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Upper Intake Manifold: Installation

WARNING: This page is about a different car, the 2006 Mercury Montego, 2006 Ford Freestyle, and 2006 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.

    All vehicles 

    NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
    Fig 1: Identifying Tightening Sequence Of Bolts
    G04655613Courtesy of FORD MOTOR CO.
  1. Position the upper intake manifold and install the 8 bolts.
    • Tighten in the sequence shown to 10 N.m (89 lb-in).
  2. Connect the throttle body electrical connector.

    3. Late build 

  3. Connect the 2 PCV coolant hoses.

    4. Early build 

  4. Connect the throttle body and PCV coolant hoses.

    5. All vehicle 

  5. Connect the EGR system module tube to the EGR system module.
    • Tighten to 40 N.m (30 lb-ft).
  6. Attach the vacuum tube to the upper intake manifold vacuum tube retainer.
  7. Connect the EGR system module electrical connector and vacuum tube.
  8. Attach the fuel tube retainer to the upper intake manifold.
  9. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold.
  10. Connect the EVAP canister purge valve tube to the upper intake manifold and attach the retainer.
  11. Clean the 4 transaxle roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads.
  12. Position the transaxle roll restrictor cross brace and install the 4 new bolts.
    • Tighten to 55 N.m (41 lb-ft).
  13. Clean the transaxle roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads.
  14. Install a new transaxle roll restrictor cross brace-to-roll restrictor bolt.
    • Tighten to 48 N.m (35 lb-ft).
  15. Install the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION .
  16. Connect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION .
  17. Fill and bleed the cooling system. For additional information, refer to COOLING SYSTEM DRAINING, FILLING AND BLEEDING .
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