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Intake Manifold: Installation

WARNING: This page is about a different car, the 2002 Ford Escort. However, it is still accessible from the selected car via links, so may be relevant.
    CAUTION: Do not use abrasive grinding discs to remove the gasket material; use only manual scrapers. Do not scratch or gouge aluminum sealing surfaces.
  1. Clean and inspect the mounting faces of both the intake manifold and the cylinder head. Both surfaces must be clean and flat.
  2. Clean and oil the manifold studs.
  3. Install the gasket and the intake manifold. Hand-tighten the nuts.
    Fig 1: Installing Intake Manifold Bolts
    G02206662Courtesy of FORD MOTOR CO.
  4. Raise and support the vehicle.
  5. Install the nuts.
    Fig 2: Installing Nuts
    G02206663Courtesy of FORD MOTOR CO.
  6. Install the oil level indicator tube.
    Fig 3: Installing Oil Level Indicator Tube
    G02206664Courtesy of FORD MOTOR CO.
  7. Lower the vehicle.
  8. Tighten the nuts.
    Fig 4: Tightening Nuts
    G02206665Courtesy of FORD MOTOR CO.
  9. Install the EGR manifold tube.
    Fig 5: Installing EGR Manifold Tube
    G02206666Courtesy of FORD MOTOR CO.
  10. Install the bolt.
    Fig 6: Installing Bolt
    G02206667Courtesy of FORD MOTOR CO.
  11. Connect the (A) IAC valve electrical and the (B) throttle position sensor connectors.
    Fig 7: Connecting IAC Valve Electrical And Throttle Position Sensor Connectors
    G02206668Courtesy of FORD MOTOR CO.
  12. Install the speed control cable bracket and bolt.
    Fig 8: Installing Speed Control Cable Bracket And Bolt
    G02206669Courtesy of FORD MOTOR CO.
  13. Connect the (1) speed control cable and the (2) accelerator cable to the throttle control lever.
    Fig 9: Connecting Speed Control Cable And Accelerator Cable To Throttle Control Lever
    G02206670Courtesy of FORD MOTOR CO.
  14. Connect the vacuum hoses to the (1) fuel pressure regulator and the (2) intake manifold.
    Fig 10: Connecting Vacuum Hoses To Fuel Pressure Regulator And Intake Manifold
    G02206671Courtesy of FORD MOTOR CO.
  15. Connect the vacuum lines to the (1) exhaust recirculation valve, the (2) positive crankcase ventilation valve, and the (3) idle air control valve.
    Fig 11: Connecting Vacuum Lines To Exhaust Recirculation Valve, Positive Crankcase Ventilation Valve, And Idle Air Control Valve
    G02206672Courtesy of FORD MOTOR CO.
  16. Install the air cleaner outlet tube.
  17. Refill the engine cooling system. For additional information, refer to ENGINE COOLING .
  18. Start the engine and check for coolant leaks.
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