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HOMESERVICE MANUALSFORD2009RANGER 2D PICKUP, 2.3 D, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 297 (ENGINE MECHANICAL)IN-VEHICLE SERVICINGINTAKE MANIFOLDINSTALLATION
2009 Ford Ranger 2D Pickup, 2.3 D, Automatic

Intake Manifold: Installation

2009 Ford Ranger 2D Pickup, 2.3 D, AutomaticSECTION Installation
WARNING: This page is about a different car, the 2009 Mercury Grand Marquis and 2009 Ford Crown Victoria. However, it is still accessible from the selected car via links, so may be relevant.
    NOTE: Align the gasket locator tabs with the slots in the cylinder head.
  1. Install new intake manifold gaskets.
    2. Fig 1: Intake Manifold Gaskets
    GF0013546Courtesy of FORD MOTOR CO.
  2. Install the intake manifold and hand-tighten the 8 bolts.
  3. Install the 8 ignition coil-on-plugs. For additional information, refer to ENGINE IGNITION - 4.6L (2V) article.
  4. Position the intake manifold crash bracket and loosely install the bolt and stud bolt.
  5. Tighten the bolts in the sequence shown in illustration.
    • Tighten to 25 Nm (18 lb-ft).
    6. Fig 2: Intake Manifold Bolt Tightening Torque Sequence
    GF0013547Courtesy of FORD MOTOR CO.
  6. Tighten the intake manifold crash bracket bolt.
    • Tighten to 25 Nm (18 lb-ft).
  7. Install the EGR system module tube. For additional information, refer to ENGINE EMISSION CONTROL article.
  8. Install the intake manifold shield and the 2 bolts.
    • Tighten to 10 Nm (89 lb-in).
  9. Connect the throttle control and the TP sensor electrical connectors.
  10. Install the coolant thermostat. For additional information, refer to ENGINE COOLING article.
  11. Install the generator bracket and the 4 bracket bolts.
    • Tighten to 10 Nm (89 lb-in).
  12. Connect the generator electrical connector.
  13. Attach the 2 generator wiring harness retainers to the generator bracket.
  14. Connect the EVAP canister purge valve hoses to the TB and the EVAP canister purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  15. Connect the intake manifold vacuum hose to the TB spacer.
  16. Connect the EGR system module vacuum and electrical connectors.
  17. Connect the PCV tube quick connect coupling to the TB spacer. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  18. Connect the brake booster vacuum hose to the intake manifold.
  19. Install the heater hose and spring clamp.
  20. Connect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
  21. Connect the 8 fuel injector electrical connectors.
  22. Install the wire harness retainer to the rear of the intake manifold.
  23. If equipped, attach the wire harness retainer to the intake manifold crash bracket.
  24. Install the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS & WASHERS article.
  25. Connect the fuel spring lock coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  26. Install the air cleaner and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING article.
  27. Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING & CABLES article.
  28. Fill and bleed the engine cooling system. For additional information, refer to ENGINE COOLING article.
    29. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to FIRE SUPPRESSION SYSTEM article. Failure to follow these instructions may result in serious personal injury.
  29. If equipped with fire suppression system, repower the system.
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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.