Intake Manifold: Installation

All engines

NOTE: 2.0L engine shown, 2.3L engine similar.

Fig 1: Locating Intake Manifold Gaskets

Courtesy of FORD MOTOR CO.

Inspect and install new intake manifold gaskets if necessary.
Install the EGR tube and tighten to 55 Nm (41 lb-ft).

Fig 2: Locating EGR Tube And Nut
Courtesy of FORD MOTOR CO.
Position the intake manifold and connect the PCV hose.
Connect the KS electrical connector.

2.3L engines

NOTE: Be sure to install the bolts in the previously marked locations.

NOTE: To ease installation of the intake manifold, lower center mounting bolt, use a 6-inch long, 5/16-inch diameter hose.

Install the intake manifold and the 7 mounting bolts.
- Tighten to 18 Nm (13 lb-ft).
  
  Fig 3: Locating Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the O-ring with clean engine oil.

Install the oil level indicator tube and 2 bolts.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 4: Locating Oil Level Indicator Tube Bolts
  Courtesy of FORD MOTOR CO.
Connect the swirl valve electrical connectors and pin-type retainers.

Fig 5: Locating Swirl Valve Electrical Connectors And Pin-Type Retainers
Courtesy of FORD MOTOR CO.

2.0L engines

NOTE: Be sure to install the bolts in the previously marked locations.

Install the intake manifold and the 7 mounting bolts.
- Tighten to 18 Nm (13 lb-ft).
  
  Fig 6: Locating Intake Manifold Bolts
  Courtesy of FORD MOTOR CO.

NOTE: Lubricate the O-ring with clean engine oil.

Install the oil level indicator tube and bolt.
- Tighten to 10 Nm (89 lb-in).
  
  Fig 7: Locating Oil Level Indicator Tube And Bolt
  Courtesy of FORD MOTOR CO.
Connect the swirl control valve electrical connector.

Fig 8: Locating Swirl Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
If equipped, connect the AIR vacuum supply hose.

Fig 9: Locating Air Vacuum Supply Hose
Courtesy of FORD MOTOR CO.

All engines

Install the lower intake manifold bolt.
- Tighten to 18 Nm (13 lb-ft).
  
  Fig 10: Locating Lower Intake Manifold Bolt
  Courtesy of FORD MOTOR CO.
Connect the MAP sensor electrical connector.
Connect the IMRC actuator electrical connector.
Attach the wiring harness pin-type retainer.

Fig 11: Locating Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Connect the fuel rail pressure and temperature sensor vacuum hose.
Connect the power brake booster vacuum tube.
- Push the vacuum tube into the quick release fitting.
  
  Fig 12: Locating Power Brake Booster Vacuum Tube And Quick Release Fitting
  Courtesy of FORD MOTOR CO.
Connect the fuel vapor return hose.
Connect the IAC valve electrical connector and wiring harness pin-type retainer.
Connect the TP sensor electrical connector and wiring harness pin-type retainer.
Connect the accelerator cable and speed control cable (if equipped).
1. Install the accelerator cable bracket and 3 bolts.
  - Tighten to 10 Nm (89 lb-in).
2. Connect the accelerator and speed control cable (if equipped) to the throttle body.
  
  Fig 13: Identifying Accelerator & Speed Control Cable And Bolts
  Courtesy of FORD MOTOR CO.
Install the accelerator control snow shield.
- Position the snow shield and tighten the retainer to 10 Nm (89 lb-in).
- Attach the evaporative emissions hose pin-type retainer.
  
  Fig 14: Locating Accelerator Control Snow Shield And Pin-Type Retainers
  Courtesy of FORD MOTOR CO.
Install the air cleaner outlet pipe.
- Tighten the clamps to 4 Nm (35 lb-in).
  
  Fig 15: Locating Air Cleaner Outlet Pipe And Clamps
  Courtesy of FORD MOTOR CO.
Install the cooling fan motor and shroud assembly. For additional information, refer to ENGINE COOLING .