Intake Manifold: Installation

All vehicles 

NOTE: The locating tabs on the gaskets must be positioned upward and toward the center of the engine, or a leak will occur.
1. Install the intake manifold gaskets and the new front module O-ring seal.
Fig 1: Locating Intake Manifold Gasket And Front Module O-Ring Seal
Courtesy of FORD MOTOR CO.
2. Install the intake manifold, 5 stud bolts and 11 bolts. Tighten in 3 stages, in the sequence shown.
   • Stage 1: Loosely install bolts 1-8.
   • Stage 2: Tighten bolts 9-16 to 11 Nm (97 lb-in).
   • Stage 3: Tighten all bolts to 11 Nm (97 lb-in).
Fig 2: Intake Manifold Tightening Sequence
Courtesy of FORD MOTOR CO.
3. Slide the EGR cooler hose forward and rotate the flat to lock.
Fig 3: Sliding EGR Cooler Hose Forward
Courtesy of FORD MOTOR CO.
4. Install the secondary fuel filter assembly and the 2 bolts.
   • Tighten to 24 Nm (18 lb-ft).
Fig 4: Locating Secondary Fuel Filter Assembly Bolts
Courtesy of FORD MOTOR CO.
NOTE: Install new copper sealing washers.
5. Install the RH fuel line and banjo bolt.
   • Tighten to 38 Nm (28 lb-ft).
Fig 5: Rh Banjo Bolt & Fuel Tube
Courtesy of FORD MOTOR CO.
6. Install the nut and connect the fuel tube at the fuel filter assembly.
   • Tighten the nut to 13 Nm (115 lb-in).
   • Tighten the fuel tube coupling to 26 Nm (19 lb-ft).
Fig 6: Fuel Tube At Fuel Filter Housing & Nut
Courtesy of FORD MOTOR CO.
NOTE: Install new copper sealing washers on the banjo fitting.
7. Reposition and connect the fuel tubes at the fuel filter housing.
   • Tighten the cylinder head-to-fuel filter tube to 26 Nm (19 lb-ft).
   • Tighten the secondary fuel filter banjo fitting to 35 Nm (26 lb-ft).
   • Tighten the fuel return tube to 43 Nm (32 lb-ft).
Fig 7: Secondary Fuel Filter Fuel Tube Fittings
Courtesy of FORD MOTOR CO.
8. Install the secondary fuel filter and cover.
   • Tighten to 14 Nm (124 lb-in).
Fig 8: Secondary Fuel Filter Cover
Courtesy of FORD MOTOR CO.
9. Connect the engine coolant vent hose.
Fig 9: Engine Coolant Vent Hose
Courtesy of FORD MOTOR CO.
10. Connect the MAP sensor hose.
Fig 10: MAP Sensor Hose
Courtesy of FORD MOTOR CO.
11. Position the engine wiring harness and connect the harness retainers.
Fig 11: Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
12. Connect the 8 fuel injector electrical connectors.
Fig 12: Identifying Fuel Injector Electrical Connector & Retainer Clip
Courtesy of FORD MOTOR CO.
13. Remove the plug or cap. Install the IAT2 sensor.
    • Tighten to 18 Nm (159 lb-in).
Fig 13: Intake Air Temperature (IAT2) Sensor
Courtesy of FORD MOTOR CO.
14. Connect the IAT2 sensor electrical connector.
Fig 14: Identifying Intake Air Temperature (IAT2) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
15. Remove the plug or cap and install the ECT sensor.
    • Tighten to 18 Nm (159 lb-in).
Fig 15: Engine Coolant Temperature (ECT) Sensor
Courtesy of FORD MOTOR CO.
16. Connect the ECT sensor electrical connector and the pin-type retainer.
Fig 16: Identifying Pin-Type Retainer And Engine Coolant Temperature (ECT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
17. Connect the EOT sensor electrical connector.
Fig 17: Locating Engine Oil Temperature Sensor
Courtesy of FORD MOTOR CO.
18. Connect the EOP sensor electrical connector.
Fig 18: Locating Engine Oil Pressure Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
19. Connect the EGR valve electrical connector.
Fig 19: Identifying Exhaust Gas Recirculation (EGR) Valve Electrical Connector
Courtesy of FORD MOTOR CO.
20. Connect the wiring retainer and the IPR valve electrical connector and position back the heat insulating wrap.
Fig 20: Wiring Retainer & Injection Pressure Regulator Valve Electrical Connector
Courtesy of FORD MOTOR CO.
NOTE: Install a new O-ring seal and apply clean engine coolant.
21. Install the heater tube and the 2 bolts.
    • Tighten to 13 Nm (115 lb-in).
Fig 21: Heater Hose Tube Bolts
Courtesy of FORD MOTOR CO.
22. Install the generator, ground wire and the 3 bolts.
    • Tighten to 47 Nm (35 lb-ft).
Fig 22: Generator Bolts
Courtesy of FORD MOTOR CO.
23. Position the transmission fluid indicator and tube, install the retaining nut and connect the pushpin retainer.
    • Tighten to 13 Nm (115 lb-in).
Fig 23: Pushpin & Transmission Fluid Indicator Tube Nut
Courtesy of FORD MOTOR CO.
24. Install the transmission fluid indicator and tube nut.
    • Tighten to 8 Nm (71 lb-in).
Fig 24: Transmission Fluid Indicator Tube Nut
Courtesy of FORD MOTOR CO.
25. Connect the generator B+ wire and electrical connector, position back the boot and connect the wiring pushpin.
    • Tighten to 8 Nm (71 lb-in).
Fig 25: Generator Electrical Connector, B+ Wire & Wiring Pushpin
Courtesy of FORD MOTOR CO.
NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the CAC tube to prevent the tube from blowing off.
26. Position the CAC tube, oil fill tube and bracket and install the 2 nuts.
Fig 26: Locating Retaining Nuts, CAC Tube, Oil Fill Tube And Bracket
Courtesy of FORD MOTOR CO.
27. Connect the oil fill tube at the valve cover.
Fig 27: Identifying Oil Fill Tube At Valve Cover
Courtesy of FORD MOTOR CO.
28. Install the 3 bolts for the CAC tube and oil fill tube.
Fig 28: Locating CAC Tube And Oil Fill Tube Bolts
Courtesy of FORD MOTOR CO.
29. Position the conduit and install the 3 bolts.
Fig 29: Wiring Bolts
Courtesy of FORD MOTOR CO.
30. Connect the pushpin. Position back the MAP sensor assembly and install the bolt.
Fig 30: Manifold Absolute Pressure (MAP) Sensor & Bolts
Courtesy of FORD MOTOR CO.
31. Connect the electrical connector pushpin. Position back the ground wire and install the bolt.
Fig 31: Identifying Ground Wire Bolt & Electrical Connector
Courtesy of FORD MOTOR CO.

Vehicles with single generator 

32. Install the accessory drive belt.
Fig 32: Rotating Accessory Drive Belt Tensioner Clockwise
Courtesy of FORD MOTOR CO.

Vehicles with dual generator 

33. Install the generator with mounting bracket and the 4 bolts.
    • Tighten to 47 Nm (35 lb-ft).
Fig 33: Identifying Generator Mounting Bracket Bolts
Courtesy of FORD MOTOR CO.
34. Connect the generator B+ wire and electrical connector and position the boot.
    • Tighten to 8 Nm (71 lb-in).
Fig 34: Generator Electrical Connector & B+ Wire
Courtesy of FORD MOTOR CO.
35. Install the accessory drive belt tensioner and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 35: Locating Accessory Drive Belt Tensioner Bolts
Courtesy of FORD MOTOR CO.
36. Position the accessory drive belt idler pulley and install the bracket and the 3 bolts.
    • Tighten to 25 Nm (18 lb-ft).
Fig 36: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts
Courtesy of FORD MOTOR CO.
37. Install the accessory drive belt.
Fig 37: Rotating Accessory Drive Belt Tensioner
Courtesy of FORD MOTOR CO.
38. Install the accessory drive belt tensioner and bolt.
    • Tighten to 25 Nm (18 lb-ft).
Fig 38: Locating Accessory Drive Belt Tensioner Bolt
Courtesy of FORD MOTOR CO.
39. Install the accessory drive belt.
Fig 39: Rotating Drive Belt Tensioner Clockwise
Courtesy of FORD MOTOR CO.

All vehicles 

40. Install the cooling fan stator. For additional information, refer to ENGINE COOLING article.
41. Install the turbocharger pedestal and turbocharger. For additional information, refer to FUEL CHARGING AND CONTROLS - TURBOCHARGER article.
42. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.