Intake Manifold: Installation

WARNING: This page is about a different car, the 2003 Ford Focus. However, it is still accessible from the selected car via links, so may be relevant.

Position the intake manifold to the rear of the engine compartment (shown with engine removed).

Fig 1: Positioning Intake Manifold To Rear Of Engine Compartment
Courtesy of FORD MOTOR CO.

NOTE: Use new gaskets.

Install the IMRC manifolds and the two studs (shown with engine removed).
- Tighten the studs in two stages.
- Stage 1: 10 Nm.
- Stage 2: 90 degrees.
  
  Fig 2: Installing IMRC Manifolds
  Courtesy of FORD MOTOR CO.

NOTE: Use new gaskets.

Install the intake manifold and retainers (shown with engine removed).
- Tighten the nuts and bolts in two stages
- Stage 1: 10 Nm.
- Stage 2: 90 degrees.
  
  Fig 3: Installing Intake Manifold And Retainers
  Courtesy of FORD MOTOR CO.
Connect the fuel lines to the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Connect the electrical connectors.
1. Ignition coil.
2. CMP sensor.
3. IMRC.
  
  Fig 4: Connecting Electrical Connectors
  Courtesy of FORD MOTOR CO.
Connect the fuel injector electrical connectors.

Fig 5: Connecting Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Install the intake manifold upper support bracket.

Fig 6: Installing Intake Manifold Upper Support Bracket
Courtesy of FORD MOTOR CO.
Raise and support the vehicle. For additional information, refer to JACKING & HOISTING .
Attach the intake manifold bracket.
- Install the bolts and tighten the nuts.
  
  Fig 7: Attaching Intake Manifold Bracket
  Courtesy of FORD MOTOR CO.
Lower the vehicle.
Install the bracket and bolt to the oil level indicator tube.

Fig 8: Installing Bracket And Bolt
Courtesy of FORD MOTOR CO.
Connect the TP sensor and the IAC valve.

Fig 9: Connecting TP Sensor And IAC Valve
Courtesy of FORD MOTOR CO.
Connect the coolant hoses to the intake manifold.
- Remove the clamps.
  
  Fig 10: Connecting Coolant Hoses To Intake Manifold
  Courtesy of FORD MOTOR CO.
Install the vacuum hose assembly.

Fig 11: Installing Vacuum Hose Assembly
Courtesy of FORD MOTOR CO.
Connect the EGR valve.
- Install a new gasket.
  
  Fig 12: Connecting EGR Valve
  Courtesy of FORD MOTOR CO.
Connect the vacuum hoses.
1. EVAP solenoid valve.
2. Brake booster.
3. DPFE system sensor.
4. EGR valve.
  
  Fig 13: Connecting Vacuum Hoses
  Courtesy of FORD MOTOR CO.
Connect the positive crankcase ventilation hoses.
- Make sure the twist-lock positive crankcase ventilation valve is secure.
  
  Fig 14: Connecting Positive Crankcase Ventilation Hoses
  Courtesy of FORD MOTOR CO.
Connect the speed control cable.
1. Connect the cable.
2. Position the speed control cable and install the plastic clip.
  
  Fig 15: Connecting Speed Control Cable
  Courtesy of FORD MOTOR CO.
Connect the accelerator cable.
1. Connect the cable.
2. Position the accelerator cable and install the plastic clip.
  
  Fig 16: Connecting Accelerator Cable
  Courtesy of FORD MOTOR CO.
Install the air cleaner housing.
1. Connect the MAF sensor electrical connector.
2. Connect the air cleaner outlet hose.
- Install the air cleaner housing into the rubber bushing.
  
  Fig 17: Installing Air Cleaner Housing
  Courtesy of FORD MOTOR CO.
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .