Safety Warning

DIY auto repair can cause serious injury, fire, or vehicle damage. These guides are for informational purposes only. Always follow OEM torque specs, wear PPE, and consult a certified mechanic if you are unsure. You are solely responsible for your safety.

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HOMESERVICE MANUALSFORD2009RANGER 2D PICKUP, 2.3 D, AUTOMATICREPAIR AND DIAGNOSISEXTERNAL PAGESDIFFERENT CARSECTION 55 (ENGINE - 6.8L)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 2008 Ford Econoline, 2008 Ford E450 Super Duty, and 2008 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the mating surfaces of the cylinder head and the intake manifold with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
Position new intake manifold gaskets and the intake manifold, and loosely install the 11 bolts.
Using a new O-ring seal, install the thermostat.

NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.

Position the thermostat housing and loosely install the 2 bolts.
Tighten the bolts in the sequence shown in 2 stages.
- Stage 1: Tighten to 2 Nm (18 lb-in).
- Stage 2: Tighten to 25 Nm (18 lb-ft).

Fig 1: Intake Manifold Bolt Torque Sequence

Courtesy of FORD MOTOR CO.

Connect the push pin retainer to the intake manifold bracket.

Fig 2: Push Pin Retainer

Courtesy of FORD MOTOR CO.

Position the 10 ignition coils and install the 10 bolts.
- Tighten to 6 Nm (53 lb-in).
Position back the LH fuel charging wiring harness and install the 2 bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 3: Fuel Charge Wiring Harness Bolts

Courtesy of FORD MOTOR CO.

Position back the RH fuel charging wiring harness and install the stud bolts.
- Tighten to 10 Nm (89 lb-in).

Fig 4: Stud Bolts

Courtesy of FORD MOTOR CO.

Position back the transmission fluid level indicator tube and install the retaining nut.
- Tighten to 10 Nm (89 lb-in).

Fig 5: Identifying Transmission Fluid Level Indicator Tube And Retaining Nut

Courtesy of FORD MOTOR CO.

Install the transmission fluid indicator and tube nut.
- Tighten to 28 Nm (21 lb-ft).

Fig 6: Transmission Fluid Indicator Tube Nut

Courtesy of FORD MOTOR CO.

Connect the 10 ignition coil electrical connectors.

Fig 7: Identifying Ignition Coil Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the 10 fuel injector electrical connectors.

Fig 8: Identifying Fuel Injector Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
Connect the vacuum connector.

Fig 9: Vacuum Connector

Courtesy of FORD MOTOR CO.

Connect the heater coolant hose.

Fig 10: Heater Coolant Hose

Courtesy of FORD MOTOR CO.

Install a new TB adapter gasket and the TB and adapter as an assembly. Tighten the 4 bolts in 2 stages.
- Stage 1: Tighten to 9 Nm (80 lb-in).
- Stage 2: Tighten an additional 90 degrees.

Fig 11: Throttle Body & Adapter Bolts

Courtesy of FORD MOTOR CO.

Connect the brake booster vacuum hose and the EVAP hose quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.

Fig 12: Brake Booster Vacuum Hose & Evaporative Emission (EVAP) Hose Quick Connect Coupling

Courtesy of FORD MOTOR CO.

Connect the 2 coolant hoses and the vacuum connector.

Fig 13: Coolant Hoses & Vacuum Tube Connector

Courtesy of FORD MOTOR CO.

Connect the PCV tube quick connect coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.

Fig 14: Positive Crankcase Ventilation (PCV) Tube Quick Connect Coupling

Courtesy of FORD MOTOR CO.

Connect the TP sensor electrical connector.
- Push in the red clip.

Fig 15: Identifying Throttle Position Sensor Electrical Connector

Courtesy of FORD MOTOR CO.

Connect the electronic TB electrical connector.
- Push in the red clip.

Fig 16: Electronic Throttle Body (TB) Electrical Connector

Courtesy of FORD MOTOR CO.

Install the upper radiator hose.

Fig 17: Upper Radiator Hose & Clamp

Courtesy of FORD MOTOR CO.

Install the generator. For additional information, refer to GENERATOR AND REGULATOR article.
Install the air cleaner assembly and tubes. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING article.
Connect the fuel hose spring lock coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION - GASOLINE AND DIESEL article.
Connect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES article.
Fill the cooling system. For additional information, refer to ENGINE COOLING article.
Install the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION article.

RENDER: 1.0x

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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.