Intake Manifold (4.6L & 5.4L): Installation

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To install, reverse removal procedure. If lower intake manifold was removed, install lower intake manifold. Tighten fasteners to specification. See Fig 3. See TORQUE SPECIFICATIONS .

NOTE: The thermostat housing bolts are tightened in sequence with the upper intake manifold bolts.

Position the new upper intake manifold gaskets. Position intake manifold assembly. Loosely install nine upper intake manifold bolts. Connect the intake manifold tuning valve electrical connector. Install the thermostat housing using a NEW "O" ring seal and loosely install the bolts. Tighten fasteners in sequence. See Fig 4. See TORQUE SPECIFICATIONS .
To complete installation, reverse removal procedure. Install the exhaust manifold to EGR valve tube hand-tight. Tighten upper EGR valve tube fitting, then lower EGR valve tube fitting. Fill and bleed the engine cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEM .

Fig 1: Exploded View Of Intake Manifold Components (4.6L)

Courtesy of FORD MOTOR CO.

Fig 2: Exploded View Of Intake Manifold Components (5.4L)

Courtesy of FORD MOTOR CO.

Fig 3: Lower Intake Manifold Tightening Sequence (4.6L)

Courtesy of FORD MOTOR CO.

Fig 4: Intake Manifold Tightening Sequence (4.6L & 5.4L)

Courtesy of FORD MOTOR CO.