2000 Ford ZX2 AutomaticFACTORY OEM SERVICE PROCEDURE

Upper Intake Manifold: Installation

WARNING: This page is about a different car, the 2005 Mercury Montego, 2005 Ford Freestyle, and 2005 Ford Five Hundred. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Clean and inspect all sealing surfaces. Install new gaskets.
  1. Position the upper intake manifold and install the 8 bolts.
    • Tighten in the sequence shown to 10 Nm (89 lb-in).
      Fig 1: Installing Bolts
      G03990081Courtesy of FORD MOTOR CO.
  2. Connect the throttle body electrical connector.
  3. Connect the throttle body and PCV coolant hoses.
  4. Connect the EGR system module tube to the EGR system module.
    • Tighten to 40 Nm (30 lb-ft).
  5. Attach the vacuum tube to the upper intake manifold vacuum tube retainer.
  6. Connect the EGR system module electrical connector and vacuum tube.
  7. Attach the fuel tube retainer to the upper intake manifold.
  8. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold.
  9. Connect the EVAP canister purge valve tube to the upper intake manifold and attach the retainer.
  10. Clean the 4 transaxle roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads.
  11. Position the transaxle roll restrictor cross brace and install the 4 new bolts.
    • Tighten to 55 Nm (41 lb-ft).
  12. Clean the transaxle roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads.
  13. Install a new transaxle roll restrictor cross brace-to-roll restrictor bolt.
    • Tighten to 48 Nm (35 lb-ft).
  14. Install the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  15. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  16. Fill and bleed the cooling system. For additional information, refer to ENGINE COOLING .
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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.

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