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Home >> Ford >> 2006 >> Focus ZX5 SE, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 60 (Engine - 6.0L Diesel -- F250-F550 Super Duty) >> In-Vehicle Repair >> Intake Manifold >> Installation

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.

    All vehicles 

    NOTE: The locating tabs on the gaskets must be up and positioned toward the center of the engine, or a leak will occur.
    Fig 1: Installing Intake Manifold Gaskets And Front Module O-Ring Seal
    G03887125Courtesy of FORD MOTOR CO.
  1. Install the intake manifold gaskets and front module O-ring seal.
    2. NOTE: When installing the manifold, apply a slight amount of all purpose grease to the mating surface of the EGR tube to keep the EGR gasket in place.
    NOTE: Install the EGR cooler V-clamp loosely in place on the turbo adapter pipe.
  2. Install the intake manifold and loosely install the bolts. Tighten the intake manifold bolts in the sequence shown.
    1. Tighten bolts 9-16 to 11 Nm (8 lb-ft).
    2. Tighten all bolts to 11 Nm (8 lb-ft) in the sequence shown.
      Fig 2: Installing Intake Manifold Bolts
      G03887127Courtesy of FORD MOTOR CO.
  3. Position the EGR cooler V-clamp over the EGR tube.
  4. Install the gasket and the EGR cooler V-clamp.
    Fig 3: Tightening EGR Cooler V-Clamp
    G03907895Courtesy of FORD MOTOR CO.
  5. Slide the EGR cooler hose forward and rotate flat to lock.
    Fig 4: Sliding EGR Cooler Hose Forward
    G03906784Courtesy of FORD MOTOR CO.
  6. Install the fuel line.
    • Install new sealing washers.
    • Install the fuel line.
    • Install the banjo fitting and the bolt.
      Fig 5: Installing Fuel Line Tightening Bolts
      G03906785Courtesy of FORD MOTOR CO.
  7. Install the oil filter return tube and bolt.
    • On new oil filter return tubes, tighten to 6 Nm (53 lb-in).
    • On used oil filter return tubes, tighten to 3 Nm (27 lb-in).
      Fig 6: Installing Oil Filter Return Tube Bolts
      G04519770Courtesy of FORD MOTOR CO.
    8. NOTE: Install a new O-ring seal.
    Fig 7: Installing Oil Filter Housing And Four Bolts
    G03906787Courtesy of FORD MOTOR CO.
  8. Install the oil filter housing and the four bolts.
    9. NOTE: Install new sealing washers on the banjo fitting.
    Fig 8: Connecting Fuel Line
    G03906788Courtesy of FORD MOTOR CO.
  9. Connect the fuel line fittings.
  10. Position the fuel injector harness and install the retaining nut. Connect the eight fuel injectors electrical connectors.
    Fig 9: Connecting Eight Fuel Injectors Electrical Connectors
    G03906789Courtesy of FORD MOTOR CO.

    11. Early build vehicles 

  11. Connect the EP sensor electrical connector.
    Fig 10: Connecting EP Sensor Electrical Connector
    G03906769Courtesy of FORD MOTOR CO.

    12. All vehicles 

  12. Connect the IAT2 sensor electrical connector.
    Fig 11: Connecting IAT2 Sensor Electrical Connector
    G03906768Courtesy of FORD MOTOR CO.
  13. Connect the engine coolant temperature (ECT) sensor and the pin-type retainer.
    Fig 12: Connecting Engine Coolant Temperature (ECT) Sensor And Pin-Type Retainer
    G03887109Courtesy of FORD MOTOR CO.
  14. Connect the engine oil temperature (EOT) sensor electrical connector.
    Fig 13: Locating Engine Oil Temperature Sensor
    G03887108Courtesy of FORD MOTOR CO.
  15. Connect the engine oil pressure (EOP) sensor electrical connector.
    Fig 14: Locating Engine Oil Pressure Sensor Electrical Connector
    G03887107Courtesy of FORD MOTOR CO.
  16. Connect the EGR valve electrical connector.
    Fig 15: Locating EGR Valve Assembly Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  17. Connect the wiring retainer and injector pressure regulator electrical connector. Position back the heat insulating wrap.
    Fig 16: Connecting Wiring Retainer And Injector
    G03906761Courtesy of FORD MOTOR CO.
    18. NOTE: Early build shown, late build similar.
    Fig 17: Installing Injector IPR Heat Shield And Bolts
    G03906799Courtesy of FORD MOTOR CO.
  18. Install the top two bolts to the injector IPR heat shield.
  19. If equipped with a heat shield bracket, install the heat shield bracket and bolts.
    Fig 18: Locating Bolts And Heat Shield Bracket
    G03906759Courtesy of FORD MOTOR CO.
  20. If equipped with a heat shield bracket, connect the wiring retainer to the back of the heat shield bracket.
    Fig 19: Locating Wiring Retainer At Back Of Heat Shield Bracket
    G03906758Courtesy of FORD MOTOR CO.
  21. If equipped with a heat shield bracket, position back the ground wire and install the retaining nuts.
    Fig 20: Identifying Ground Wire Retaining Nuts
    G03906757Courtesy of FORD MOTOR CO.
  22. Install the fuel injector control module. For additional information, refer to ELECTRONIC ENGINE CONTROLS - DIESEL ENGINE .
  23. Connect the engine coolant vent hose and clamp.
    Fig 21: Connecting Engine Coolant Vent Hose And Clamp
    G03906756Courtesy of FORD MOTOR CO.
  24. Connect the MAP sensor hose.
    Fig 22: Connecting MAP Sensor Hose
    G03906804Courtesy of FORD MOTOR CO.
    25. NOTE: Install a new O-ring seal on the heater hose tube.
    Fig 23: Installing Heater Hose Tube And Bolts
    G03906805Courtesy of FORD MOTOR CO.
  25. Install the heater hose tube and bolts.
    26. NOTE: Engine side shown, charge-air-cooler (CAC) side similar.
    Fig 24: Charge Air Cooler Duct And Clamp - With Torque Specification
    G03906806Courtesy of FORD MOTOR CO.
  26. Install the CAC duct and tighten the clamps.
  27. Install the turbocharger pedestal and turbocharger. For additional information, refer to FUEL CHARGING AND CONTROLS - TURBOCHARGER .
    28. NOTE: Alternately tighten the bolts to specification.
    Fig 25: Installing Adapter Pipe Nuts And Bolts - With Torque Specification
    G03906967Courtesy of FORD MOTOR CO.
  28. Tighten the nuts and bolts in the adapter pipe.
  29. Install the generator and the three bolts.
    Fig 26: Generator And Bolts - With Torque Specification
    G03906807Courtesy of FORD MOTOR CO.
  30. Connect the generator B+ wire land electrical connector and position the boot back.
    Fig 27: Connecting Generator Electrical Connector
    G03906808Courtesy of FORD MOTOR CO.

    31. Vehicles with single generator 

  31. Install the accessory drive belt.
    Fig 28: Rotating Accessory Drive Belt Tensioner Clockwise
    G03906750Courtesy of FORD MOTOR CO.

    32. Vehicles with dual generators 

  32. Install the generator with mounting bracket and bolts.
    Fig 29: Locating Bolts And Generator Mounting Bracket - With Torque Specification
    G03887159Courtesy of FORD MOTOR CO.
  33. Connect the B+ wire, generator electrical connector and wire retainer.
    Fig 30: Locating Generator Electrical Connector, Harness and Retainer - With Torque Specification
    G03906811Courtesy of FORD MOTOR CO.
  34. Install the accessory drive belt tensioner and bolts.
    Fig 31: Primary Accessory Drive Belt Tensioner Bolts - With Torque Specification
    G03887161Courtesy of FORD MOTOR CO.
  35. Position the accessory drive belt idler pulley. Install the bracket and bolts.
    Fig 32: Secondary Accessory Drive Belt Idler Pulley Bolts - With Torque Specification
    G03887162Courtesy of FORD MOTOR CO.
  36. Install the accessory drive belt.
    Fig 33: Rotating Accessory Drive Belt Tensioner Clockwise
    G03887088Courtesy of FORD MOTOR CO.
  37. Install the accessory drive belt tensioner and bolt.
    Fig 34: Secondary Accessory Drive Belt Tensioner Bolt - With Torque Specification
    G03907183Courtesy of FORD MOTOR CO.
  38. Install the accessory drive belt.
    Fig 35: Rotating Drive Belt Tensioner Clockwise
    G03887086Courtesy of FORD MOTOR CO.

    39. All vehicles 

    NOTE: Engine side shown, CAC side similar.
    NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler duct to prevent the duct from blowing off.
    Fig 36: Turbocharger-To-Charge Air Cooler Duct Clamp - With Torque Specification
    G03907177Courtesy of FORD MOTOR CO.
  39. Install the turbocharger-to-CAC duct.
  40. Install the upper radiator hose.
    Fig 37: Installing Upper Radiator Hose
    G03906741Courtesy of FORD MOTOR CO.
  41. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  42. Install the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  43. Install the cooling fan stator - 6.0L diesel engine. For additional information, refer to ENGINE COOLING .
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