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Intake Manifold: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup, 2005 Ford F550 Super Duty, 2005 Ford F450 Super Duty, and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using new intake manifold gaskets, position the intake manifold.
  2. Using new gaskets, position the coolant crossover tube and install the 2 bolts
    • Tighten to 10 Nm (89 lb-in).
  3. Install the intake manifold bolts and tighten in 2 stages in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
      Fig 1: Identifying Intake Manifold Bolt Tightening Sequence
      G03920576Courtesy of FORD MOTOR CO.
  4. Connect the throttle position (TP) sensor and electronic throttle control electrical connectors.
  5. Connect the engine wiring harness position retainers to the intake manifold.
  6. Connect the brake booster and engine vacuum hose connections to the rear of the intake manifold.
  7. Connect the positive crankcase ventilation (PCV) tube quick connect coupling to the intake manifold. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
  8. Position the evaporative emissions (EVAP) tube and connect the quick connect couplings. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
    Fig 2: Connecting Quick Connect Couplings
    G03920575Courtesy of FORD MOTOR CO.
  9. Connect the 2 heated PCV coolant hoses to the intake manifold.
  10. Connect the 10 fuel injector electrical connectors.
  11. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
  12. Connect the intake manifold runner control (IMRC) actuator electrical connector.
  13. Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION - GASOLINE AND DIESEL .
  14. Connect the heater coolant hose to the coolant crossover assembly.
  15. Connect the heated PCV coolant hose to the coolant crossover assembly.
  16. Connect the upper radiator hose to the thermostat housing.
  17. Install the generator. For additional information, refer to GENERATOR AND REGULATOR .
  18. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  19. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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