Upper Intake Manifold: Installation

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.

Clean all the sealing surfaces.
Inspect the upper intake manifold gaskets. Install new gasket as necessary.

Fig 1: Identifying Upper Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.
Install the upper intake manifold. Tighten bolts in two stages in the sequence shown.
1. Stage 1: Tighten the bolts hand tight.
2. Stage 2: Tighten the bolts to 10 Nm (89 lb-in).
Fig 2: Identifying Bolts Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Connect the spark plug holder and the radio interference capacitor electrical connector.

Fig 3: Connecting Spark Plug Holder And Radio Interference Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the wire harness retaining clip.

Fig 4: Connecting Wire Harness Retaining Clip
Courtesy of FORD MOTOR CO.
Connect the vacuum regulator solenoid vacuum and electrical connections. Connect the vacuum hose to the upper intake manifold.

Fig 5: Connecting Vacuum Regulator Solenoid Vacuum And Electrical Connections
Courtesy of FORD MOTOR CO.
Connect the vacuum hose to the EGR valve.

Fig 6: Connecting Vacuum Hose
Courtesy of FORD MOTOR CO.
Connect the EGR tube to the EGR valve.

Fig 7: Connecting EGR Tube Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Connect the PCV tube to the upper intake manifold.

Fig 8: Connecting PCV Tube Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Install the upper intake manifold support bracket.

Fig 9: Installing Upper Intake Manifold Support Bracket
Courtesy of FORD MOTOR CO.
Connect the engine wiring harness to the intake manifold support bracket.

Fig 10: Connecting Engine Wiring Harness Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Connect the IAC and TP sensor electrical connectors.

Fig 11: Connecting IAC And TP Sensor Electrical Connectors Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Connect the evaporative emissions return tube and the vacuum hose.

Fig 12: Connecting Evaporative Emissions Return Tube And Vacuum Hose
Courtesy of FORD MOTOR CO.
Position the accelerator cable bracket and install the bolts.

Fig 13: Positioning Bolts Of Accelerator Cable Bracket
Courtesy of FORD MOTOR CO.
Connect the accelerator control cable, speed control cable and the throttle return spring.

Fig 14: Connecting Accelerator Control Cable, Speed Control Cable And Throttle Return Spring
Courtesy of FORD MOTOR CO.
Install the snow shield.

Fig 15: Installing Snow Shield
Courtesy of FORD MOTOR CO.
Install the air cleaner assembly and the air cleaner outlet tube. For additional information, refer to REMOVAL & INSTALLATION .
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .