Intake Manifold: Installation

WARNING: This page is about a different variant/trim than selected.

NOTE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Visually inspect the intake manifold gasket for nicks, cuts and abrasions. If these conditions are not present, the gaskets may be re-used.

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NOTE: Apply threadlock 262 to the intake manifold bolt threads.

NOTE: Make sure the KS wiring connectors are properly routed and not trapped behind the intake manifold while installing the intake manifold.

Install the intake manifold and tighten the bolts in sequence shown below.

Material: Motorcraft ® Threadlock 262 / TA-26 (WSK-M2G351-A6)

Torque:

Stage 1: Tighten bolts 1, 2 and 7 to: 18 lb.in (2 Nm)

Stage 2: Tighten bolts 3 and 4 to: 18 lb.in (2 Nm)

Stage 3: Tighten bolts 1 and 2 to: 159 lb.in (18 Nm)

Stage 4: Tighten bolts 3, 4, 5 and 6 to: 89 lb.in (10 Nm)

Stage 5: Retighten bolts 1 and 2 to: 159 lb.in (18 Nm)

Stage 6: Tighten bolt 7 to: 159 lb.in (18 Nm)

Stage 7: Retighten bolts 3, 4, 5 and 6 to: 89 lb.in (10 Nm)

Fig 1: Intake Manifold Bolts Tightening Sequence
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Position the vacuum tube and install the retainer.
Torque: 89 lb.in (10 Nm)

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Install the intake manifold support bracket bolt.
Torque: 159 lb.in (18 Nm)

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Position the wire harness and attach the wiring harness retainers.

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Connect the throttle body electrical connector and the wiring harness retainer.

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Connect the electrical connectors and the wiring harness retainers.

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1. Connect the (KS) knock sensors.
2. Attach the (KS) knock sensors.
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- Install the hose.
  Use the General Equipment: Hose Clamp Remover/Installer
- Connect the vent tube.
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Install the CAC intake pipe on the throttle body.

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1. Tighten the CAC intake pipe clamp.
  Torque
  
  : 44 lb.in (5 Nm)
2. Install the CAC intake pipe bolt.
  Torque
  
  : 71 lb.in (8 Nm)
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Connect the wiring harness electrical connectors and retainer.

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- Position the crankcase vent tube and release clamp.
  Use the General Equipment: Hose Clamp Remover/Installer
- Connect the crankcase pressure sensor wiring harness electrical connector.
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Install the following items:
1. Install the generator. Refer to: Generator .
2. Install the charge air cooler. Refer to: Charge Air Cooler (CAC) .
3. Install the EVAP canister purge valve. Refer to: Evaporative Emission Canister Purge Valve .
4. Install the upper air cleaner outlet pipe. Refer to: Air Cleaner Outlet Pipe .
5. Install the air cleaner. Refer to: Air Cleaner .
Connect the battery ground cable. Refer to: Battery Disconnect and Connect .