Intake Manifold: Installation

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

Apply clean engine oil to the O-ring and install a new gasket.
Material: Motorcraft® SAE 5W-40 Full Synthetic Diesel Motor Oil / XO-5W40-5Q3SD (WSS-M2C171-F1)

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NOTE: During installation of the intake manifold, the mixer tube will have to be installed into the intake manifold.

Position the mixer tube in the vehicle. Install the intake manifold and the bolts.

Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 115 lb.in (13 Nm) Stage 3: 142 lb.in (16 Nm)

Fig 1: Intake Manifold Tightening Sequence
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Using a new gasket, install the EGR valve bolts.
Torque: 17 lb.ft (23 Nm)

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Install the mixer tube nuts at the EGR valve.
Torque: Stage 1: 44 lb.in (5 Nm) Stage 2: 89 lb.in (10 Nm)

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Install the mixer tube bolts at the intake manifold.
Torque: 89 lb.in (10 Nm)

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NOTE: During the installation of the EGRT sensor, the threaded bushing must be held with a wrench to prevent damage to the connecting EGR tube.

NOTE: Before installing the EGRT sensor apply a light coat of anti-seize lubricant to the threads of the EGRT sensor.

Install the EGRT sensor.

Material: Motorcraft® High Temperature Nickel Anti-Seize Lubricant / XL-2

Torque: 32 lb.ft (44 Nm)

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Install the throttle body (TB). Refer to: Throttle Body .
Connect the EGRT sensor electrical connector and the wire retainer.

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Install the bolts. Connect the electrical connectors and the wire retainer.
Torque: Front bolt: 44 lb.in (5 Nm) Rear bolt: 89 lb.in (10 Nm)

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Position back the brake booster tube bracket and install the bolt.
Torque: 35 lb.in (4 Nm)

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Position back the fuel tubes and connect the retaining clip. Connect the fuel tubes at the fuel injection pump. Refer to: Quick Release Coupling .

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Install the bolts for the fuel rail.
Torque: 17 lb.ft (23 Nm)

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Connect the glow plug connector to the bracket. Connect the electrical connectors and the wire harness retainer.

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Position back the transmission vent tube and connect the retainers.

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NOTE: Vehicle with rear climate control shown, others similar.

Position back the coolant hose and install the bolt. Connect the retainers and the coolant hose. Use the General Equipment: Hose Clamp Remover/Installer

Torque: 35 lb.in (4 Nm)

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Position back and connect the fuel tubes. Refer to: Quick Release Coupling .

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Remove the oil filler cap and install the engine appearance cover. Install the oil filler cap.

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Position back the coolant hose and connect. Install the coolant hose into the engine appearance cover. Use the General Equipment: Hose Clamp Remover/Installer

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Fill the engine cooling system. Refer to: Engine Cooling System Draining, Vacuum Filling and Bleeding .
Connect the battery ground cable. Refer to: Battery Disconnect and Connect - Vehicles With: Dual Batteries .
Bleed the fuel system. Refer to: Fuel System Bleeding .