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Intake Manifold: Installation

    NOTE: Align the gasket locator tabs with the slots in the cylinder head.
    Fig 1: Installing Intake Manifold Gaskets
    G03881839Courtesy of FORD MOTOR CO.
  1. Install new intake manifold gaskets.
  2. Install the intake manifold and hand-tighten the bolts at the locations shown.
    Fig 2: Installing Intake Manifold
    G04001857Courtesy of FORD MOTOR CO.
  3. Install the ignition coils and tighten the bolts.
    Fig 3: Installing Ignition Coils
    G04001862Courtesy of FORD MOTOR CO.
  4. Install the crash bracket and loosely install the bolt and the stud.
    Fig 4: Installing Crash Bracket
    G03881486Courtesy of FORD MOTOR CO.
  5. Tighten the bolts in the sequence shown.
    Fig 5: Identifying Tightening Sequence Of Intake Manifold
    G04001864Courtesy of FORD MOTOR CO.
  6. Tighten the stud.
    Fig 6: Tightening Stud
    G04001865Courtesy of FORD MOTOR CO.
  7. Connect the EGR system module tube to the EGR system module.
    Fig 7: Connecting EGR System Module Tube To EGR System Module
    G04001866Courtesy of FORD MOTOR CO.
  8. Install the EGR tube nut at the exhaust manifold.
    Fig 8: Installing EGR Tube Nut At Exhaust Manifold
    G03881468Courtesy of FORD MOTOR CO.
  9. Position the EGR system module tube heat shield and install the bolts.
    Fig 9: Installing EGR System Module Tube Heat Shield
    G03881491Courtesy of FORD MOTOR CO.
  10. Connect the throttle control and the TP sensor electrical connectors.
    Fig 10: Locating Electrical Connectors
    G03881492Courtesy of FORD MOTOR CO.
  11. Install the thermostat and O-ring.
    Fig 11: Installing Thermostat And O-Ring
    G04002392Courtesy of FORD MOTOR CO.
  12. Install the thermostat housing and the bolts
    Fig 12: Installing Thermostat Housing
    G04001871Courtesy of FORD MOTOR CO.
    13. NOTE: Do not reuse hose clamps. Use appropriately sized worm-style clamps in place of the constant tension clamps.
    Fig 13: Installing Upper Radiator Hose
    G04001841Courtesy of FORD MOTOR CO.
  13. Install the upper radiator hose.
  14. Connect the heater hose.
    Fig 14: Connecting Heater Hose
    G04001843Courtesy of FORD MOTOR CO.
  15. Install the generator mounting bracket and the bolts.
    Fig 15: Installing Generator Mounting Bracket
    G04002498Courtesy of FORD MOTOR CO.
  16. Connect the electrical connector.
    Fig 16: Connecting Electrical Connector
    G04001875Courtesy of FORD MOTOR CO.
  17. Position the vacuum harness and connect the vacuum hoses to the EVAP canister purge valve.
    Fig 17: Connecting Vacuum Hoses To EVAP Canister Purge Valve
    G04001838Courtesy of FORD MOTOR CO.
  18. Connect the electrical connector and the vacuum hoses.
    Fig 18: Connecting Electrical Connector And Vacuum Hoses
    G04001837Courtesy of FORD MOTOR CO.
  19. Connect the fuel pressure and temperature sensor electrical connector and the vacuum hose.
    Fig 19: Connecting Fuel Pressure And Temperature Sensor Electrical Connector
    G04001849Courtesy of FORD MOTOR CO.
  20. Connect the fuel charging wiring electrical connectors to the eight fuel injectors.
    Fig 20: Connecting Fuel Charging Wiring Electrical Connectors To Fuel Injectors
    G04001879Courtesy of FORD MOTOR CO.
  21. Connect the fuel charging wiring electrical connectors to the eight ignition coils.
    Fig 21: Connecting Fuel Charging Wiring Electrical Connectors To Ignition Coils
    G04001880Courtesy of FORD MOTOR CO.
  22. Install the fuel charging wiring pin-type retainer to the rear of the manifold.
    Fig 22: Installing Fuel Charging Wiring Pin-Type Retainer To Rear Of Manifold
    G04001851Courtesy of FORD MOTOR CO.
  23. Install the generator harness position retainer to the LH front stud.
    Fig 23: Installing Generator Harness Position Retainer To LH Front Stud
    G04001850Courtesy of FORD MOTOR CO.
  24. Attach the fuel charging wiring pin-type retainer to the crash bracket.
    Fig 24: Attaching Fuel Charging Wiring Pin-Type Retainer To Crash Bracket
    G04001846Courtesy of FORD MOTOR CO.
  25. Connect the ground wire connector to the RH rear stud.
    Fig 25: Connecting Ground Wire Connector To RH Rear Stud
    G04001852Courtesy of FORD MOTOR CO.
  26. Connect the coolant temperature sensor electrical connector.
    Fig 26: Connecting Coolant Temperature Sensor Electrical Connector
    G04001885Courtesy of FORD MOTOR CO.
  27. Install the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS AND WASHERS .
  28. Connect the fuel spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  29. Install the air cleaner and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  30. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  31. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
    32. WARNING: If equipped with fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM .
  32. If equipped with fire suppression system, repower the system.
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