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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 797 (Engine - 4.6L And 5.4L) >> In-Vehicle Repair >> Intake Manifold - 4.6L >> Installation

Intake Manifold - 4.6L: Installation

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. 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 sealing surfaces.
  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
      G03885112Courtesy of FORD MOTOR CO.
  3. Install the thermostat.
    1. Install the thermostat.
    2. Install a new O-ring seal.
      Fig 2: Installing Thermostat
      G03885169Courtesy of FORD MOTOR CO.
    4. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.
    Fig 3: Installing Thermostat Housing Bolts
    G03886347Courtesy of FORD MOTOR CO.
  4. Install the thermostat housing and loosely install the bolts.
  5. Tighten the 11 bolts in two stages in the sequence shown in Fig 4.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
      Fig 4: Tightening Bolts In Sequence
      G03885115Courtesy of FORD MOTOR CO.
  6. Connect the fuel pressure sensor electrical connector and the vacuum hose.
    Fig 5: Connecting Fuel Pressure Sensor Electrical Connector
    G03885108Courtesy of FORD MOTOR CO.
  7. Install the generator upper support bracket.
    Fig 6: Installing Generator Upper Support Bracket
    G03885117Courtesy of FORD MOTOR CO.
  8. Install the eight ignition coils and bolts.
    Fig 7: Installing Eight Ignition Coils
    G03885118Courtesy of FORD MOTOR CO.
    9. NOTE: LH shown; RH similar.
    Fig 8: Connecting Eight Fuel Injector Electrical Connectors
    G03885105Courtesy of FORD MOTOR CO.
  9. Connect the eight fuel injector electrical connectors.
    10. NOTE: LH shown; RH similar.
    Fig 9: Connecting Eight Coil-On-Plug Electrical Connectors
    G03885104Courtesy of FORD MOTOR CO.
  10. Connect the eight coil-on-plug electrical connectors.
  11. Position a new throttle body adapter gasket and throttle body adapter assembly. Install the four bolts.
    Fig 10: Installing Throttle Body Adapter Assembly
    G03885121Courtesy of FORD MOTOR CO.
  12. Connect the emissions vapor hose.
    Fig 11: Connecting Emissions Vapor Hose
    G03885102Courtesy of FORD MOTOR CO.
  13. Connect the vacuum harness connector.
    Fig 12: Connecting Vacuum Harness Connector
    G03885100Courtesy of FORD MOTOR CO.
  14. If equipped, connect the auxiliary heater hoses. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 13: Connecting Auxiliary Heater Hoses
    G03885101Courtesy of FORD MOTOR CO.
  15. Connect the following vacuum hoses:
    • The brake booster vacuum hose.
    • The positive crankcase ventilation (PCV) valve hose.
    • The coolant hoses.
      Fig 14: Connecting Brake Booster Vacuum Hose
      G03885099Courtesy of FORD MOTOR CO.
  16. Install the exhaust manifold to EGR system module tube.
    • Hand-tighten the upper and lower fittings.
    • Tighten to 40 Nm (30 lb-ft).
      Fig 15: Installing Exhaust Manifold To EGR System Module Tube
      G03885126Courtesy of FORD MOTOR CO.
  17. Connect the vacuum hoses at the EGR system module.
    Fig 16: Connecting Vacuum Hoses
    G03885097Courtesy of FORD MOTOR CO.
  18. Connect the EGR system module electrical connector.
    Fig 17: Connecting EGR System Module Electrical Connector
    G03885096Courtesy of FORD MOTOR CO.
  19. Connect the fuel hose spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  20. Connect the TP sensor electrical connector.
    • Push in the red clip.
      Fig 18: Locating Throttle Position (TP) Sensor Electrical Connector
      G03885095Courtesy of FORD MOTOR CO.
  21. Connect the electronic throttle body electrical connector.
    • Push in the red clip.
      Fig 19: Connecting Electronic Throttle Body Electrical Connector
      G03885094Courtesy of FORD MOTOR CO.
  22. Connect the coolant hose.
    Fig 20: Connecting Coolant Hose
    G03885093Courtesy of FORD MOTOR CO.
  23. Install the upper radiator hose and position the clamp.
    Fig 21: Installing Upper Radiator Hose
    G03885132Courtesy of FORD MOTOR CO.
  24. Position back the transmission fluid indicator and tube. Install the retaining bolt.
    Fig 22: Positioning Back Transmission Fluid Indicator And Tube
    G03885091Courtesy of FORD MOTOR CO.
  25. Install the bolt for the transmission fluid tube and indicator.
    Fig 23: Installing Transmission Fluid Tube And Indicator
    G03885090Courtesy of FORD MOTOR CO.
  26. Install the air cleaner outlet pipe and tighten the clamp. Connect the engine vent tube.
    Fig 24: Installing Cleaner Outlet Pipe
    G03885135Courtesy of FORD MOTOR CO.
  27. Connect the MAF sensor and position the ACL.
    Fig 25: Connecting MAF Sensor
    G03885139Courtesy of FORD MOTOR CO.
  28. Install the ACL.
    1. Install the four bolts.
    2. Tighten the clamp.
      Fig 26: Installing Four Bolts
      G03885137Courtesy of FORD MOTOR CO.
  29. Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  30. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  31. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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