Intake Manifold: Installation

WARNING: This page is about a different car, the 2003 Ford Mustang. However, it is still accessible from the selected car via links, so may be relevant.

Install the intake manifold and gaskets, tighten the bolts in the sequence shown.

Fig 1: Identifying Tightening Sequence Of Intake Manifold Bolts
Courtesy of FORD MOTOR CO.

NOTE: The O-ring is to be installed on the top of the thermostat.

Fig 2: Installing Water Thermostat And O-Ring

G01624027

Courtesy of FORD MOTOR CO.

Install the water thermostat and the O-ring.
- Install a new O-ring as necessary.
Install the water outlet adapter.

Fig 3: Installing Water Outlet Adapter
Courtesy of FORD MOTOR CO.
Connect the water temperature indicator sender.

Fig 4: Connecting Water Temperature Indicator Sender
Courtesy of FORD MOTOR CO.
Position the engine harness and attach to the intake manifold in two locations.

Fig 5: Installing Engine Harness And Attaching It To Intake Manifold
Courtesy of FORD MOTOR CO.
Connect the heater hose.

Fig 6: Connecting Heater Hose
Courtesy of FORD MOTOR CO.
Install the generator.

Fig 7: Installing Generator
Courtesy of FORD MOTOR CO.
Connect the electrical connector.

Fig 8: Connecting Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the battery lead.

Fig 9: Connecting Battery Lead
Courtesy of FORD MOTOR CO.
Install the generator support brace.

Fig 10: Installing Generator Support Brace
Courtesy of FORD MOTOR CO.
Install the ignition coils.

Fig 11: Installing Ignition Coils
Courtesy of FORD MOTOR CO.
Install the fuel injection supply manifold and fuel injectors as an assembly.

Fig 12: Installing Fuel Injection Supply Manifold And Fuel Injectors As An Assembly
Courtesy of FORD MOTOR CO.
Install four studs.

Fig 13: Installing Studs
Courtesy of FORD MOTOR CO.
Position the vacuum harness and connect to the climate control vacuum supply hoses.

Fig 14: Installing Vacuum Harness And Connecting To Climate Control Vacuum Supply Hoses
Courtesy of FORD MOTOR CO.
Connect the ignition coils and the fuel injectors.

Fig 15: Connecting Ignition Coils And Fuel Injectors
Courtesy of FORD MOTOR CO.
Connect the fuel charging ground wire.

Fig 16: Connecting Fuel Charging Ground Wire
Courtesy of FORD MOTOR CO.
Connect the fuel pressure sensor electrical connector and the vacuum hose.

Fig 17: Connecting Fuel Pressure Sensor Electrical Connector And Vacuum Hose
Courtesy of FORD MOTOR CO.
Install the throttle body and adapter as an assembly.

Fig 18: Installing Throttle Body And Adapter As An Assembly
Courtesy of FORD MOTOR CO.
Tighten the bolts in the sequence shown.

Fig 19: Identifying Tightening Sequence Of Bolts
Courtesy of FORD MOTOR CO.
Connect the throttle position sensor (TPS) electrical connector.

Fig 20: Connecting Throttle Position Sensor (TPS) Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the main vacuum supply to the base of the throttle body adapter.

Fig 21: Connecting Main Vacuum Supply To Base Of Throttle Body Adapter
Courtesy of FORD MOTOR CO.
Connect the idle air control (IAC) valve electrical connector.

Fig 22: Connecting Idle Air Control (IAC) Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the vacuum hose to the EGR valve.

Fig 23: Connecting Vacuum Hose To EGR Valve
Courtesy of FORD MOTOR CO.
Connect the hose to the PCV valve.

Fig 24: Connecting Hose To PCV Valve
Courtesy of FORD MOTOR CO.
Connect the PCV hose to the base of the throttle body assembly.

Fig 25: Connecting PCV Hose To Base Of Throttle Body Assembly
Courtesy of FORD MOTOR CO.
Connect the EGR tube to the EGR valve.

Fig 26: Connecting EGR Tube To EGR Valve
Courtesy of FORD MOTOR CO.
Install the EGR vacuum regulator solenoid bracket.

Fig 27: Installing EGR Vacuum Regulator Solenoid Bracket
Courtesy of FORD MOTOR CO.
Connect the EGR vacuum regulator solenoid vacuum supply.

Fig 28: Connecting EGR Vacuum Regulator Solenoid Vacuum Supply
Courtesy of FORD MOTOR CO.
Connect the EGR vacuum regulator solenoid electrical connector.

Fig 29: Connecting EGR Vacuum Regulator Solenoid Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the hoses to the differential pressure feedback EGR transducer.

Fig 30: Connecting Hoses To Differential Pressure Feedback EGR Transducer
Courtesy of FORD MOTOR CO.
Connect the differential pressure feedback EGR electrical connector.

Fig 31: Connecting Differential Pressure Feedback EGR Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the evaporative emissions return line.

Fig 32: Connecting Evaporative Emissions Return Line
Courtesy of FORD MOTOR CO.
Install the breather tube.

Fig 33: Installing Breather Tube
Courtesy of FORD MOTOR CO.
Position the cables and install the bracket.

Fig 34: Installing Bracket
Courtesy of FORD MOTOR CO.
Connect the accelerator cable, speed control actuator cable and the return spring.

Fig 35: Connecting Accelerator Cable, Speed Control Actuator Cable And Return Spring
Courtesy of FORD MOTOR CO.
Connect the upper radiator hose.

Fig 36: Connecting Upper Radiator Hose
Courtesy of FORD MOTOR CO.
Connect the upper radiator hose to the water outlet adapter.

Fig 37: Connecting Upper Radiator Hose To Water Outlet Adapter
Courtesy of FORD MOTOR CO.
Connect the fuel line. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
Install the air cleaner outlet tube. For additional information, refer to REMOVAL & INSTALLATION .
Refill the engine cooling system. For additional information, refer to ENGINE COOLING or SUPERCHARGER COOLING .