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Intake Manifold: Installation

    NOTE: Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at rear of the intake manifold. Use extreme care on installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses.
  1. Using new intake manifold gaskets, position the intake manifold.
  2. Using new gaskets, position the engine coolant crossover assembly and install the 3 bolts.
    • Tighten to 10 Nm (89 lb-in).
  3. Connect the engine wiring harness retainer to the CMCV stud and install the nut.
    • Tighten to 10 Nm (89 lb-in).
  4. Connect the CMCV electrical connector.
  5. Connect the CHT sensor jumper harness electrical connector.
    6. Fig 1: Locating Cylinder Head Temperature (CHT) Sensor Jumper Harness Electrical Connector
    GF0002732Courtesy of FORD MOTOR CO.
  6. Connect the LH and RH KS electrical connectors.
    7. Fig 2: Locating LH & RH Knock Sensor (KS) Electrical Connectors
    GF0002733Courtesy of FORD MOTOR CO.
  7. Install the intake manifold bolts and tighten in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
    8. Fig 3: Identifying Intake Manifold Bolts And Tightening Sequence
    GF0002734Courtesy of FORD MOTOR CO.
  8. Install the intake manifold vacuum tube support bracket bolt and connect the intake manifold vacuum tube-to-intake manifold hose.
    • Tighten to 10 Nm (89 lb-in).
  9. Connect the intake manifold vacuum tube support retainer to the valve cover and position the intake manifold vacuum tube aside.
  10. Connect the brake booster vacuum hose to the intake manifold vacuum tube.
  11. Connect the heated PCV intake fitting electrical connector.
  12. Connect the TP sensor and electronic acceleration control electrical connectors.
  13. Connect the 8 fuel injector electrical connectors.
  14. Connect the 8 ignition coil electrical connectors.
  15. Position the air cleaner outlet pipe-to-TB adapter and install the 4 bolts.
    • Tighten to 10 Nm (89 lb-in).
  16. Connect the crankcase ventilation tube quick connect coupling to the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  17. Position the EVAP hose and connect the quick connect coupling to the intake manifold. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  18. Connect the EVAP hose position retainer to the intake manifold.
    19. Fig 4: EVAP Hose Position Retainer
    GF0022000Courtesy of FORD MOTOR CO.
  19. Position the PCV tube and connect the quick connect couplings. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  20. Connect the upper radiator and heater coolant hoses to the engine coolant crossover assembly.
  21. Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  22. Install the generator. For additional information, refer to GENERATOR AND REGULATOR article.
  23. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
  24. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
  25. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING article.
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