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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 - 5.4L >> Installation

Intake Manifold - 5.4L: 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 and inspect all sealing surfaces.
  2. Position the intake manifold gaskets and the intake manifold.
    Fig 1: Positioning Intake Manifold
    G03905345Courtesy of FORD MOTOR CO.
  3. Loosely install the nine bolts.
    Fig 2: Installing Nine Bolts
    G03885110Courtesy of FORD MOTOR CO.
  4. Install the thermostat.
    1. Install the thermostat.
    2. Install a new O-ring seal.
      Fig 3: Installing Thermostat
      G03885169Courtesy of FORD MOTOR CO.
    5. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.
    Fig 4: Installing Thermostat Housing Bolts
    G03885109Courtesy of FORD MOTOR CO.
  5. Loosely install the thermostat housing and bolts.
  6. Tighten the bolts in two stages, in the sequence shown in Fig 5.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
      Fig 5: Tightening Bolts In Sequence
      G03905349Courtesy of FORD MOTOR CO.
  7. Install the eight ignition coils and bolts.
    Fig 6: Installing Eight Ignition Coils
    G03885118Courtesy of FORD MOTOR CO.
    8. NOTE: LH shown; RH similar.
    Fig 7: Connecting Eight Fuel Injector Electrical Connectors
    G03885105Courtesy of FORD MOTOR CO.
  8. Connect the eight fuel injector electrical connectors.
    9. NOTE: LH shown; RH similar.
    Fig 8: Connecting Eight Ignition Coil Electrical Connectors
    G03885104Courtesy of FORD MOTOR CO.
  9. Connect the eight ignition coil electrical connectors.
  10. Connect the fuel pressure sensor vacuum hose and electrical connector.
    Fig 9: Connecting Fuel Pressure Sensor Vacuum Hose
    G03885160Courtesy of FORD MOTOR CO.
  11. Install the PCV hose and valve.
    Fig 10: Installing PCV Hose
    G03885159Courtesy of FORD MOTOR CO.
  12. Install the new throttle body adapter gasket.
    Fig 11: Installing Throttle Body Adapter Gasket
    G03885177Courtesy of FORD MOTOR CO.
  13. Install the throttle body and adapter assembly. Install the four bolts.
    Fig 12: Installing Throttle Body And Adapter Assembly
    G03885178Courtesy of FORD MOTOR CO.
  14. Install the exhaust manifold-to-EGR valve tube and tighten the fitting in two stages.
    • Stage 1: Hand-tighten the fittings.
    • Stage 2: Tighten to 50 Nm (37 lb-ft).
      Fig 13: Installing Exhaust Manifold-To-EGR Valve Tube
      G03885157Courtesy of FORD MOTOR CO.
  15. Connect the brake booster and the main engine vacuum harnesses.
    Fig 14: Connecting Brake Booster
    G03885156Courtesy of FORD MOTOR CO.
  16. Connect the EGR vacuum hose.
    Fig 15: Connecting EGR Vacuum Hose
    G03885155Courtesy of FORD MOTOR CO.
  17. Install the evaporative emission canister purge valve.
    Fig 16: Installing Evaporative Emission Canister Purge Valve
    G03885182Courtesy of FORD MOTOR CO.
  18. Connect the EGR vacuum regulator solenoid connections.
    Fig 17: Connecting EGR Vacuum Regulator Solenoid Connections
    G03885153Courtesy of FORD MOTOR CO.
  19. If equipped, connect the auxiliary heater hoses. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 18: Connecting Auxiliary Heater Hoses
    G03885101Courtesy of FORD MOTOR CO.
  20. Connect the evaporative emissions hose on the intake manifold.
    Fig 19: Connecting Evaporative Emissions Hose On Intake Manifold
    G03885151Courtesy of FORD MOTOR CO.
  21. Position back the transmission fluid indicator and tube. Install the retaining nut.
    Fig 20: Positioning Back Transmission Fluid Indicator And Tube
    G03886354Courtesy of FORD MOTOR CO.
  22. Install the transmission fluid filler tube bracket and bolt.
    Fig 21: Installing Transmission Fluid Filler Tube Bracket
    G03887955Courtesy of FORD MOTOR CO.
  23. Install the generator upper support bracket.
    Fig 22: Installing Generator Upper Support Bracket
    G03885188Courtesy of FORD MOTOR CO.
  24. Install the differential pressure feedback EGR system bracket.
    Fig 23: Installing Differential Pressure Feedback EGR System Bracket
    G03885189Courtesy of FORD MOTOR CO.
  25. Connect the differential pressure feedback EGR sensor.
    1. Connect the electrical connector.
    2. Connect the two hoses.
      Fig 24: Connecting Electrical Connector
      G03885146Courtesy of FORD MOTOR CO.
  26. If equipped, connect the coolant hoses to the TB.
    Fig 25: Connecting Coolant Hoses
    G03885145Courtesy of FORD MOTOR CO.
  27. Connect the coolant hose.
    Fig 26: Connecting Coolant Hose
    G03885093Courtesy of FORD MOTOR CO.
  28. Connect the upper radiator hose.
    Fig 27: Connecting Upper Radiator Hose
    G03885193Courtesy of FORD MOTOR CO.
  29. Connect the TP sensor electrical connector.
    • Push back the red clip.
      Fig 28: Locating Throttle Position (TP) Sensor Electrical Connector
      G03885095Courtesy of FORD MOTOR CO.
  30. Connect the electronic TB electrical connector.
    • Push back the red clip.
      Fig 29: Connecting Electronic TB Electrical Connector
      G03885094Courtesy of FORD MOTOR CO.
  31. Install the air cleaner outlet pipe and tighten the clamp. Connect the engine vent tube.
    Fig 30: Connecting Engine Vent Tube
    G03885135Courtesy of FORD MOTOR CO.
  32. Connect the MAF sensor and position the ACL.
    Fig 31: Connecting MAF Sensor
    G03885139Courtesy of FORD MOTOR CO.
  33. Install the ACL.
    1. Install the four bolts.
    2. Tighten the clamp.
      Fig 32: Installing Four Bolts
      G03885137Courtesy of FORD MOTOR CO.
  34. Connect the fuel hose spring lock couplings. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  35. Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  36. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  37. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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