2005 Ford Expedition RWDFACTORY OEM SERVICE PROCEDURE

Intake Manifold: Installation

    NOTE: Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at rear of the intake manifold. Use extreme care on installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses.
  1. Using new intake manifold gaskets, position the intake manifold.
  2. Using new gaskets, position the coolant crossover and install the 3 bolts
    • Tighten to 10 Nm (89 lb-in).
  3. Install the intake manifold bolts and tighten in 2 stages, in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 lb-in).
    • Stage 2: Tighten to 10 Nm (89 lb-in).
    Fig 1: Identifying Tighten Sequence Of Intake Manifold Bolts
    G03919851Courtesy of FORD MOTOR CO.
  4. Connect the engine wiring harness retainer to the CMCV stud and install the nut.
    • Tighten to 10 Nm (89 lb-in).
  5. Connect the CMCV electrical connector.
  6. Connect the CHT sensor jumper harness electrical connector.
    Fig 2: Connecting CHT Sensor Jumper Harness Electrical Connector
    G03919848Courtesy of FORD MOTOR CO.
  7. Connect the LH and RH KS electrical connectors.
    Fig 3: Connecting LH And RH KS Electrical Connectors
    G03919849Courtesy of FORD MOTOR CO.
  8. Connect the manifold vacuum tube to the support bracket and the valve cover stud.
  9. Connect the brake booster vacuum hose to the intake manifold vacuum tube.
  10. Connect the heated PCV intake fitting electrical connector.
    Fig 4: Connecting Heated PCV Intake Fitting Electrical Connector
    G03919845Courtesy of FORD MOTOR CO.
  11. Connect the LH H02S electrical connector and attach the wiring harness retainer.
    Fig 5: Connecting LH H02S Electrical Connector
    G03933349Courtesy of FORD MOTOR CO.
  12. Connect the EOP sensor electrical connector.
    Fig 6: Locating Engine Oil Pressure (EOP) Sensor Electrical Connector
    G03919846Courtesy of FORD MOTOR CO.
  13. Connect the VCT solenoid electrical connector.
  14. Connector the CMP sensor electrical connector.
    Fig 7: Identifying LH CMP Sensor Electrical Connector
    G03919847Courtesy of FORD MOTOR CO.
  15. Connect the LH radio ignition capacitor electrical connector.
  16. Connect the TP sensor and electronic acceleration control electrical connectors.
  17. Connect the 8 fuel injector electrical connectors.
  18. Connect the 4 LH ignition coil electrical connectors.
    Fig 8: Identifying LH Ignition Coil Electrical Connectors
    G03919844Courtesy of FORD MOTOR CO.
  19. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
  20. Connect the fuel supply spring lock coupling to the fuel rail. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  21. Position the PCV tube and connect the quick connect couplings. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  22. Position the EVAP tube and connect the quick connect coupling to the intake manifold. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  23. Connect the heater coolant hose to the coolant bypass.
  24. Connect the upper radiator hose to the thermostat housing.
  25. Install the generator. For additional information, refer to GENERATOR AND REGULATOR .
  26. Install the air cleaner. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  27. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING .
Factory Service Tools

Use the Manual With the Right Hardware

Pair factory procedures with proven DIY tools so the instructions are easier to execute.

Disclosure: Verified tool recommendations may earn an affiliate commission at no cost to you.

Shop Manual-Ready ToolsCompare Repair QuoteQuote Shield Pro

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.