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Intake Manifold: Installation

WARNING: This page is about a different car, the 2010 Ford Pickup, 2010 Ford F550 Super Duty, 2010 Ford F450 Super Duty, 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 10 new intake manifold gaskets, position the intake manifold.
  2. Using 2 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 in illustration.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
      Fig 1: Intake Manifold Bolt Tightening Sequence
      G06773256Courtesy 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 .
  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 .
  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 .
  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 .
  19. Install the generator. For additional information, refer to CHARGING SYSTEM .
  20. Install the ACL  outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  21. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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