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Intake Manifold: Installation

WARNING: This page is about a different car, the 2010 Ford Pickup and 2010 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
    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.
  1. Using new intake manifold gaskets, position the intake manifold and intake manifold vacuum tube as an assembly.
  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 10 intake manifold bolts and tighten in 2 stages in the sequence shown in illustration.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
      Fig 1: Identifying Intake Manifold Bolts Tightening Sequence
      G06169237Courtesy of FORD MOTOR CO.
  4. Connect the engine wiring harness retainer to the rear of the intake manifold.
  5. Connect the intake manifold vacuum tube to the support bracket and the valve cover stud.
  6. Connect the brake booster vacuum hose to the intake manifold vacuum tube and position the clamp.
  7. Position the engine wiring harness and connect the wiring harness retainers to the LH valve cover stud bolts.
  8. Connect the LH radio ignition interference capacitor electrical connector.
  9. Connect the LH VCT  solenoid electrical connector.
  10. Connect the TP  sensor and electronic acceleration control electrical connectors.
  11. Connect the 8 fuel injector electrical connectors.
    12. NOTE: RH shown in illustration, LH similar.
    Fig 2: Locating Ignition Coil Electrical Connectors
    G06772559Courtesy of FORD MOTOR CO.
  12. Connect the 8 ignition coil electrical connectors.
  13. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
  14. Position the ACL  outlet pipe-to- TB  adapter and install the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
  15. Connect the crankcase vent tube quick connect coupling to the ACL  outlet pipe-to- TB  adapter. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  16. Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  17. Position the PCV tube and connect the quick connect couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  18. Connect the EVAP  tube quick connect coupling to the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL .
  19. Connect the heater coolant hose to the engine coolant crossover manifold assembly.
  20. Connect the upper radiator hose to the thermostat housing.
  21. Install the generator. For additional information, refer to CHARGING SYSTEM .
  22. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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