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.

Position new gaskets in the upper intake manifold.
Position the upper intake manifold and install the bolts in the sequence shown.

Fig 1: Installing Sequence Of Upper Intake Manifold Bolts
Courtesy of FORD MOTOR CO.
Install the EGR vacuum regulator valve.
1. Position the valve.
2. Install the bolts.
3. Connect the electrical connector.
4. Connect the vacuum hose.
Fig 2: Installing EGR Vacuum Regulator Valve
Courtesy of FORD MOTOR CO.
Install the EGR valve.
1. Position the EGR.
2. Install the bolts.
3. Install the nuts
4. Connect the vacuum hose.
Fig 3: Installing EGR Valve
Courtesy of FORD MOTOR CO.
Connect the PCV and EVAP vacuum hoses.

Fig 4: Connecting PCV And EVAP Vacuum Hoses
Courtesy of FORD MOTOR CO.
Connect the EGR vacuum regulator valve and vacuum supply hoses.

Fig 5: Connecting EGR Vacuum Regulator Valve And Vacuum Supply Hoses
Courtesy of FORD MOTOR CO.
Connect the harness to the throttle body stud.

Fig 6: Connecting Harness To Throttle Body Stud
Courtesy of FORD MOTOR CO.
Connect the TPS and IAC valve electrical connectors.

Fig 7: Connecting TPS And IAC Valve Electrical Connectors
Courtesy of FORD MOTOR CO.
Connect the throttle cable and the cruise control cable.

Fig 8: Connecting Throttle Cable And Cruise Control Cable
Courtesy of FORD MOTOR CO.
Install the pin-type retainers and the accelerator cable splash shield.

Fig 9: Installing Pin-Type Retainers And Accelerator Cable Splash Shield
Courtesy of FORD MOTOR CO.
Install the air cleaner outlet tube.
1. Position the air cleaner outlet tube.
2. Install the clamps.
3. Install the hoses.
Fig 10: Installing Air Cleaner Outlet Tube
Courtesy of FORD MOTOR CO.