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Intake Manifold: Installation

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Install new intake manifold gaskets if damaged.
  1. Position the intake manifold and gaskets.
  2. Install the right side intake manifold stud.
    Fig 1: Installing Right Side Intake Manifold Stud
    G03430145Courtesy of FORD MOTOR CO.
    3. NOTE: Illustration shown with throttle body removed for clarity.
    Fig 2: Intake Manifold Nuts & Bolts Tightening Sequence
    G03430146Courtesy of FORD MOTOR CO.
  3. Tighten the nuts and bolts using the sequence shown.
    4. NOTE: The EGR valve sealing surfaces are soft metals. Carefully clean all sealing surfaces and install a new EGR valve gasket.
    Fig 3: Installing EGR Valve Bolts
    G03430147Courtesy of FORD MOTOR CO.
  4. Install the EGR valve bolts.
  5. Connect the PCV vacuum hose.
    Fig 4: Connecting PCV Vacuum Hose
    G03430148Courtesy of FORD MOTOR CO.
  6. Connect the four vacuum hoses.
    Fig 5: Connecting Four Vacuum Hoses
    G03430149Courtesy of FORD MOTOR CO.
  7. Connect the brake booster vacuum supply hose to the intake manifold.
    Fig 6: Connecting Brake Booster Vacuum Supply Hose To Intake Manifold
    G03430150Courtesy of FORD MOTOR CO.
  8. Install the (CHT) sensor wire clip, and attach the CHT wiring harness.
    Fig 7: Attaching CHT Wiring Harness
    G03430151Courtesy of FORD MOTOR CO.
  9. Connect the (CHT) sensor.
    Fig 8: Connecting (CHT) Sensor
    G03430152Courtesy of FORD MOTOR CO.
  10. Install the retainer for the HO2S wiring harness mount.
    Fig 9: Installing Retainer For HO2S Wiring Harness Mount
    G03430153Courtesy of FORD MOTOR CO.
  11. Connect the HO2S sensor wiring harness to the bracket.
    Fig 10: Connecting HO2S Sensor Wiring Harness To Bracket
    G03430154Courtesy of FORD MOTOR CO.
  12. Connect the PCM wiring harness to the bracket.
    Fig 11: Connecting PCM Wiring Harness To Bracket
    G03430155Courtesy of FORD MOTOR CO.
  13. Connect the main engine control sensor wiring connector to the mounting bracket.
    Fig 12: Connecting Main Engine Control Sensor Wiring Connector To Mounting Bracket
    G03430156Courtesy of FORD MOTOR CO.
  14. Connect the IAC electrical connector and attach the wiring harness to the bracket.
    Fig 13: Connecting IAC Electrical Connector
    G03430157Courtesy of FORD MOTOR CO.
  15. Connect the TP sensor electrical connector.
    Fig 14: Connecting TP Sensor Electrical Connector
    G03430158Courtesy of FORD MOTOR CO.
  16. Connect the fuel injector electrical connectors.
    • Position the harness back onto the valve cover stud.
    Fig 15: Connecting Fuel Injector Electrical Connectors
    G03430159Courtesy of FORD MOTOR CO.
  17. Connect the fuel pulse damper vacuum hose.
    Fig 16: Connecting Fuel Pulse Damper Vacuum Hose
    G03430160Courtesy of FORD MOTOR CO.
  18. Connect the accelerator cable and, if equipped, the speed control actuator cable.
    Fig 17: Connecting Accelerator Cable
    G03430161Courtesy of FORD MOTOR CO.
  19. Connect the fuel tube.
    • Install the safety clip.
    Fig 18: Connecting Fuel Tube & Safety Clip
    G03430162Courtesy of FORD MOTOR CO.
  20. Install the air cleaner outlet pipe. .
  21. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
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