LEMON Manuals: Even more car manuals for everyone: 1960-2025
Home >> Ford >> 2002 >> Mustang Base, 2D Convertible, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 249 (Engine - 6.8L) >> In-Vehicle Repair >> Intake Manifold >> Installation
April 5, 2026: LEMON Manuals is launched! Read the announcement.

Intake Manifold: Installation

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E550 Super Duty, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Position the lower intake manifold gasket and the upper intake manifold on the intake manifold, and loosely install the ten bolts.
    Fig 1: Installing Lower Intake Manifold Gasket And Upper Intake Manifold On Intake Manifold
    G01537181Courtesy of FORD MOTOR CO.
  2. Tighten the bolts in the sequence shown in two stages.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
    Fig 2: Tightening Upper Intake Manifold-to-Lower Intake Manifold Bolts
    G01537182Courtesy of FORD MOTOR CO.
  3. Install the intake manifold.
    • Position the intake manifold gaskets and the intake manifold, and loosely install the bolts.
    Fig 3: Installing Intake Manifold
    G01537183Courtesy of FORD MOTOR CO.
    4. NOTE: Do not tighten the bolts at this time.
  4. Install the water thermostat housing.
  5. 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 4: Tightening Intake Manifold Assembly
    G01537184Courtesy of FORD MOTOR CO.
  6. Install the ten ignition coils. For additional information, refer to IGNITION COILS .
  7. Connect the five LH fuel injector electrical connectors.
    Fig 5: Connecting LH Fuel Injector Electrical Connectors
    G01537185Courtesy of FORD MOTOR CO.
  8. Connect the five RH fuel injector electrical connectors.
    Fig 6: Connecting RH Fuel Injector Electrical Connectors
    G01537186Courtesy of FORD MOTOR CO.
  9. 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).
  10. Install the positive crankcase ventilation (PCV) hose.
  11. Install the exhaust manifold-to-EGR valve tube, if equipped.
    Fig 7: Installing Exhaust Manifold-To-EGR Valve Tube
    G01537187Courtesy of FORD MOTOR CO.
  12. Install the engine vacuum harness. Connect the harness as follows:
    1. Exhaust gas recirculation (EGR) valve, if equipped.
    2. EGR vacuum regulator solenoid, if equipped.
    3. Vacuum source.
    4. Fuel pressure regulator.
    Fig 8: Installing Engine Vacuum Harness
    G01537188Courtesy of FORD MOTOR CO.
  13. Connect the EGR vacuum regulator solenoid connector, if equipped.
    Fig 9: Connecting EGR Vacuum Regulator Solenoid Connector
    G01537189Courtesy of FORD MOTOR CO.
  14. Connect the idle air control (IAC) valve electrical connector.
    Fig 10: Connecting Idle Air Control (IAC) Valve Electrical Connector
    G01537190Courtesy of FORD MOTOR CO.
  15. Install the idle air control (IAC) valve fresh air hose.
    Fig 11: Installing Idle Air Control (IAC) Valve Fresh Air Hose
    G01537191Courtesy of FORD MOTOR CO.
  16. Install the evaporative emission canister purge valve and bracket.
    Fig 12: Installing Evaporative Emission Canister Purge Valve And Bracket
    G01537192Courtesy of FORD MOTOR CO.
  17. Connect the evaporative emission canister purge valve hose and the vacuum hose.
    Fig 13: Connecting Evaporative Emission Canister Purge Valve Hose And Vacuum Hose
    G01537193Courtesy of FORD MOTOR CO.
  18. Connect the auxiliary heater hoses, if equipped. For additional information refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 14: Connecting Auxiliary Heater Hoses
    G01537194Courtesy of FORD MOTOR CO.
  19. Position the transmission fluid indicator tube and install the nut on the rear bracket.
    Fig 15: Installing Nut On Rear Bracket
    G01537195Courtesy of FORD MOTOR CO.
  20. Install the nut on the transmission fluid indicator tube front bracket.
    Fig 16: Installing Nut On Transmission Fluid Indicator Tube Front Bracket
    G01537196Courtesy of FORD MOTOR CO.
  21. Install the accelerator cable routing bracket.
    Fig 17: Installing Accelerator Cable Routing Bracket
    G01537197Courtesy of FORD MOTOR CO.
  22. Connect the throttle body control linkage.
    1. Connect the accelerator cable.
    2. Connect the speed control actuator cable.
    3. Connect the throttle control return spring.
    Fig 18: Connecting Throttle Body Control Linkage
    G01537198Courtesy of FORD MOTOR CO.
  23. Connect the throttle position (TP) sensor.
    1. Connect the electrical connector.
    2. Attach the harness routing clip.
    Fig 19: Connecting Throttle Position (TP) Sensor
    G01537199Courtesy of FORD MOTOR CO.
  24. Connect the heater water hose.
    Fig 20: Connecting Heater Water Hose
    G01537200Courtesy of FORD MOTOR CO.
  25. Install the generator upper support bracket.
    Fig 21: Installing Generator Upper Support Bracket
    G01537201Courtesy of FORD MOTOR CO.
  26. Install the accelerator cable routing bracket.
    Fig 22: Installing Accelerator Cable Routing Bracket
    G01537202Courtesy of FORD MOTOR CO.
  27. Connect the water temperature sensor electrical connector.
    Fig 23: >Connecting Water Temperature Sensor Electrical Connector
    G01537203Courtesy of FORD MOTOR CO.
  28. Install the upper radiator hose.
    Fig 24: Installing Upper Radiator Hose
    G01537204Courtesy of FORD MOTOR CO.
  29. Install the accelerator cable snow shield.
    Fig 25: Installing Accelerator Cable Snow Shield
    G01537205Courtesy of FORD MOTOR CO.
  30. Connect the fuel hose spring lock couplings. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL
  31. Fill the cooling system. For additional information, refer to ENGINE COOLING .
  32. Install the interior engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  33. Install the air cleaner assembly and tubes.
  34. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
scientia non olet · About LEMON Manuals