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Home › Ford › 2002 › Thunderbird › Repair and Diagnosis › Engine Mechanical › Mechanical › Engine - 3.9L › In-Vehicle Repair › Intake Manifold › Installation

Intake Manifold: Installation

  1. If removed, install the gaskets.
    Fig 1: Installing Gaskets
    G03421369Courtesy of FORD MOTOR CO.
    2. NOTE: Make sure that the throttle body heater return hose is positioned between the heat shield and the intake manifold.
    Fig 2: Intake Manifold Bolt Tightening Sequence
    G03421370Courtesy of FORD MOTOR CO.
  2. Install the intake manifold and tighten the bolts in the sequence shown.
  3. Install the differential pressure feedback sensor.
    1. Install the sensor and the bolts.
    2. Connect the electrical connector.
    3. Connect the hoses.
    Fig 3: Installing Differential Pressure Feedback Sensor
    G03421371Courtesy of FORD MOTOR CO.
  4. Connect the RH fuel injector electrical connectors, and position the engine wiring harness.
    Fig 4: Connecting RH Fuel Injector Electrical Connectors
    G03421372Courtesy of FORD MOTOR CO.
  5. Connect the hoses.
    1. Connect the hoses to the throttle body and position the clamps.
    2. Attach the hose to the clip.
    Fig 5: Connecting Hoses To Throttle Body
    G03421373Courtesy of FORD MOTOR CO.
  6. Connect the crankcase ventilation tube.
    Fig 6: Connecting Crankcase Ventilation Tube
    G03421374Courtesy of FORD MOTOR CO.
  7. Connect the IAC valve and TPS electrical connectors.
    Fig 7: Connecting IAC Valve & TPS Electrical Connectors
    G03421375Courtesy of FORD MOTOR CO.
  8. Connect the LH fuel injector electrical connectors and position the engine wiring harness.
    Fig 8: Connecting LH Fuel Injector Electrical Connectors
    G03421376Courtesy of FORD MOTOR CO.
  9. Install the bracket.
    1. Install the bracket and nuts.
    2. Install the hose.
    Fig 9: Installing Bracket & Nuts
    G03421377Courtesy of FORD MOTOR CO.
  10. Install the bracket and the nut.
    Fig 10: Installing Bracket & Nut
    G03421378Courtesy of FORD MOTOR CO.
  11. Install the electrical connectors on the bracket.
    1. Install the LH KS electrical connector.
    2. Install the CHT sensor electrical connector.
    Fig 11: Connecting LH KS & CHT Sensor Electrical Connectors
    G03421379Courtesy of FORD MOTOR CO.
  12. Connect the fuel hose. For additional information, refer to FUEL SYSTEM .
  13. Connect the vacuum connector to the fuel pressure sensor.
    Fig 12: Connecting Vacuum Connector To Fuel Pressure Sensor
    G03421380Courtesy of FORD MOTOR CO.
  14. Connect the fuel pressure sensor electrical connector.
    Fig 13: Connecting Fuel Pressure Sensor Electrical Connector
    G03421381Courtesy of FORD MOTOR CO.
  15. Connect the evaporative emission canister purge valve hose.
    Fig 14: Connecting Evaporative Emission Canister Purge Valve Hose
    G03421382Courtesy of FORD MOTOR CO.
  16. Connect the CMP sensor electrical connector, and position the connector on the fuel injection supply manifold.
    Fig 15: Connecting CMP Sensor Electrical Connector
    G03421383Courtesy of FORD MOTOR CO.
  17. Connect the exhaust manifold to EGR valve tube.
    Fig 16: Connecting Exhaust Manifold-To-EGR Valve Tube
    G03421384Courtesy of FORD MOTOR CO.
  18. Connect the vacuum hose.
    Fig 17: Connecting Vacuum Hose
    G03421385Courtesy of FORD MOTOR CO.
  19. Connect the vacuum hoses.
    Fig 18: Connecting Vacuum Hoses
    G03421386Courtesy of FORD MOTOR CO.
  20. Connect the accelerator and speed control cables.
    Fig 19: Connecting Accelerator & Speed Control Cables
    G03421387Courtesy of FORD MOTOR CO.
  21. Install the engine compartment brace.
    Fig 20: Installing Engine Compartment Brace
    G03421388Courtesy of FORD MOTOR CO.
  22. Install the cowl vent screen. For additional information, refer to FRONT END BODY PANELS .
  23. Install the air cleaner outlet tube.
  24. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
    25. CAUTION: The cooling system filling and bleeding procedure must be followed exactly or damage to the engine can occur.
  25. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
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