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Intake Manifold: Installation

WARNING: This page is about a different car, the 2005 Ford Pickup and 2005 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at the rear of the intake manifold. Use extreme care on installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses.
  1. Using new intake manifold gaskets, position the intake manifold.
  2. Using new gaskets, position the coolant crossover and install the 3 bolts
    • Tighten to 10 Nm (89 lb-in).
  3. Install the intake manifold bolts and tighten in 2 stages in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
      Fig 1: Installing Intake Manifold Bolts In Sequence
      G03919851Courtesy of FORD MOTOR CO.
  4. Connect the HO2S electrical connector and attach the electrical connector retainer.
    Fig 2: Locating HO2S Electrical Connector Retainer At Coolant Tube Support Bracket
    G03919850Courtesy of FORD MOTOR CO.
  5. Connect the engine wiring harness retainer to the CMCV stud and install the nut.
    • Tighten to 10 Nm (89 lb-in).
  6. Connect the CMCV electrical connector.
  7. Connect the CHT sensor jumper harness electrical connector.
    Fig 3: Connecting CHT Sensor Jumper Harness Electrical Connector
    G03919848Courtesy of FORD MOTOR CO.
  8. Connect the LH and RH KS electrical connectors.
    Fig 4: Connecting LH And RH KS Electrical Connectors
    G03919849Courtesy of FORD MOTOR CO.
  9. Connect the intake manifold vacuum tube to the support bracket and the valve cover stud.
  10. Connect the brake booster vacuum hose to the intake manifold vacuum tube.
  11. Position the engine wiring harness and connect the wiring harness retainers to the LH valve cover stud bolts.
  12. Connect the LH radio ignition interference capacitor electrical connector.
  13. Connect the LH VCT solenoid electrical connector.
  14. Connect the LH CMP sensor electrical connector.
    Fig 5: Identifying LH CMP Sensor Electrical Connector
    G03919847Courtesy of FORD MOTOR CO.
  15. Connect the EOP sensor electrical connector.
    Fig 6: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
    G03919846Courtesy of FORD MOTOR CO.
  16. Connect the 4 LH ignition coil electrical connectors.
    Fig 7: Identifying LH Ignition Coil Electrical Connectors
    G03919844Courtesy of FORD MOTOR CO.
  17. Connect the heated PCV intake fitting electrical connector.
    Fig 8: Connecting Heated PCV Intake Fitting Electrical Connector
    G03919845Courtesy of FORD MOTOR CO.
  18. Connect the TP sensor and electronic acceleration control electrical connectors.
  19. Connect the 8 fuel injector electrical connectors.
  20. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
  21. Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to SPRING LOCK COUPLINGS .
  22. Position the PCV tube and connect the quick connect couplings. For additional information, refer to QUICK CONNECT COUPLING .
  23. Connect the EVAP tube quick connect coupling to the intake manifold. For additional information, refer to QUICK CONNECT COUPLING .
  24. Connect the heater coolant hose to the coolant bypass.
  25. Connect the upper radiator hose to the thermostat housing.
  26. Install the generator. For additional information, refer to GENERATOR -- GASOLINE ENGINES .
  27. Install the air cleaner. For additional information, refer to AIR CLEANER ELEMENT -- 5.4L (3V) .
  28. Fill and bleed the engine cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
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