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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 - 5.4L >> Installation

Intake Manifold - 5.4L: 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, 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: Inspecting All Sealing Surfaces
    G02762723Courtesy of FORD MOTOR CO.
  3. Loosely install the nine bolts.
    Fig 2: Installing Bolts
    G02762724Courtesy of FORD MOTOR CO.
  4. Install the thermostat.
    1. Install the thermostat.
    2. Install a new O-ring seal.
    Fig 3: Installing Thermostat
    G02762725Courtesy 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
    G02762726Courtesy 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
    G02762727Courtesy of FORD MOTOR CO.
  7. Install the eight ignition coils and bolts.
    Fig 6: Installing Ignition Coils And Bolts
    G02762728Courtesy of FORD MOTOR CO.
    8. NOTE: LH shown, RH similar.
    Fig 7: Connecting Fuel Injector Electrical Connectors
    G02762729Courtesy of FORD MOTOR CO.
  8. Connect the eight fuel injector electrical connectors.
    9. NOTE: LH shown, RH similar.
    Fig 8: Connecting Ignition Coil Electrical Connectors
    G02762730Courtesy of FORD MOTOR CO.
  9. Connect the eight ignition coil electrical connectors.
  10. Install the PCV hose and valve.
    Fig 9: Installing PCV Hose And Valve
    G02762731Courtesy of FORD MOTOR CO.
  11. Install the new throttle body adapter gasket.
    Fig 10: Installing Throttle Body Adapter Gasket
    G02762732Courtesy of FORD MOTOR CO.
  12. Install the throttle body and adapter assembly.
    Fig 11: Installing Throttle Body And Adapter Assembly
    G02762733Courtesy 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 50 Nm (37 lb-ft).
    Fig 12: Installing Exhaust Manifold-To-EGR Valve
    G02762734Courtesy of FORD MOTOR CO.
  14. Connect the differential pressure EGR sensor hoses to the EGR valve tube.
    Fig 13: Connecting Differential Pressure EGR Sensor Hoses To EGR Valve Tube
    G02762735Courtesy of FORD MOTOR CO.
  15. Connect the brake booster and the main engine vacuum harnesses.
    Fig 14: Connecting Brake Booster And Main Engine Vacuum Harnesses
    G02762736Courtesy of FORD MOTOR CO.
  16. Connect the IAC electrical connector.
    Fig 15: Connecting IAC Electrical Connector
    G02762737Courtesy of FORD MOTOR CO.
  17. Connect the EGR vacuum hose.
    Fig 16: Connecting EGR Vacuum Hose
    G02762738Courtesy of FORD MOTOR CO.
  18. Connect the EGR vacuum regulator solenoid connections.
    Fig 17: Connecting EGR Vacuum Regulator Solenoid Connections
    G02762739Courtesy of FORD MOTOR CO.
  19. Connect the fuel pressure sensor vacuum hose and electrical connector.
    Fig 18: Connecting Fuel Pressure Sensor Vacuum Hose And Electrical Connector
    G02762740Courtesy of FORD MOTOR CO.
  20. Install the evaporative emission canister purge valve and bracket.
    Fig 19: Installing Evaporative Emission Canister Purge Valve And Bracket
    G02762741Courtesy of FORD MOTOR CO.
  21. Connect the evaporative emission canister purge valve hoses.
    Fig 20: Connecting Evaporative Emission Canister Purge Valve Hoses
    G02762742Courtesy of FORD MOTOR CO.
  22. Connect the IAC fresh air hose.
    Fig 21: Connecting IAC Fresh Air Hose
    G02762743Courtesy of FORD MOTOR CO.
  23. If equipped, connect the auxiliary heater hoses. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 22: Connecting Auxiliary Heater Hoses
    G02762744Courtesy of FORD MOTOR CO.
  24. 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 .
  25. Install the accelerator cable bracket.
    Fig 23: Installing Accelerator Cable Bracket
    G02762745Courtesy of FORD MOTOR CO.
  26. Install the transmission fluid filler tube bracket and bolt.
    Fig 24: Installing Transmission Fluid Filler Tube Bracket And Bolt
    G02762746Courtesy of FORD MOTOR CO.
  27. Install the generator upper support bracket.
    Fig 25: Installing Generator Upper Support Bracket
    G02762747Courtesy of FORD MOTOR CO.
  28. Install the accelerator cable routing bracket.
    Fig 26: Installing Accelerator Cable Routing Bracket
    G02762748Courtesy of FORD MOTOR CO.
  29. Install the differential pressure feedback EGR system bracket.
    Fig 27: Installing Differential Pressure Feedback EGR System Bracket
    G02762749Courtesy of FORD MOTOR CO.
  30. Connect the differential pressure feedback EGR sensor.
    1. Connect the electrical connector.
    2. Connect the two hoses.
    Fig 28: Connecting Differential Pressure Feedback EGR Sensor
    G02762750Courtesy of FORD MOTOR CO.
  31. Connect the TP sensor.
    1. Connect the electrical connector.
    2. Attach the harness routing clip.
    Fig 29: Connecting TP Sensor
    G02762751Courtesy of FORD MOTOR CO.
  32. Connect the coolant hose.
    Fig 30: Connecting Coolant Hose
    G02762752Courtesy of FORD MOTOR CO.
  33. Connect the coolant hose.
    Fig 31: Connecting Coolant Hose
    G02762753Courtesy of FORD MOTOR CO.
  34. Connect the upper radiator hose.
    Fig 32: Connecting Upper Radiator Hose
    G02762754Courtesy of FORD MOTOR CO.
    35. NOTE: Typical is shown.
    Fig 33: Connecting Throttle Controls
    G02762755Courtesy of FORD MOTOR CO.
  35. Connect the throttle controls.
    1. Connect the accelerator cable.
    2. Connect the speed control actuator cable.
    3. Install the throttle return spring.
  36. Install the accelerator cable snow shield.
    Fig 34: Installing Accelerator Cable Snow Shield
    G02762756Courtesy of FORD MOTOR CO.
  37. Install the air cleaner outlet pipe and tighten the clamp.
    Fig 35: Installing Air Cleaner Outlet Pipe
    G02762757Courtesy of FORD MOTOR CO.
  38. Connect the two hoses to the air cleaner outlet pipe.
    Fig 36: Connecting Hoses To Air Cleaner Outlet Pipe
    G02762758Courtesy of FORD MOTOR CO.
  39. Connect the MAF sensor and position the ACL.
    Fig 37: Connecting MAF Sensor
    G02762759Courtesy of FORD MOTOR CO.
  40. Install the ACL.
    • Install the four bolts.
    • Tighten the clamp.
    Fig 38: Installing ACL
    G02762760Courtesy of FORD MOTOR CO.
  41. Install the interior engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  42. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  43. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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