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Intake Manifold: Installation

WARNING: This page is about a different car, the 2006 Ford Pickup, 2006 Ford F550 Super Duty, 2006 Ford F450 Super Duty, and 2006 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

    NOTE: The locating tabs on the gaskets must be up and positioned toward the center of the engine or a leak will occur.
    Fig 1: Locating Intake Manifold Gasket And Front Module O-Ring Seal
    G03887125Courtesy of FORD MOTOR CO.
  1. Install the intake manifold gaskets and front module O-ring seal.
  2. Install the intake manifold and bolts and tighten in 3 stages, in the sequence shown.
    • Stage 1: Loosely install bolts 1 through 8.
    • Stage 2: Tighten bolts 9 through 16 to 11 Nm (8 lb-ft).
    • Stage 3: Tighten all bolts to 11 Nm (8 lb-ft).
      Fig 2: Identifying Intake Manifold Bolts Tightening Sequence
      G04648381Courtesy of FORD MOTOR CO.
  3. Position the EGR cooler V-clamp over the EGR tube.
  4. Install the gasket and the EGR cooler V-clamp.
    • Tighten to 6 Nm (53 lb-in).
      Fig 3: Locating EGR Cooler V-Clamp
      G03899122Courtesy of FORD MOTOR CO.
  5. Slide the EGR cooler hose forward and rotate flat to lock.
    Fig 4: Sliding EGR Cooler Hose
    G04648383Courtesy of FORD MOTOR CO.
  6. Using new sealing washers, install the fuel tube banjo fitting bolt and the support bracket bolt.
    • Tighten the fuel tube banjo fitting bolt to 38 Nm (28 lb-ft).
    • Tighten the bolt to 13 Nm (10 lb-ft).
      Fig 5: Locating Support Bracket Bolts
      G04648384Courtesy of FORD MOTOR CO.
  7. Install the oil filter return tube and bolt.
    • On new oil filter return tubes, tighten to 6 Nm (53 lb-in).
    • On used oil filter return tubes, tighten to 3 Nm (27 lb-in).
      Fig 6: Locating Oil Filter Return Tube Bolt
      G04519770Courtesy of FORD MOTOR CO.
    8. NOTE: Install a new O-ring seal.
  8. Install the oil filter housing and the 4 bolts.
    • Tighten to 15 Nm (11 lb-ft).
      Fig 7: Locating Oil Filter Housing Bolts
      G04648386Courtesy of FORD MOTOR CO.
    9. NOTE: Install new sealing washers on the banjo fitting.
  9. Connect the fuel tube fittings.
    1. Tighten to 26 Nm (19 lb-ft).
    2. Tighten to 38 Nm (28 lb-ft).
    3. Tighten to 26 Nm (19 lb-ft).
    4. Tighten to 43 Nm (32 lb-ft).
      Fig 8: Identifying Fuel Tube Fittings
      G04648387Courtesy of FORD MOTOR CO.
  10. Connect the 8 fuel injectors electrical connectors.
    Fig 9: Identifying Fuel Injector Electrical Connector & Retainer Clip
    G03887113Courtesy of FORD MOTOR CO.
  11. Connect the IAT2 sensor electrical connector.
    Fig 10: Locating IAT2 Sensor Electrical Connector
    G04648389Courtesy of FORD MOTOR CO.
  12. Connect the ECT sensor and the pin-type retainer.
    Fig 11: Identifying Pin-Type Retainer And Engine Coolant Temperature (ECT) Sensor Electrical Connector
    G03887109Courtesy of FORD MOTOR CO.
  13. Connect the EOT sensor electrical connector.
    Fig 12: Locating Engine Oil Temperature Sensor
    G03887108Courtesy of FORD MOTOR CO.
  14. Connect the EOP sensor electrical connector.
    Fig 13: Locating Engine Oil Pressure Sensor Electrical Connector
    G03887107Courtesy of FORD MOTOR CO.
  15. Connect the EGR valve electrical connector.
    Fig 14: Identifying Exhaust Gas Recirculation (EGR) Valve Electrical Connector
    G03887106Courtesy of FORD MOTOR CO.
  16. Connect the wiring retainer and injector pressure regulator electrical connector. Position back the heat insulating wrap.
    Fig 15: Locating Injector Pressure Regulator Electrical Connector
    G04648394Courtesy of FORD MOTOR CO.
  17. Position the turbocharger heat shield and install the 3 bolts.
    1. Tighten to 49 Nm (36 lb-ft).
    2. Tighten to 11 Nm (8 lb-ft).
      Fig 16: Locating Turbocharger Heat Shield Bolts
      G04648395Courtesy of FORD MOTOR CO.
  18. Install the heat shield bracket and bolts.
    Fig 17: Locating Heat Shield Bracket Bolts
    G03906759Courtesy of FORD MOTOR CO.
  19. Connect the wiring retainer to the back of the heat shield bracket.
    Fig 18: Locating Wiring Retainer
    G03906758Courtesy of FORD MOTOR CO.
  20. Position back the ground wire and install the retaining nuts.
    Fig 19: Locating Harness Retainer Nut And Ground Wire Nut
    G03906757Courtesy of FORD MOTOR CO.
  21. Install the fuel injector control module. For additional information, refer to ELECTRONIC ENGINE CONTROLS - DIESEL ENGINE .
  22. Connect the engine coolant vent hose and clamp.
    Fig 20: Locating Engine Coolant Vent Hose And Clamp
    G04648399Courtesy of FORD MOTOR CO.
  23. Connect the MAP sensor hose.
    Fig 21: Locating MAP Sensor Hose
    G04648400Courtesy of FORD MOTOR CO.
    24. NOTE: Install a new O-ring seal on the heater hose tube.
  24. Install the heater hose tube and the 2 bolts.
    • Tighten to 13 Nm (10 lb-ft).
      Fig 22: Locating Heater Hose Tube Bolts
      G04648401Courtesy of FORD MOTOR CO.
    25. NOTE: Engine side shown, CAC side similar.
  25. Install the CAC duct and tighten the clamps.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 23: Locating CAC Duct Clamps
      G04648402Courtesy of FORD MOTOR CO.
  26. Install the turbocharger pedestal and turbocharger. For additional information, refer to FUEL CHARGING & CONTROLS - TURBOCHARGER .
    27. NOTE: Alternately tighten the bolts to specification.
  27. Tighten the nuts and bolts in the adapter pipe.
    • Tighten to 27 Nm (20 lb-ft).
      Fig 24: Identifying Adapter Pipe Bolts
      G03899293Courtesy of FORD MOTOR CO.
  28. Install the generator and the 3 bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 25: Locating Generator Bolts
      G03907094Courtesy of FORD MOTOR CO.
  29. Connect the generator B+ wire, the electrical connector and position the boot back.
    • Tighten to 8 Nm (71 lb-in).
      Fig 26: Locating Generator B+ Wire, Electrical Connector
      G04648405Courtesy of FORD MOTOR CO.

    30. Vehicles with single generator 

  30. Install the accessory drive belt.
    Fig 27: Rotating Accessory Drive Belt Tensioner
    G03906750Courtesy of FORD MOTOR CO.

    31. Vehicles with dual generators 

  31. Install the generator with mounting bracket and the 4 bolts.
    • Tighten to 47 Nm (35 lb-ft).
      Fig 28: Identifying Generator Mounting Bracket Bolts
      G03887092Courtesy of FORD MOTOR CO.
  32. Connect the B+ wire, generator electrical connector and wiring harness retainer.
    • Tighten to 8 Nm (71 lb-in).
      Fig 29: Locating Wire Retainer And Generator Electrical Connectors
      G03907090Courtesy of FORD MOTOR CO.
  33. Install the accessory drive belt tensioner and bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 30: Locating Accessory Drive Belt Tensioner Bolts
      G03887090Courtesy of FORD MOTOR CO.
  34. Position the accessory drive belt idler pulley. Install the bracket and bolts.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 31: Locating Bracket And Accessory Drive Belt Idler Pulley Bolts
      G03887089Courtesy of FORD MOTOR CO.
  35. Install the accessory drive belt.
    Fig 32: Rotating Accessory Drive Belt Tensioner
    G03887088Courtesy of FORD MOTOR CO.
  36. Install the accessory drive belt tensioner and bolt.
    • Tighten to 25 Nm (18 lb-ft).
      Fig 33: Locating Accessory Drive Belt Tensioner Bolt
      G03887087Courtesy of FORD MOTOR CO.
  37. Install the accessory drive belt.
    Fig 34: Rotating Drive Belt Tensioner Clockwise
    G03887086Courtesy of FORD MOTOR CO.

    38. All vehicles 

    NOTE: Engine side shown, CAC side similar.
    NOTE: If there is any oil residue, clean both connecting ports and the inside surface of the charge air cooler duct to prevent the duct from blowing off.
  38. Install the turbocharger-to-CAC duct.
    • Tighten to 12 Nm (9 lb-ft).
      Fig 35: Locating Turbocharger-To-CAC Duct
      G04648414Courtesy of FORD MOTOR CO.
  39. Connect the upper radiator hose.
    Fig 36: Locating Upper Radiator Hose
    G04648415Courtesy of FORD MOTOR CO.
  40. Install the degas bottle. For additional information, refer to ENGINE COOLING .
  41. Install the auxiliary battery. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  42. Install the cooling fan stator. For additional information, refer to ENGINE COOLING .
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