Installation

Installation

All vehicles





1. Install the intake manifold.
^ Position the intake manifold gaskets.
^ Position the intake manifold.
^ Loosely install the nine bolts.








2. Install the water thermostat.
^ Install the thermostat.
^ Install a new O-ring seal.

3. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts. Do not tighten the thermostat housing bolts during thermostat installation.

Install the water thermostat housing and loosely install the bolts.

5.4L - Lower Intake To Upper Intake Sequence:

4. Tighten the bolts in two stages, in the sequence shown.
1. Stage 1: Tighten to 2 Nm (18 inch lbs.).
2. Stage 2: Tighten to 25 Nm (18 ft. lbs.).





5. Install the heater water hose and position the clamp.





6. Connect the eight fuel injector electrical connectors.





7. Install the eight ignition coils.





8. Connect the eight ignition coil electrical connectors.





9. Position the vacuum harness and connect the fuel pressure regulator vacuum hose.





10. Connect the PCV valve tube to the intake manifold.





11. Connect the fuel tubes and install the safety clips.





12. Install a new throttle body adapter gasket.





13. Install the throttle body adapter.
^ Position the throttle body adapter.
^ Install the four bolts.

Vehicles with EGR system





14. Connect the EGR valve vacuum hose.





15. Connect the EGR vacuum regulator solenoid connections.





16. Install the differential pressure feedback EGR system bracket.





17. Connect the exhaust manifold to EGR valve tube upper fitting.
Tighten both fittings starting at the top in three steps.
^ Hand-tighten.
^ Tighten the upper fitting to 40 - 60 Nm (30 - 44 ft. lbs.).
^ Tighten the lower fitting to 40 - 60 Nm (30 - 44 ft. lbs.).

All vehicles





18. Connect the IAC electrical connector.





19. Connect the brake booster vacuum hose and main vacuum harness to the throttle body adapter.





20. Connect the evaporative emission canister purge valve vacuum hose to the throttle body adapter.





21. Install the IAC fresh air tube and insert it in the routing clip.





22. Connect the TP sensor electrical connector.





23. Install the accelerator cable bracket.
^ Position the accelerator cable bracket.
^ Install the bolts.





24. Connect the throttle body cam.
^ Connect the accelerator cable.
^ If equipped, connect speed control cable.
^ Install the return spring.





25. Install the accelerator control splash shield.





26. Position the generator and install the lower mounting bolts.





27. Install the generator upper mounting bracket stud and bolt.





28. Install the harness routing clips on the generator stud and the engine front cover.

Vehicles without A/C





29. Rotate the belt tensioner counterclockwise and install the belt on the generator pulley.

Vehicles with A/C





30. Rotate the belt tensioner clockwise and install the belt on the generator pulley.

All vehicles





31. Install the upper radiator hose and reposition the clamp.





32. Position the air cleaner, air cleaner outlet housing and the air cleaner outlet pipe in the vehicle and connect the MAF sensor electrical connector.





33. Join the air cleaner outlet housing to the air cleaner inlet housing and secure the clamp.





34. Connect the air cleaner outlet pipe to the throttle body and tighten the clamp.





35. Connect the IAC fresh air tube and crankcase ventilation tube to the air cleaner outlet pipe.
36. Fill the cooling system.
37. Connect the battery ground cable.