Intake Manifold Assembly: Assembly

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

Position a new lower intake manifold gasket and the upper intake manifold on the lower intake manifold and loosely install the bolts.

Fig 1: Positioning A New Lower Intake Manifold Gasket
Courtesy of FORD MOTOR CO.
Tighten the bolts in two stages using the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 10 Nm (89 lb-in).
  
  Fig 2: Tightening Bolts
  Courtesy of FORD MOTOR CO.

CAUTION: Check for leakage after installation is complete.

NOTE: Be sure fuel injectors and fuel rail are fully seated.

Fig 3: Installing Fuel Rail

Courtesy of FORD MOTOR CO.

Lubricate the new fuel injector O-ring seals with clean engine oil prior to installation. Install the fuel rail.
Install the TB adapter.
- Position a new TB adapter press-in-place gasket.
- Position the TB adapter.
- Install the four bolts in 2 stages:
  - Stage 1: Tighten to 9 Nm (80 lb-in).
  - Stage 2: Tighten an additional 90 degrees.
    
    Fig 4: Installing Four Bolts
    Courtesy of FORD MOTOR CO.

NOTE: Thermostat must be installed as illustrated.

Fig 5: Positioning Coolant Thermostat In Upper Intake Manifold

Courtesy of FORD MOTOR CO.

Use a new (A) O-ring seal to position the (B) coolant thermostat in the (C) upper intake manifold.
Connect the heated PCV hose.

Fig 6: Connecting Heated PCV Hose
Courtesy of FORD MOTOR CO.