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Home >> Ford >> 2009 >> Flex Limited, FWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 1202 (Engine - 3.0L (4V)) >> In-Vehicle Servicing >> Upper Intake Manifold >> Installation

Upper Intake Manifold: Installation

WARNING: This page is about a different car, the 2008 Mercury Mariner and 2008 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
  1. Position the upper intake manifold and install the bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    2. Fig 1: Identifying Tightening Sequence Of Upper Intake Manifold Bolts
    GF0024211Courtesy of FORD MOTOR CO.
  2. Connect the 2 throttle body coolant hoses.
  3. Attach the 2 main engine control wiring harness electrical connectors to the upper intake manifold.
  4. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold.
  5. Attach the wiring retainer to the EGR vacuum regulator stud bolt and install the nut.
    • Tighten to 6 Nm (53 lb-in).
  6. Connect the EGR vacuum regulator electrical connector.
  7. Connect the IAC valve electrical connector and wiring harness retainer.
  8. Connect the EVAP tube to the upper intake manifold.
  9. Connect the vacuum harness tube fittings to the EGR valve and the EGR vacuum regulator.
  10. Connect the TP sensor electrical connector and attach the wiring retainer.
  11. Attach the transaxle vent tube pin-type retainer to the throttle body.
  12. Install the EGR tube fitting to the EGR valve.
    • Tighten to 40 Nm (30 lb-ft).
  13. Position the accelerator/speed control cables and brackets and install the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
  14. Attach the speed control and accelerator cables to the throttle body.
  15. Install the accelerator cable snow shield and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
  16. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING - 3.0L (4V) article.
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