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Home >> Ford >> 2002 >> Crown Victoria Base, 4.6 9 >> Repair and Diagnosis (Single Page) >> Engine Mechanical >> Mechanical >> Engine - 4.6L >> In-Vehicle Repair >> Intake Manifold - Natural Gas Engines >> Installation

Intake Manifold - Natural Gas Engines: Installation

  1. Install new intake manifold gaskets.
    Fig 1: Identifying Intake Manifold Gaskets
    G01941177Courtesy of FORD MOTOR CO.
  2. Install the intake manifold.
    Fig 2: Identifying Intake Manifold
    G01941178Courtesy of FORD MOTOR CO.
  3. Install the bolts and tighten in the sequence shown in illustration.
    Fig 3: Identifying Intake Manifold Bolt Tightening Sequence
    G01941179Courtesy of FORD MOTOR CO.
  4. Install the water thermostat and a new O-ring.
    Fig 4: Identifying Water Thermostat
    G01941180Courtesy of FORD MOTOR CO.
  5. Install the water outlet adapter and tighten the bolts.
    Fig 5: Tightening Water Outlet Adapter Bolts
    G01941181Courtesy of FORD MOTOR CO.
  6. Install the generator support bracket and tighten the bolts.
    Fig 6: Tightening Generator Support Bracket Bolts
    G01941182Courtesy of FORD MOTOR CO.
  7. Install the eight ignition coils and tighten the bolts.
    Fig 7: Tightening Ignition Coil Bolts
    G01941183Courtesy of FORD MOTOR CO.
  8. Connect the upper radiator hose to the water outlet adapter.
    Fig 8: Identifying Upper Radiator Hose & Water Outlet Adapter
    G01941184Courtesy of FORD MOTOR CO.
  9. Connect the heater water hose to the intake manifold.
    Fig 9: Connect Heater Water Hose To Intake Manifold
    G01941185Courtesy of FORD MOTOR CO.
  10. Install the fuel injectors and the fuel injection supply manifold as an assembly.
    Fig 10: Identifying Fuel Injection Supply Manifold
    G01941186Courtesy of FORD MOTOR CO.
  11. Install the four bolts.
    Fig 11: Tightening Fuel Injection Supply Manifold Bolts
    G01941187Courtesy of FORD MOTOR CO.
  12. Install the bolts in the isolation valve and tighten.
    Fig 12: Identifying Isolation Valve
    G01941188Courtesy of FORD MOTOR CO.
  13. Connect the EGR tube to the EGR valve.
    Fig 13: Tightening EGR Tube
    G01941189Courtesy of FORD MOTOR CO.
  14. Connect the vacuum hoses to the EGR vacuum regulator solenoid.
    Fig 14: Identifying EGR Vacuum Regulator Solenoid Vacuum Hoses
    G01941190Courtesy of FORD MOTOR CO.
  15. Connect the vacuum hoses to the throttle body adapter.
    Fig 15: Identifying Throttle Body Adapter Vacuum Hoses
    G01941191Courtesy of FORD MOTOR CO.
  16. Install the crankcase ventilation tube and connect at two locations.
    Fig 16: Identifying Crankcase Ventilation Tube
    G01941192Courtesy of FORD MOTOR CO.
  17. Connect the main chassis vacuum supply hose to the throttle body adapter.
    Fig 17: Identifying Throttle Body Adapter Main Chassis Vacuum Supply Hose
    G01941193Courtesy of FORD MOTOR CO.
  18. Connect the vacuum hose to the EGR valve.
    Fig 18: Identifying EGR Valve Vacuum Hose
    G01941194Courtesy of FORD MOTOR CO.
  19. Connect the hoses to the differential pressure feedback exhaust gas recirculation (EGR) system.
    Fig 19: Identifying Pressure Feedback Exhaust Gas Recirculation (EGR) System Hoses
    G01941195Courtesy of FORD MOTOR CO.
  20. Connect the fuel lines. For additional information, refer to FUEL SYSTEMS .
  21. Position the fuel charging wiring and install the bolts.
    Fig 20: Tightening Fuel Charging Wiring Harness Bolts
    G01941196Courtesy of FORD MOTOR CO.
  22. Position the cables and the bracket and install the bolts.
    Fig 21: Tightening Throttle Cable & Speed Control Actuator Cable Bracket Bolts
    G01941197Courtesy of FORD MOTOR CO.
  23. Connect the throttle cable and the speed control actuator cable to the throttle body.
    Fig 22: Identifying Throttle Cable & Speed Control Actuator Cable
    G01941198Courtesy of FORD MOTOR CO.
  24. Connect the fuel charging wiring to the idle air control valve.
    Fig 23: Identifying Idle Air Control Valve Fuel Charging Wiring
    G01941199Courtesy of FORD MOTOR CO.
  25. Connect the differential pressure feedback EGR system electrical connector.
    Fig 24: Identifying Differential Pressure Feedback EGR System Electrical Connector
    G01941200Courtesy of FORD MOTOR CO.
  26. Connect the fuel charging wiring to the EGR vacuum regulator solenoid.
    Fig 25: Identifying EGR Vacuum Regulator Solenoid Fuel Charging Wiring
    G01941201Courtesy of FORD MOTOR CO.
  27. Connect the fuel charging wiring to the radio ignition interference capacitor.
    Fig 26: Identifying fuel Charging Wiring & Radio Ignition Interference Capacitor
    G01941202Courtesy of FORD MOTOR CO.
  28. Connect the fuel charging wiring electrical connector to the throttle position sensor.
    Fig 27: Identifying Throttle Position Sensor Fuel Charging Electrical Connector
    G01941203Courtesy of FORD MOTOR CO.
  29. Connect the fuel charging wiring electrical connector to the generator.
    Fig 28: Identifying Generator Fuel Charging Electrical Connector
    G01941204Courtesy of FORD MOTOR CO.
  30. Connect the fuel charging wiring electrical connector to the camshaft position sensor.
    Fig 29: Identifying Fuel Charging Electrical Connector
    G01941205Courtesy of FORD MOTOR CO.
  31. Connect the fuel charging wiring electrical connector to the cylinder head temperature sensor jumper.
    Fig 30: Identifying Fuel Charging Wiring Electrical Connector & Cylinder Head Temperature Sensor Jumper
    G01941206Courtesy of FORD MOTOR CO.
  32. Connect the fuel charging wiring electrical connector to the A/C pressure transducer.
    Fig 31: Identifying A/C Pressure Transducer Fuel Charging Electrical Connector
    G01941207Courtesy of FORD MOTOR CO.
  33. Connect the fuel charging wiring electrical connectors at the inner fender splash shield.
    Fig 32: Identifying Fuel Charging Wiring Electrical Connectors
    G01941208Courtesy of FORD MOTOR CO.
  34. Reposition the wiring on the stud and tighten the nut.
    Fig 33: Identifying Power Distribution Cable Nut
    G01941209Courtesy of FORD MOTOR CO.
  35. Install the power distribution box access cover.
    Fig 34: Identifying Power Distribution Box Access Cover
    G01941210Courtesy of FORD MOTOR CO.
  36. Connect the generator battery cable and tighten the nut.
    Fig 35: Tightening Generator Battery Cable Nut
    G01941211Courtesy of FORD MOTOR CO.
  37. Connect the isolation valve jumper to the fuel charging wiring electrical connector.
    Fig 36: Connecting Isolation Valve Jumper To Fuel Charging Wiring Electrical Connector
    G01941212Courtesy of FORD MOTOR CO.
  38. Connect the fuel charging wiring electrical connector to the engine coolant temperature sensor.
    Fig 37: Identifying Engine Coolant Temperature Sensor Fuel Charging Electrical Connector
    G01941213Courtesy of FORD MOTOR CO.
  39. Connect the fuel charging wiring electrical connector to the fuel temperature sensor.
    Fig 38: Identifying Fuel Temperature Sensor Fuel Charging Electrical Connector
    G01941214Courtesy of FORD MOTOR CO.
  40. Connect the fuel charging wiring electrical connector to the fuel pressure sensor.
    Fig 39: Identifying Fuel Pressure Sensor Fuel Charging Electrical Connector
    G01941215Courtesy of FORD MOTOR CO.
  41. Connect the fuel charging wiring electrical connectors to the eight ignition coils and the eight fuel injectors.
    Fig 40: Identifying Ignition Coil & Fuel Injector Fuel Charging Electrical Connectors
    G01941216Courtesy of FORD MOTOR CO.
  42. Install the wiper arm and pivot shaft. For additional information, refer to MOUNTING ARM AND PIVOT SHAFT .
  43. Install the air cleaner outlet tube.
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