Installation

1. Clean and inspect sealing surfaces of intake manifold and throttle body.

CAUTION: Use care when cleaning gasket material because aluminum gouges easily which forms leak paths.

NOTE: Lightly oil all bolt and stud bolt threads with clean engine oil meeting Ford specification WSS-M2C153-G prior to installation except those specifying special sealant.

2. Install guide pins (if available).
3. If removed, install idle air control valve to the upper intake manifold.
4. If removed, install the throttle body to the upper intake manifold.
5. If removed, install the EGR valve, EGR backpressure transducer and EGR vacuum regulator solenoid.
6. Place intake manifold upper gasket on lower intake manifold.
7. Aligning bolt holes, install upper intake manifold on lower intake manifold. Install stud bolts and retaining bolts. Tighten to 20-30 Nm (15-22 ft. lbs.).
8. Install generator brace to upper intake manifold mounting stud and generator mounting bracket. Tighten nut and bolts to 12-20 Nm (9-14 ft. lbs.).
9. Install intake manifold support to the throttle body and RH cylinder head. Tighten retaining bolts as shown in the illustration.








10. Install degas tube to the upper intake manifold. Tighten retaining nuts to 16-20 Nm (12- 14 ft. lbs.).
11. Install the engine control sensor wiring bracket onto the throttle body retaining stud bolts.
12. Connect crankcase ventilation tube, aspirator vacuum supply hose and evaporative emission return tube to fittings underneath upper intake manifold.
13. Install EGR valve to exhaust manifold tube to EGR valve. Tighten to 35-65 Nm (26-47 ft. lbs.).
14. Connect vacuum hose to fuel pressure regulator.
15. Connect engine control sensor wiring connections to idle air control valve, throttle position sensor, EGR backpressure transducer and EGR vacuum regulator solenoid.
16. Install accelerator cable bracket to side of throttle body. Tighten retaining bolts to 17 Nm (13 ft. lbs.).
17. Connect accelerator cable and speed control actuator cable to throttle body lever. Install accelerator retracting spring.
18. Install accelerator cable shield. Tighten bolts to 1.4 Nm (13 inch. lbs.).
19. Install air cleaner outlet tube.
20. Connect battery ground cable.
21. Fill engine cooling system.
22. Start engine and check for vacuum and exhaust leaks.
23. Check engine idle. Adjust as necessary.

NOTE: This adjustment must be performed if the throttle body is removed for any reason and if throttle plate idle adjustment screw position is changed.