Intake Manifold: Installation

All engines 

NOTE: 2.0L engine shown, 2.3L engine similar.
1. Inspect and install new intake manifold gaskets if necessary.
Fig 1: Locating Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.
2. Install the EGR tube and tighten to 55 Nm (41 lb-ft).
Fig 2: Locating EGR Tube And Nut
Courtesy of FORD MOTOR CO.
3. Position the intake manifold and connect the PCV hose.
4. 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.
5. 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.
6. 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.
7. 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.
8. 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.
9. Install the oil level indicator tube and bolt.
   • Tighten to 10 Nm (89 lb-in).
Fig 7: Locating Bolt And Oil Level Indicator Tube
Courtesy of FORD MOTOR CO.
10. Connect the swirl control valve electrical connector.
Fig 8: Locating Swirl Control Valve Electrical Connector
Courtesy of FORD MOTOR CO.
11. If equipped, connect the AIR vacuum supply hose.
Fig 9: Locating Secondary Air Injection Vacuum Supply Hose
Courtesy of FORD MOTOR CO.

All engines 

12. 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.
13. Connect the MAP sensor electrical connector.
14. Connect the IMRC actuator electrical connector.
15. Attach the wiring harness pin-type retainer.
Fig 11: Locating Wiring Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
16. Connect the fuel rail pressure and temperature sensor vacuum hose.
17. 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 Locking Ring
Courtesy of FORD MOTOR CO.
18. Connect the fuel vapor return hose.
19. Connect the IAC valve electrical connector and wiring harness pin-type retainer.
20. Connect the TP sensor electrical connector and wiring harness pin-type retainer.
21. 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.
22. 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 Snow Shield, Screw And Pin-Type Retainers
Courtesy of FORD MOTOR CO.
23. Install the air cleaner outlet pipe.
    • Tighten the clamps to 4 Nm (35 lb-in).
Fig 15: Locating Vent Tube, Outlet Pipe And Clamp
Courtesy of FORD MOTOR CO.
24. Install the cooling fan motor and shroud assembly. For additional information, refer to ENGINE COOLING article.