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Home >> Mercury >> 2009 >> Mariner Base, 2.5 7, AWD >> Repair and Diagnosis >> External Pages >> Different car >> Section 79 (Engine Mechanical - 5.4L (4V)) >> Disassembly And Assembly Of Subassemblies >> Intake Manifold Assembly >> Assembly

Intake Manifold Assembly: Assembly

WARNING: This page is about a different car, the 2009 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Apply threadlock and sealer to the CAC bolts prior to installation.
  1. Position the CAC, the 2 CAC rail supports and install the 10 bolts.
    • Tighten the bolts in the sequence shown in 2 stages:
      • Stage 1: Tighten to 2 Nm (18 lb-in).
      • Stage 2: Tighten to 10 Nm (89 lb-in).
    2. Fig 1: Positioning CAC & Tightening Bolts In Sequence
    GF0000590Courtesy of FORD MOTOR CO.
  2. Install a new gasket, the lower intake manifold cover and the 13 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
    3. Fig 2: Positioning Gasket Lower Intake Manifold Cover & Tightening Bolts In Sequence
    GF0000591Courtesy of FORD MOTOR CO.
    NOTE: Apply clean engine coolant to the new CAC coolant connector tube O-ring seals.
  3. Install new O-ring seals on the CAC coolant connector tubes.
    • Install the CAC coolant connector tubes.
  4. Install a new gasket, the CAC coolant tube assembly and the 5 bolts.
    • Tighten to 10 Nm (89 lb-in).
  5. Install the IAT2 sensor.
    • Tighten to 15 Nm (133 lb-in).
  6. Install the vacuum tube.
  7. Install a new gasket, the SC and the 10 bolts.
    • Tighten the bolts in the sequence shown in 2 stages:
      • Tighten to 5 Nm (44 lb-in).
      • Tighten to 25 Nm (18 lb-ft).
    8. Fig 3: Positioning Supercharger & Tightening Bolts In Sequence
    GF0000592Courtesy of FORD MOTOR CO.
    NOTE: Lubricate the new O-ring seal with clean engine oil prior to installation.
  8. Install new O-ring seals on each of the fuel injectors.
  9. Install the fuel injectors onto the fuel rail and install the locking clips.
  10. Install the fuel rail and fuel injector assembly onto the intake manifold.
  11. Install the 4 fuel rail bolts.
    • Tighten to 10 Nm (89 lb-in).
  12. Connect the vacuum tube to the fuel rail and pressure temperature sensor.
  13. Install a new gasket, the EGR system module and the 2 bolts.
    • Tighten to 25 Nm (18 lb-ft).
  14. Install the upper and lower SC bypass actuator vacuum tubes.
  15. Install the SC bubbler hose.
  16. Install the heater hose.
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