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Intake Manifold: Installation

WARNING: This page is about a different car, the 2009 Ford Pickup, 2009 Ford F550 Super Duty, 2009 Ford F450 Super Duty, and 2009 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. Using new intake manifold gaskets, position the intake manifold.
  2. Using new gaskets, position the engine coolant crossover manifold assembly 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).
    4. Fig 1: Identifying Intake Manifold Bolt Tightening Sequence
    GF0005562Courtesy of FORD MOTOR CO.
  4. Connect the TP sensor and ETC electrical connectors.
  5. Connect the engine wiring harness position retainers to the intake manifold.
  6. Connect the engine vacuum hose connections to the rear of the intake manifold.
  7. Connect the wiring harness and vacuum harness retainers to the rear of the intake manifold.
  8. Connect the PCV tube quick connect coupling to the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  9. Position the EVAP tube and connect the quick connect coupling to the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  10. Connect the 2 heated PCV coolant hoses to the intake manifold.
  11. Connect the 10 fuel injector electrical connectors.
  12. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
  13. Connect the IMRC actuator electrical connector.
  14. Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  15. Connect the heater coolant hose to the coolant crossover assembly.
  16. Connect the heated PCV coolant hose to the coolant crossover assembly.
  17. Connect the upper radiator hose to the thermostat housing.
  18. Position the crankcase ventilation tube and connect the quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
  19. Install the generator. For additional information, refer to CHARGING SYSTEM - GENERAL INFORMATION AND DIAGNOSTICS article.
  20. Install the ACL outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  21. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING article.
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