Upper Intake Manifold: Installation

NOTE: The upper intake manifold gaskets are reusable. Inspect the gaskets for damage and install new gaskets if necessary.

NOTE: Use new upper intake manifold bolts.

Fig 1: Identifying Upper Intake Manifold Bolts Tightening Sequence

G02176706

Courtesy of FORD MOTOR CO.

Install the gaskets, the upper intake manifold, and the bolts. Tighten the bolts in the sequence shown in two stages.
- Stage 1: Tighten to 10 Nm (89 lb-in).
- Stage 2: Tighten an additional 90 degrees.
Connect the VMV vacuum hose.

Fig 2: Connecting VMV Vacuum Hose
Courtesy of FORD MOTOR CO.
Install the EGR adapter.
- Install a new gasket.
- Position the EGR valve adapter.
- Install the bolts.
Fig 3: Installing EGR Adapter
Courtesy of FORD MOTOR CO.
Connect the vacuum hose to the EGR valve.

Fig 4: Connecting Vacuum Hose To EGR Valve
Courtesy of FORD MOTOR CO.
Connect the vacuum hose.

Fig 5: Connecting Vacuum Hose
Courtesy of FORD MOTOR CO.
Connect the brake booster vacuum hose.

Fig 6: Connecting Brake Booster Vacuum Hose
Courtesy of FORD MOTOR CO.
Position the oil fill tube and install the stud.

Fig 7: Installing Oil Fill Tube
Courtesy of FORD MOTOR CO.
Position the power steering reservoir bracket and install the bolts.

Fig 8: Installing Power Steering Reservoir Bracket
Courtesy of FORD MOTOR CO.
Install the nut.

Fig 9: Installing Power Steering Reservoir Bracket Nut
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Connect the two hoses and the electrical connector to the differential pressure feedback EGR.

Fig 10: Connecting Two Hoses And Electrical Connector
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Connect the vacuum hoses and the electrical connector to the EGR vacuum regulator.

Fig 11: Connecting Vacuum Hoses And Electrical Connector
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Connect the IAC valve electrical connector.

Fig 12: Connecting IAC Valve Electrical Connector
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Connect the TP sensor electrical connector.

Fig 13: Connecting TP Sensor Electrical Connector
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Install the balance tube gaskets and the balance tube.

Fig 14: Installing Balance Tube
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Install the wiring harness shield, the bolts, and the five clips.

Fig 15: Installing Wiring Harness Shield
Courtesy of FORD MOTOR CO.
Install the cowl grille.
Connect the intake manifold tuning valve electrical connector.

Fig 16: Connecting Intake Manifold Tuning Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Install the tube assembly and connect the PCV valve tube.

Fig 17: Connecting PCV Valve Tube
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Remove the plugs and connect the PCV fitting heater coolant hoses.

Fig 18: Connecting Heater Coolant Hoses
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Connect the EVAP return hose.

Fig 19: Connecting EVAP Return Hose
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Position the cables and bracket and install the bolts.

Fig 20: Positioning Cables And Bracket
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Connect the accelerator cable, speed control cable, and the return spring.

Fig 21: Connecting Accelerator Cable, Speed Control Cable And Return Spring
Courtesy of FORD MOTOR CO.
Install the engine appearance cover and the three bolts.

Fig 22: Installing Engine Appearance Cover
Courtesy of FORD MOTOR CO.
Install the air cleaner assembly.
Connect the battery negative cable.
Fill the engine cooling system. Refer to ENGINE COOLING .