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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 972 (Engine - 4.6L (2V) - F150 Pickup) >> In-Vehicle Repair >> Intake Manifold >> Installation

Intake Manifold: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup. 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 other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
  1. Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep and silicone gasket remover. Follow the directions on the packaging.
  2. Install the intake manifold.
    1. Position the new intake manifold gaskets.
    2. Position the intake manifold.
    3. Loosely install the 9 intake manifold bolts.
    Fig 1: Installing Intake Manifold
    G03962362Courtesy of FORD MOTOR CO.
  3. Tighten the intake manifold bolts in the sequence shown.
    • Tighten to 10 Nm (89 lb-in).
    Fig 2: Tightening Intake Manifold Bolts In Sequence
    G03962363Courtesy of FORD MOTOR CO.
  4. Attach the wiring harness to the left valve cover.
  5. Install the thermostat.
  6. Install the thermostat housing and a new thermostat housing O-ring seal.
  7. Install the 2 thermostat housing bolts.
    • Tighten to 25 Nm (18 lb-ft).
  8. Connect the electronic throttle control electrical connector.
  9. Install the 8 ignition coil and the 8 ignition coils bolts.
    • Tighten to 6 Nm (53 lb-in).
  10. Connect the 8 ignition coil electrical connectors.
  11. Connect the 8 fuel injector electrical connectors.
  12. Install the generator and the 2 lower generator bolts.
    • Tighten to 25 Nm (18 lb-ft).
  13. Install the generator support bracket and the 4 generator support bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
  14. Attach the generator wiring harness retainer.
  15. Install the generator battery cable and the generator battery cable nut.
    • Tighten to 10 Nm (89 lb-in).
  16. Connect the generator electrical connector.
  17. Connect the TB spacer coolant hose to the intake manifold.
    Fig 3: Connecting TB Spacer Coolant Hose To Intake Manifold
    G03962361Courtesy of FORD MOTOR CO.
  18. If equipped, connect the vacuum hose.
    Fig 4: Connecting Vacuum Hose
    G03962983Courtesy of FORD MOTOR CO.
  19. Rotate the tensioner clockwise and install the accessory drive belt.
    Fig 5: Rotating Tensioner Clockwise And Installing Accessory Drive Belt
    G03886148Courtesy of FORD MOTOR CO.
  20. Install the PCV coolant return hose and install the PCV coolant hose clamp.
  21. Connect the PCV tube quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  22. Connect the fuel supply tube spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  23. Connect the EGR system module vacuum and electrical connectors.
  24. Install the EGR system module-to-exhaust manifold tube.
    • Tighten to 40 Nm (30 lb-ft).
  25. Connect the brake booster tube and position the brake booster bracket and install the nut.
    • Tighten to 10 Nm (89 lb-in).
  26. Connect the IPR sensor vacuum connector.
  27. Connect the IPR sensor electrical connector.
  28. Install the power steering reservoir support bracket and the 2 power steering reservoir support bracket bolts.
    • Tighten to 17 Nm (13 lb-ft).
  29. Install the power steering reservoir support bracket bolt.
    • Tighten to 11 Nm (8 lb-ft).
  30. Connect the TP sensor electrical connector.
  31. Connect the vapor tube quick connect coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  32. Install the heater hose and install the heater hose clamp.
  33. Install the upper radiator hose and clamp.
  34. Install the air cleaner outlet tube. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  35. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  36. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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