Upper Intake Manifold: Installation

WARNING: This page is about a different car, the 2010 Mercury Mariner and 2010 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

NOTE: Clean and inspect all sealing surfaces. Install new gaskets.

Position the upper intake manifold and install the 7 bolts.
- Tighten the bolts in 2 stages in the sequence shown.
  - Stage 1: Tighten to 10 Nm (89 lb-in).
  - Stage 2: Tighten an additional 45 degrees.
    
    Fig 1: Identifying Upper Intake Manifold Bolts In Sequence
    Courtesy of FORD MOTOR CO.
Install the 2 upper intake manifold support bracket bolts.
- Tighten to 10 Nm (89 lb-in).
Connect the MAP electrical connector and attach the wiring retainer.
Connect the PCV tube to the upper intake manifold.
Attach the engine control wiring harness retainer to the upper intake manifold.
Connect the EVAP tube-to- EVAP canister purge valve quick connect coupling and the brake booster vacuum tube to the upper intake manifold.
Connect the EGR regulator electrical connector and attach the wiring retainer.
Connect the EVAP canister purge valve electrical connector.
Connect the electronic throttle control electrical connector.
Install the EGR tube fitting to the EGR valve.
- Tighten to 40 Nm (30 lb-ft).
Install the ACL outlet pipe and the ACL . For additional information, refer to AIR CLEANER OUTLET PIPE .