Lower Intake Manifold: Installation

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

Install the lower intake manifold front and rear end seals.
1. Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated.
2. Install the lower intake manifold front and rear end seals.
Fig 1: Installing Lower Intake Manifold Front And Rear End Seals
Courtesy of FORD MOTOR CO.
Install the intake manifold gaskets.

Fig 2: Installing Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.

NOTE: The lower intake manifold must be installed within fifteen minutes of applying sealant.

Fig 3: Installing Lower Intake Manifold

Courtesy of FORD MOTOR CO.

Position the lower intake manifold.
1. Apply a bead of sealant to the lower intake manifold mounting at the points indicated.
2. Position the lower intake manifold.

NOTE: Refer to the location note made during removal and make sure the bolts are installed in the correct location.

Fig 4: Installing Intake Manifold Bolts

Courtesy of FORD MOTOR CO.

Install the (A) long bolts and the (B) short bolts.
Tighten the bolts in two stages in the sequence shown:
- Stage 1: Tighten the bolts to 5 Nm (44 lb-in).
- Stage 2: Tighten the bolts to 10 Nm (89 lb-in).
Fig 5: Tightening Bolts In Sequence
Courtesy of FORD MOTOR CO.
Connect the fuel lines. For additional information, refer to FUEL TANK & LINES-GASOLINE & DIESEL or FUEL TANK & LINES-NATURAL GAS .
Connect the fuel pressure regulator vacuum line and the IMRC electrical connector.

Fig 6: Connecting Fuel Pressure Regulator Vacuum Line
Courtesy of FORD MOTOR CO.
Install the upper radiator hose to the lower intake manifold. For additional information, refer to ENGINE COOLING .
Connect the EGR valve vacuum hose.

Fig 7: Connecting EGR Valve Vacuum Hose
Courtesy of FORD MOTOR CO.
Install the EGR valve tube upper fitting.

Fig 8: Installing EGR Valve Tube Upper Fitting
Courtesy of FORD MOTOR CO.
Connect the water bypass hose and the heater water hose.

Fig 9: Connecting Water Bypass Hose
Courtesy of FORD MOTOR CO.

NOTE: Left shown, right similar.

Fig 10: Connecting Fuel Injector Electrical Harness

Courtesy of FORD MOTOR CO.

Connect the fuel injector electrical harness to the fuel injector supply manifold.

NOTE: One shown, all similar.

Fig 11: Connecting Fuel Injector Electrical Connectors

Courtesy of FORD MOTOR CO.

Connect the fuel injector electrical connectors.
Install the intake manifold spacer assembly. For additional information, refer to the INTAKE MANIFOLD - SPACER ASSEMBLY .