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Intake Manifold: Installation

WARNING: This page is about a different car, the 2004 Ford RV Cutaway, 2004 Ford Econoline, 2004 Ford E450 Super Duty, and 2004 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Install the intake manifold.
    • Position the intake manifold gaskets and the intake manifold, and loosely install the bolts.
    Fig 1: Installing Intake Manifold
    G02763778Courtesy of FORD MOTOR CO.
    2. NOTE: Do not tighten the bolts at this time.
  2. Install the thermostat housing.
  3. Tighten the bolts in the sequence shown in two stages.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 25 Nm (18 lb-ft).
    Fig 2: Intake Manifold Bolt Tightening Sequence
    G02763779Courtesy of FORD MOTOR CO.
  4. Install the screws and the 10 coils.
    • Apply dielectric grease to the inside of the coil boots.
    Fig 3: Installing Ignition Coils
    G02763780Courtesy of FORD MOTOR CO.
  5. Connect the cylinder head temperature (CHT) sensor electrical connectors.
    Fig 4: Connecting Cylinder Head Temperature (CHT) Sensor Electrical Connectors
    G02763781Courtesy of FORD MOTOR CO.
  6. Connect the 10 ignition coil electrical connectors.
    Fig 5: Connecting Ignition Coil Electrical Connectors
    G02763782Courtesy of FORD MOTOR CO.
  7. Connect the 10 fuel injector electrical connectors.
    Fig 6: Connecting Fuel Injector Electrical Connectors
    G02763783Courtesy of FORD MOTOR CO.
  8. Install the throttle body adapter gasket and the throttle body and adapter as an assembly. Tighten the bolts in two stages.
    • Stage 1: Tighten the bolts to 9 Nm (80 lb-in).
    • Stage 2: Tighten the bolts an additional 90 degrees (1/4 turn).
    Fig 7: Installing Throttle Body Adapter Gasket
    G02763784Courtesy of FORD MOTOR CO.
  9. Install the positive crankcase ventilation (PCV) hose.
  10. Connect the brake booster and the main engine vacuum harness.
    Fig 8: Connecting Brake Booster And Main Engine Vacuum Harness
    G02763785Courtesy of FORD MOTOR CO.
  11. Connect the idle air control (IAC) valve electrical connector.
    Fig 9: Connecting Idle Air Control (IAC) Valve Electrical Connector
    G02763786Courtesy of FORD MOTOR CO.
  12. Install the IAC valve fresh air hose.
    Fig 10: Installing IAC Valve Fresh Air Hose
    G02763787Courtesy of FORD MOTOR CO.
  13. Install the evaporative emission canister purge valve and bracket.
    Fig 11: Installing Evaporative Emission Canister Purge Valve And Bracket
    G02763788Courtesy of FORD MOTOR CO.
  14. Connect the evaporative emission canister purge valve hose and the vacuum hose.
    Fig 12: Connecting Evaporative Emission Canister Purge Valve Hose And Vacuum Hose
    G02763789Courtesy of FORD MOTOR CO.
  15. If equipped, connect the auxiliary heater hoses. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 13: Connecting Auxiliary Heater Hoses
    G02763790Courtesy of FORD MOTOR CO.
  16. Position the transmission fluid indicator tube and install the nut on the rear bracket.
    Fig 14: Positioning Transmission Fluid Indicator Tube
    G02763791Courtesy of FORD MOTOR CO.
  17. Install the four retainers on the fuel charging wiring harness.
    Fig 15: Installing Four Retainers On Fuel Charging Wiring Harness
    G02763792Courtesy of FORD MOTOR CO.
  18. Install the transmission fluid level indicator tube and bracket retaining nut.
    Fig 16: Installing Transmission Fluid Level Indicator Tube And Bracket
    G02763793Courtesy of FORD MOTOR CO.
  19. Install the accelerator cable routing bracket.
    Fig 17: Installing Accelerator Cable Routing Bracket
    G02763794Courtesy of FORD MOTOR CO.
  20. Connect the throttle body linkage.
    1. Connect the accelerator cable.
    2. Connect the speed control actuator cable.
    3. Connect the throttle control return spring.
    Fig 18: Connecting Throttle Control Return Spring
    G02763795Courtesy of FORD MOTOR CO.
  21. Connect the throttle position (TP) sensor.
    • Connect the electrical connector.
    • Attach the harness routing clip.
    Fig 19: Connecting Throttle Position (TP) Sensor
    G02763796Courtesy of FORD MOTOR CO.
  22. Connect the coolant hose.
    Fig 20: Connecting Coolant Hose
    G02763797Courtesy of FORD MOTOR CO.
  23. Install the generator upper support bracket.
    Fig 21: Installed Generator Upper Support Bracket
    G02763798Courtesy of FORD MOTOR CO.
  24. Install the accelerator cable routing bracket.
    Fig 22: Installed Accelerator Cable Routing Bracket
    G02763799Courtesy of FORD MOTOR CO.
  25. Connect the coolant temperature sensor electrical connector.
    Fig 23: Connecting Coolant Temperature Sensor Electrical Connector
    G02763800Courtesy of FORD MOTOR CO.
  26. Install the upper radiator hose.
    Fig 24: Installing Upper Radiator Hose
    G02763801Courtesy of FORD MOTOR CO.
  27. Install the accelerator cable snow shield.
    Fig 25: Installing Accelerator Cable Snow Shield
    G02763802Courtesy of FORD MOTOR CO.
  28. Connect the fuel hose spring lock couplings. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL .
  29. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  30. Install the interior engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  31. Install the air cleaner assembly and tubes. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  32. Fill the cooling system. For additional information, refer to ENGINE COOLING .
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