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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1121 (Engine - 4.6L And 5.4L) >> In-Vehicle Servicing >> Intake Manifold - 5.4L >> Installation

Intake Manifold - 5.4L: Installation

WARNING: This page is about a different car, the 2008 Ford RV Cutaway, 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which can cause leak paths. Use a plastic scraping tool to clean sealing surfaces.
  1. Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
  2. Position new intake manifold gaskets, the intake manifold and loosely install the 9 bolts.
  3. Using a new O-ring seal, install the thermostat.
    4. Fig 1: Thermostat & O-Ring
    GF0011609Courtesy of FORD MOTOR CO.
    NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.
  4. Loosely install the thermostat housing and the 2 bolts.
    5. Fig 2: Identifying Thermostat Housing And Bolts
    G03885109Courtesy of FORD MOTOR CO.
  5. Tighten the 11 bolts in 2 stages in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    6. Fig 3: Intake Manifold Bolt Torque Sequence
    GF0011610Courtesy of FORD MOTOR CO.
  6. Install the 8 ignition coils and the 8 bolts.
    • Tighten to 6 Nm (53 lb-in).
    7. NOTE: LH shown, RH similar.
  7. Connect the 8 fuel injector electrical connectors.
    8. Fig 4: Fuel Injector Electrical Connectors
    G03885105Courtesy of FORD MOTOR CO.
    NOTE: LH shown, RH similar.
  8. Connect the 8 ignition coil electrical connectors.
    9. Fig 5: Identifying Ignition Coil Electrical Connectors
    G03885104Courtesy of FORD MOTOR CO.
  9. Connect the fuel rail pressure and temperature sensor vacuum hose and electrical connector.
    10. Fig 6: Fuel Rail Pressure & Temperature Sensor Vacuum Hose & Electrical Connector
    GF0011607Courtesy of FORD MOTOR CO.
  10. Position the PCV tube and connect the quick connect couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  11. If equipped, connect the auxiliary heater hoses. For additional information, refer to CLIMATE CONTROL SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
    12. Fig 7: Identifying Auxiliary Heater Hoses
    G03885101Courtesy of FORD MOTOR CO.
  12. Position the transmission fluid indicator and tube and install the retaining nut.
    • Tighten to 28 Nm (21 lb-ft).
    13. Fig 8: Identifying Transmission Fluid Indicator Tube Retaining Nut
    G03885597Courtesy of FORD MOTOR CO.
  13. Install the transmission fluid filler tube support bracket bolt.
    • Tighten to 10 Nm (89 lb-in).
    14. Fig 9: Identifying Tube Support Bracket Bolt
    G03887936Courtesy of FORD MOTOR CO.
  14. Install the generator upper support bracket and the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
  15. Connect the coolant hose.
    16. Fig 10: Locating Heater Coolant Hose
    G03885093Courtesy of FORD MOTOR CO.
  16. Connect the upper radiator hose.
  17. Position the crankcase ventilation tube and connect quick connect coupling to the LH valve cover. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
    18. Fig 11: Crankcase Ventilation Tube Connect Quick Connect Coupling
    GF0011611Courtesy of FORD MOTOR CO.
  18. Install the TB spacer. For additional information, refer to FUEL CHARGING AND CONTROLS - 4.6L (2V) AND 5.4L (2V) article.
  19. Connect the fuel supply tube spring lock coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  20. Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.
  21. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  22. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING article.
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