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Lower 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. Using a plastic scraping tool, silicone gasket remover and metal surface prep, clean the gasket mating surfaces. Follow the directions on the packaging.
    2. NOTE: If the lower intake manifold is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 1: Installing Lower Intake Manifold Front And Rear Seals
    G03961988Courtesy of FORD MOTOR CO.
  2. Install the lower intake manifold front and rear seals.
    1. Apply a bead of silicone gasket and sealant to the intake manifold front and rear seal mounting points as indicated.
    2. Install the lower intake manifold front and rear seals.
  3. Install the intake manifold gaskets.
    Fig 2: Installing Intake Manifold Gaskets
    G03961989Courtesy of FORD MOTOR CO.
    4. NOTE: If the lower intake manifold is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
    Fig 3: Positioning Lower Intake Manifold
    G03961990Courtesy of FORD MOTOR CO.
  4. Position the lower intake manifold.
    1. Apply a bead of silicone gasket and sealant to the lower intake manifold gaskets and front and rear seal junctions in 4 places as shown.
    2. Position the lower intake manifold.
    5. NOTE: Make sure the bolts are installed in the correct locations. The long bolts are installed in positions 1, 2, 3, 4, 11 and 12.
    Fig 4: Tightening Bolts In Sequence
    G03961991Courtesy of FORD MOTOR CO.
  5. Tighten the bolts in the sequence shown in 2 stages.
    • Stage 1: Tighten to 5 Nm (44 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
  6. Connect the heater inlet hose and position the clamp.
  7. Connect the bypass hose and position the clamp.
  8. Connect the upper radiator hose and position the clamp.
  9. Connect the heater outlet hose and position the clamp.
  10. Position the fuel rail, the fuel charging wiring harness and the engine vacuum hose harness as an assembly and install the bolts.
    • Tighten to 10 Nm (89 lb-in).
  11. Connect the IMRC actuator and the fuel charging wiring harness-to-main engine wiring harness electrical connectors.
  12. Connect the fuel supply spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  13. Install the upper intake manifold. For additional information, refer to UPPER INTAKE MANIFOLD .
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