Installation Manual

5.4 LITER FORD INTAKE MANIFOLD
INSTALLATION INSTRUCTIONS
ATTENTION!
Refer to the appropriate shop manual for your vehicle to obtain specific service procedures for this part. If you do not have a service
manual or lack the skill to install this part, it is recommended that you seek the services of a qualified technician. Pay special attention to
all cautions and warnings included in the shop manual! Read and follow all instructions carefully! Failure to do so will result in severe
damage to the intake manifold and to the engine!
1. Carefully remove intake manifold per the service procedure outlined in shop manual.
2. Clean all mounting surfaces.
3. Reinstall intake manifold per shop manual.
4. Tighten intake bolts as follows:
Stage One: 2 Nm (18 in-lbs)
Stage Two: 25 Nm (18 ft-lbs)
5. Install intake bolts in sequence shown.
TECH TIPS
This air intake manifold design does not require
additional intake gaskets. The intake gaskets are already
installed into the manifold.
Be sure to fully seat the injectors into intake manifold
when installing the fuel rail. Failure to do so will result
in a vacuum leak and/or may prevent fuel rail from
being properly attached.
There are two sizes of thread-forming screws.
The small thread-forming screws are used for
mounting the ignition coils. Tighten to 2.7 to 3.3
Nm torque. DO NOT OVERTIGHTEN!
The large thread-forming screws are to be
tightened to 6 to 7 Nm. DO NOT
OVERTIGHTEN!
To install fuel rail fasteners, start each large
fasteners for three full rotations before
tightening any fastener completely.
Some large self tapping screws provided may not be
used in your application – number of fasteners used will
vary based upon vehicle application
To attach PCV system connector at back of manifold,
after installing o-ring, point PCV connector towards
passenger side of vehicle, lower connector into intake
manifold and rotate connector clockwise until PCV
connector locks/clicks into place.
 Transferring NVH cover from original manifold is not
required, if original manifold was provided with one.
 Provided in the component kit will be an auxiliary
coolant fitting that has sealant pre-applied to the threads.
Only for original applications that require an additional
coolant connection, the installed plug must be removed.
The provided auxiliary coolant fitting should be installed
wrench-tight. Do not exceed 10 Nm. 1-3 threads
showing. DO NOT BOTTOM OUT FITTING!
AUXILIARY COOLANT FITTING
Installed plug should be replaced only
by customers that require second
coolant connection. Install fitting
wrench-tight. Do not exceed 10 Nm
torque. 1-3 threads will be showing for
properly installed fitting. DO NOT
BOTTOM OUT FITTING!
615-188 Installation Instructions RN036-238 Rev C