    5. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.
    Fig 4: Installing Thermostat Housing
    G02762660Courtesy 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
    G02762661Courtesy of FORD MOTOR CO.
  7. Connect the fuel pressure sensor electrical connector and the vacuum hose.
    Fig 6: Connecting Fuel Pressure Sensor Electrical Connector And Vacuum Hose
    G02762662Courtesy of FORD MOTOR CO.
  8. Install the generator upper support bracket.
    Fig 7: Installing Generator Upper Support Bracket
    G02762663Courtesy of FORD MOTOR CO.
  9. Install the eight ignition coils and bolts.
    Fig 8: Installing Ignition Coils And Bolts
    G02762664Courtesy of FORD MOTOR CO.
    10. NOTE: LH shown, RH similar.
    Fig 9: Connecting Eight Fuel Injector Electrical Connectors
    G02762665Courtesy 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
    G02762666Courtesy 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
    G02762667Courtesy of FORD MOTOR CO.
  13. Connect the coolant hoses and the emissions tube.
    Fig 12: Connecting Coolant Hoses And Emissions Tube
    G02762668Courtesy of FORD MOTOR CO.
  14. Connect the IAC valve electrical connector and the EGR valve vacuum connector.
    Fig 13: Connecting IAC Valve Electrical Connector And EGR Valve Vacuum Connector
    G02762669Courtesy of FORD MOTOR CO.
  15. Connect the following vacuum hoses:
    • The brake booster vacuum hose.
    • The positive crankcase ventilation (PCV) valve hose.
    • The coolant hose.
    • The IAC fresh air hose.
    Fig 14: Connecting Vacuum Hoses
    G02762670Courtesy of FORD MOTOR CO.
  16. Connect the EGR vacuum regulator solenoid electrical connector and the vacuum hoses.
    Fig 15: Connecting EGR Vacuum Regulator Solenoid Electrical Connector And Vacuum Hoses
    G02762671Courtesy of FORD MOTOR CO.
  17. Install the exhaust manifold to EGR valve tube.
    • Hand-tighten the upper and lower fittings.
    • Tighten the fittings to 40 Nm (30 lb-ft).
    Fig 16: Installing Exhaust Manifold To EGR Valve Tube
    G02762672Courtesy of FORD MOTOR CO.
  18. Connect the differential pressure feedback EGR sensor vacuum hoses to the EGR valve tube.
    Fig 17: Connecting Differential Pressure Feedback EGR Sensor Vacuum Hoses To EGR Valve Tube
    G02762673Courtesy of FORD MOTOR CO.
  19. Connect the differential pressure feedback EGR sensor electrical connector.
    Fig 18: Connecting Differential Pressure Feedback EGR Sensor Electrical Connector
    G02762674Courtesy of FORD MOTOR CO.
  20. Connect the fuel hose spring lock coupling. 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
    G02762675Courtesy of FORD MOTOR CO.
  21. Connect the TP sensor electrical connector.
    22. NOTE: Typical is shown.
    Fig 20: Installing Bolts
    G02762676Courtesy of FORD MOTOR CO.
  22. Position the accelerator cable bracket and install the bolts.
    23. NOTE: Typical is shown.
    Fig 21: Connecting Throttle Body Control Linkage
    G02762677Courtesy 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
    G02762678Courtesy of FORD MOTOR CO.
  25. Connect the evaporative emission canister purge valve hoses.
    Fig 23: Connecting Evaporative Emission Canister Purge Valve Hoses
    G02762679Courtesy of FORD MOTOR CO.
  26. If equipped, connect the auxiliary heater hoses. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 24: Connecting Auxiliary Heater Hoses
    G02762680Courtesy of FORD MOTOR CO.
  27. Install the transmission fluid filler tube bracket and bolt.
    Fig 25: Installing Transmission Fluid Filler Tube Bracket And Bolt
    G02762681Courtesy of FORD MOTOR CO.
  28. Install the evaporative emission canister purge valve and bracket.
    Fig 26: Installing Evaporative Emission Canister Purge Valve And Bracket
    G02762682Courtesy of FORD MOTOR CO.
  29. Install the upper radiator hose and position the clamp.
    Fig 27: Installing Upper Radiator Hose And Position Clamp
    G02762683Courtesy of FORD MOTOR CO.
  30. Install the air cleaner outlet pipe and tighten the clamp.
    Fig 28: Installing Air Cleaner Outlet Pipe
    G02762684Courtesy of FORD MOTOR CO.
  31. Connect the two hoses to the air cleaner outlet pipe.
    Fig 29: Connecting Hoses To Air Cleaner Outlet Pipe
    G02762685Courtesy of FORD MOTOR CO.
  32. Connect the MAF sensor and position the ACL.
    Fig 30: Connecting MAF Sensor
    G02762686Courtesy of FORD MOTOR CO.
  33. Install the ACL.
    • Install the four bolts.
    • Tighten the clamp.
    Fig 31: Installing ACL
    G02762687Courtesy of FORD MOTOR CO.
  34. Install the interior engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  35. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  36. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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