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Intake Manifold: Installation

WARNING: This page is about a different car, the 2010 Lincoln Town Car. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Align the gasket locator tabs with the slots in the cylinder head.
  1. Install new intake manifold gaskets.
    2. Fig 1: Intake Manifold Gaskets
    GF0013546Courtesy of FORD MOTOR CO.
  2. Install the intake manifold and hand-tighten the 8 bolts.
  3. Install the 8 ignition coil-on-plugs. For additional information, refer to ENGINE IGNITION - 4.6L (2V) article.
  4. Position the intake manifold crash bracket and loosely install the bolts.
  5. Tighten the intake manifold bolts in the sequence shown in illustration.
    • Tighten to 25 Nm (18 lb-ft).
    6. Fig 2: Intake Manifold Bolt Tightening Torque Sequence
    GF0013547Courtesy of FORD MOTOR CO.
  6. Tighten the intake manifold crash bracket bolt.
    • Tighten to 25 Nm (18 lb-ft).
  7. Install the EGR system module tube. For additional information, refer to ENGINE EMISSION CONTROL article.
  8. Install the intake manifold shield and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
  9. Connect the throttle control and the TP sensor electrical connectors.
  10. Install the coolant thermostat. For additional information, refer to ENGINE COOLING article.
  11. Install the generator bracket and the 4 bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
  12. Connect the generator electrical connector.
  13. Attach the 2 generator wiring harness retainers to the generator bracket.
  14. Connect the EVAP canister purge valve hose quick connect couplings to the TB and the EVAP canister purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  15. Connect the intake manifold vacuum hose to the TB spacer.
  16. Connect the EGR system module vacuum and electrical connectors.
  17. Connect the PCV tube quick connect coupling to the TB spacer. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  18. Connect the brake booster vacuum hose to the intake manifold.
  19. Install the heater hose and spring clamp.
  20. Connect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
  21. Connect the 8 fuel injector electrical connectors.
  22. Install the wire harness retainer to the rear of the intake manifold.
  23. Attach the wire harness retainer to the intake manifold crash bracket.
  24. Install the LH cowl extension and the 3 retainer screws and connect the wiring harness electrical connector.
  25. Install the RH cowl extension, 5 retainer screws and the 2 EVAP canister purge valve bracket nuts.
    • Tighten the nuts to 10 Nm (89 lb-in).
  26. Install the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS AND WASHERS article.
  27. Connect the fuel spring lock coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  28. Install the air cleaner and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  29. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  30. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING article.
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