Upper Intake Manifold: Installation

Install the upper intake manifold gasket.

Fig 1: Installing Upper Intake Manifold Gasket
Courtesy of FORD MOTOR CO.

NOTE: Install new bolts.

Fig 2: Positioning Upper Intake Manifold

G01562847

Courtesy of FORD MOTOR CO.

Position the upper intake manifold and loosely install the new bolts.
Tighten the bolts in the sequence shown in two stages.
- Tighten to 10Nm (89 lb-in).
- Tighten an additional 90 degrees.
  
  Fig 3: Tightening Bolts In Sequence
  Courtesy of FORD MOTOR CO.
Install the EGR adapter using a new gasket.

Fig 4: Installing EGR Adapter Using Gasket
Courtesy of FORD MOTOR CO.
Connect the vacuum hose to the EGR valve.

Fig 5: Connecting Vacuum Hose To EGR Valve
Courtesy of FORD MOTOR CO.
Connect the vacuum hose at the right rear of the intake manifold.

Fig 6: Connecting Vacuum Hose At Right Rear Of Intake Manifold
Courtesy of FORD MOTOR CO.
Connect the vacuum hose.

Fig 7: Connecting Vacuum Hose
Courtesy of FORD MOTOR CO.
Connect the brake booster vacuum hose.

Fig 8: Connecting Brake Booster Vacuum Hose
Courtesy of FORD MOTOR CO.
Position the oil fill tube and install the stud.

Fig 9: Positioning Oil Fill
Courtesy of FORD MOTOR CO.
Position the power steering reservoir bracket and install the bolts.

Fig 10: Positioning Power Steering Reservoir Bracket And Installing Bolts
Courtesy of FORD MOTOR CO.
Install the nut.

Fig 11: Installing Nut
Courtesy of FORD MOTOR CO.
Connect the two vacuum hoses and the electrical connector to the differential pressure feedback EGR system.

Fig 12: Connecting Vacuum Hoses And Electrical Connector To Differential Pressure Feedback EGR System
Courtesy of FORD MOTOR CO.
Connect the vacuum hoses and the electrical connector to the EGR vacuum regulator solenoid.

Fig 13: Connecting Vacuum Hoses And Electrical Connector To Egr Vacuum Regulator Solenoid
Courtesy of FORD MOTOR CO.
Connect the IAC valve electrical connector.

Fig 14: Connecting Iac Valve Electrical Connector
Courtesy of FORD MOTOR CO.
Connect the TP sensor electrical connector.

Fig 15: Connecting TP Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Install the balance tube gaskets.

Fig 16: Installing Balance Tube Gaskets
Courtesy of FORD MOTOR CO.
Install the balance tube, the bolts and the stud.

Fig 17: Installing Balance Tube, Bolts And Stud
Courtesy of FORD MOTOR CO.
Connect the electrical connector to the intake manifold tuning valve.

Fig 18: Connecting Electrical Connector To Intake Manifold Tuning Valve
Courtesy of FORD MOTOR CO.
Connect the PCV heater coolant hoses.

Fig 19: Connecting PCV Heater Coolant Hoses
Courtesy of FORD MOTOR CO.
Install the tube assembly and connect the PCV valve tube.

Fig 20: Installing Tube Assembly And Connecting Pcv Valve Tube
Courtesy of FORD MOTOR CO.
Connect the EVAP return hose.

Fig 21: Connecting EVAP Return Hose
Courtesy of FORD MOTOR CO.
Position the cables and bracket, and install the bolts.

Fig 22: Positioning Cables And Bracket, And Installing Bolts
Courtesy of FORD MOTOR CO.
Connect the accelerator cable, speed control cable and the return spring.

Fig 23: Connecting Accelerator Cable, Speed Control Cable And Return Spring
Courtesy of FORD MOTOR CO.
Install the engine appearance cover.

Fig 24: Installing Engine Appearance Cover
Courtesy of FORD MOTOR CO.
Install the engine air cleaner and outlet tube. For additional information, refer to REMOVAL & INSTALLATION - BLACKWOOD, EXPEDITION, F150 PICKUP & NAVIGATOR - GASOLINE .
Install the wiring harness shield, the bolts and five clips.

Fig 25: Installing Wiring Harness Shield, Bolts And Five Clips
Courtesy of FORD MOTOR CO.
Install the cowl grille. For additional information, refer to FRONT END BODY PANELS .
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Fill the engine cooling system. For additional information, refer to ENGINE COOLING .