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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 726 (Engine 6.0L Diesel (99P E-Series & 99P F450/550)) >> In-Vehicle Repair >> Intake Manifold >> Installation

Intake Manifold: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

    ALL VEHICLES 

    NOTE: The locating tabs on the gaskets must be positioned upward and toward the center of the engine, or a leak will occur.
    Fig 1: Installing Intake Manifold Gaskets
    G02764378Courtesy of FORD MOTOR CO.
  1. Install the intake manifold gaskets. Install a new front module O-ring seal.
  2. Install the intake manifold and bolts and tighten in the following sequence.
    1. Loosely install bolts 1-8.
    2. Tighten bolts 9-16 to 11 Nm (8 lb-ft).
    3. Tighten all bolts to 11 Nm (8 lb-ft).
    Fig 2: Intake Manifold Bolt Tightening Sequence
    G02764379Courtesy of FORD MOTOR CO.
  3. Slide the EGR cooler hose forward and rotate the flat to lock.
    Fig 3: Sliding EGR Cooler Hose Forward
    G02764380Courtesy of FORD MOTOR CO.
  4. Install the turbocharger heat shield and nuts.
    Fig 4: Installing Turbocharger Heat Shield And Nuts
    G02764381Courtesy of FORD MOTOR CO.
  5. Install the secondary fuel filter assembly and bolts.
    Fig 5: Installing Secondary Fuel Filter Assembly And Bolts
    G02764382Courtesy of FORD MOTOR CO.
    6. NOTE: Install new copper sealing washers.
    Fig 6: Installing Fuel Line And Banjo Bolt
    G02764383Courtesy of FORD MOTOR CO.
  6. Install the fuel line and banjo bolt.
  7. Install the retaining nut and connect the fuel tube at the fuel filter assembly.
    Fig 7: Connecting Fuel Tube Fuel Filter Assembly
    G02764384Courtesy of FORD MOTOR CO.
    8. NOTE: Install new copper sealing washers on the banjo fitting.
    Fig 8: Installing Copper Sealing Washers On Banjo Fitting
    G02764385Courtesy of FORD MOTOR CO.
  8. Reposition and connect the fuel tubes at the fuel filter housing.
  9. Install the secondary fuel filter and cover.
    Fig 9: Installing Secondary Fuel Filter And Cover
    G02764386Courtesy of FORD MOTOR CO.
  10. Connect the engine coolant vent hose.
    Fig 10: Connecting Engine Coolant Vent Hose
    G02764387Courtesy of FORD MOTOR CO.
  11. Connect the MAP sensor hose.
    Fig 11: Connecting MAP Sensor Hose
    G02764388Courtesy of FORD MOTOR CO.
  12. Position back the engine wiring harness as needed. Connect the harness retainers.
    Fig 12: Connecting Harness Retainers
    G02764389Courtesy of FORD MOTOR CO.
    13. NOTE: Only one injector shown, others similar.
    Fig 13: Connecting Fuel Injector Electrical Connectors
    G02764390Courtesy of FORD MOTOR CO.
  13. Connect the eight fuel injector electrical connectors.
  14. Remove the plug or cap. Install the IAT2 sensor.
    Fig 14: Installing IAT2 Sensor
    G02764391Courtesy of FORD MOTOR CO.
  15. Connect the IAT2 sensor electrical connector.
    Fig 15: Connecting IAT2 Sensor Electrical Connector
    G02764392Courtesy of FORD MOTOR CO.
  16. Remove the plug or cap. Install the ECT sensor.
    Fig 16: Installing ECT Sensor
    G02764393Courtesy of FORD MOTOR CO.
  17. Connect the ECT sensor electrical connector and the pin-type retainer.
    Fig 17: Connecting ECT Sensor Electrical Connector
    G02764394Courtesy of FORD MOTOR CO.
  18. Connect the EGR throttle position sensor electrical connector.
    Fig 18: Connecting EGR Throttle Position Sensor Electrical Connector
    G02764395Courtesy of FORD MOTOR CO.
  19. Connect the EGR throttle position control module electrical connector.
    Fig 19: Connecting EGR Throttle Position Control Module Electrical Connector
    G02764396Courtesy of FORD MOTOR CO.
  20. Connect the EOT sensor electrical connector.
    Fig 20: Connecting EOT Sensor Electrical Connector
    G02764397Courtesy of FORD MOTOR CO.
  21. Connect the EOP sensor electrical connector.
    Fig 21: Connecting EOP Sensor Electrical Connector
    G02764398Courtesy of FORD MOTOR CO.
  22. Connect the EGR valve electrical connector.
    Fig 22: Connecting EGR Valve Electrical Connector
    G02764399Courtesy of FORD MOTOR CO.
  23. Connect the injector pressure regulator valve electrical connector and position back the heat insulating wrap. Install the wiring retainer and retaining nut.
    Fig 23: Connecting Injector Pressure Regulator Valve Electrical Connector
    G02764400Courtesy of FORD MOTOR CO.
    24. NOTE: Install a new O-ring seal and apply clean engine coolant
    Fig 24: Installing Heater Tube And Bolts
    G02764401Courtesy of FORD MOTOR CO.
  24. Install the heater tube and bolts.
  25. Install the generator, ground wire and the three bolts.
    Fig 25: Installing Generator, Ground Wire And Three Bolts
    G02764402Courtesy of FORD MOTOR CO.
  26. Position back the transmission fluid indicator and tube and install the retaining nut. Connect the push pin retainer.
    Fig 26: Connecting Push Pin Retainer
    G02764403Courtesy of FORD MOTOR CO.
  27. Install the retaining nut for the transmission fluid indicator and tube.
    Fig 27: Installing Retaining Nut For Transmission Fluid Indicator And Tube
    G02764404Courtesy of FORD MOTOR CO.
  28. Connect the generator B+ wire and electrical connector. Position back the boot. Connect the wiring push pin.
    Fig 28: Connecting Wiring Push Pin
    G02764405Courtesy of FORD MOTOR CO.
    29. NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler tube to prevent the tube from blowing off.
    Fig 29: Installing Retaining Nuts
    G02764406Courtesy of FORD MOTOR CO.
  29. Position the charge air cooler (CAC) tube, oil fill tube and bracket. Install the retaining nuts.
  30. Connect the oil fill tube at the valve cover.
    Fig 30: Connecting Oil Fill Tube Valve Cover
    G02764407Courtesy of FORD MOTOR CO.
  31. Install the bolts for the charge air cooler tube and oil fill tube.
    Fig 31: Installing Charge Air Cooler Tube Bolts
    G02764408Courtesy of FORD MOTOR CO.
  32. Install the conduit and bolts.
    • Install the wiring harness into the conduit and connect the push pin.
    • Install the bolts.
    • Connect the locking tab.
    Fig 32: Connecting Locking Tab
    G02764409Courtesy of FORD MOTOR CO.
  33. Connect the electrical connector push pin. Position back the ground wire and install the bolt.
    Fig 33: Connecting Electrical Connector Push Pin
    G02764410Courtesy of FORD MOTOR CO.

    34. VEHICLES WITH SINGLE GENERATOR 

  34. Install the accessory drive belt.
    Fig 34: Installing Accessory Drive Belt
    G02764411Courtesy of FORD MOTOR CO.

    35. VEHICLES WITH DUAL GENERATOR 

  35. Install the generator with mounting bracket and bolts.
    Fig 35: Installing Generator With Mounting Bracket And Bolts
    G02764412Courtesy of FORD MOTOR CO.
  36. Connect the generator B+ wire and electrical connector. Position the boot.
    Fig 36: Connecting Generator B+ Wire And Electrical Connector
    G02764413Courtesy of FORD MOTOR CO.
  37. Install the accessory drive belt tensioner and bolts.
    Fig 37: Installing Accessory Drive Belt Tensioner And Bolts
    G02764414Courtesy of FORD MOTOR CO.
  38. Position the accessory drive belt idler pulley. Install the bracket and bolts.
    Fig 38: Installing Bracket And Bolts
    G02764415Courtesy of FORD MOTOR CO.
  39. Install the accessory drive belt.
    Fig 39: Installing Accessory Drive Belt
    G02764416Courtesy of FORD MOTOR CO.
  40. Install the accessory drive belt tensioner and bolt.
    Fig 40: Installing Accessory Drive Belt Tensioner And Bolt
    G02764417Courtesy of FORD MOTOR CO.
  41. Install the accessory drive belt.
    Fig 41: Installing Accessory Drive Belt
    G02764418Courtesy of FORD MOTOR CO.

    42. ALL VEHICLES 

  42. Install the turbocharger pedestal and turbocharger. For additional information, refer to FUEL CHARGING & CONTROLS-TURBOCHARGER .
  43. Install the cooling fan stator. For additional information, refer to ENGINE COOLING .
  44. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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