Lower
Lower Intake Manifold
Removal
1. Drain engine cooling system.
2. Remove upper intake manifold as outlined.
3. Disconnect upper radiator hose at water outlet connection.
4. Disconnect water bypass hose at lower intake manifold
5. Remove heater water hose.
6. Remove bolt retaining power steering line bracket to coil bracket.
7. Remove bolt securing fuel rail assembly bracket and rear intake manifold support to cylinder head, then remove rear intake manifold support.
8. Remove bolt and nut securing coil bracket to lower intake manifold
9. Remove fuel injector and fuel injection supply manifold.
10. Remove nut securing front intake manifold support to lower intake manifold and remove intake manifold support.
11. Disconnect engine control sensor wiring.
12. Remove lower intake manifold retaining bolts.
CAUTION:
The lower intake manifold is sealed at each corner with RTV-type sealer. To break the seal, it may be necessary to pry on the front of the intake manifold with a screwdriver blade. If it is necessary to pry on the lower intake manifold use care to prevent damage to machined surfaces.
13. Remove lower intake manifold.
14. Remove intake manifold gasket and end seals, and discard.
Intake Manifold Gasket Installation
Item Description
1 Intake Manifold Gasket
2 Rear Seal
3 Front Seal
4 Head Gasket
A Apply Sealant
NOTE: The water bypass tube is pressed in, and not serviceable.
15. If lower intake manifold assembly is to be disassembled, perform the following:
a. Remove water hose connection and water thermostat.
b. Remove engine coolant temperature sensor (ECT sensor).
c. Remove hot water heater elbow connection.
d. Remove all vacuum and electrical fittings.
e. Remove water temperature indicator sender unit.
Thermostat
Item Description
1 Water Hose Connection
2 Water Outlet Connection Gasket
3 Water Thermostat
4 Bolt (2 Required)
A Tighten to 20-30 Nm (15-22 lb-ft)
Item Description
1 Bolt (12 Required)
2 Lower Intake Manifold
3 Intake Manifold Gasket
4 End Seal
5 Stud (2 Required)
Installation
NOTE: Lightly oil all retaining bolt and stud bolt threads before installation.
NOTE: When using silicone rubber sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to setup, and its sealing effectiveness may be reduced.
1. The lower intake manifold, cylinder head, and cylinder block mating surfaces should be clean and free of old gasketing material. Use a suitable solvent to clean these surfaces.
2. If intake manifold was disassembled:
- Apply a coat of Pipe Sealant with Teflon� D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-AZl2A to the threads of the water temperature indicator sender unit, all vacuum fillings, hot water heater elbow connections, engine coolant temperature sensor and electrical fillings, if equipped. Tighten water temperature indicator sender unit to 12-16 Nm (9-12 lb-ft) and tighten engine coolant temperature sensor to 14-19 Nm (10-14 lb-ft).
- Install water thermostat (note direction) and water hose connection . Install water hose connection Tighten retaining bolts to 20-30 Nm (15-22 lb-ft).
3. Apply Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specification ESE-M2G52-A to each cylinder head mating surface. Press new intake manifold gaskets into place, using locating pins as necessary to aid in assembly.
NOTE: Using solvent, clean sealing surfaces of cylinder heads and intake manifold before applying silicone rubber.
4. Apply a 3-4mm (1/8-inch) bead of Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A at each corner where the cylinder head joins the cylinder block.
5. Install front and rear intake manifold end seals.
6. Carefully install intake manifold into position on cylinder block and cylinder heads. Use locating pins as necessary to guide intake manifold.
7. Install bolts in their original locations. Tighten in numerical sequence as shown in the following illustration to the following specifications in two steps:
a. 18Nm (13 lb-ft)
b. 22Nm (16 lb-ft)
8. Connect engine control sensor wiring to water temperature indicator sender unit and engine coolant temperature sensor.
9. Position front intake manifold support to lower intake manifold and install nut. Tighten nut to 20-30 Nm (15-22 lb-ft).
10. Install fuel injectors and fuel injection supply manifold.
11. Install bolt and nut securing coil bracket to lower intake manifold . Tighten bolt and nut to 20-30 Nm (15-22 lb-ft).
12. Position rear intake manifold support behind fuel rail assembly bracket and to camshaft sprocket. Tighten bolt to 20-30 Nm (15-22 lb-ft).
13. Position power steering line bracket to coil bracket and install retaining bolt. Tighten bolt securely.
14. Install heater water hose.
15. Connect water bypass hose to lower intake manifold.
16. Connect upper radiator hose to water outlet connection.
17. Install upper intake manifold.
18. Fill and bleed engine cooling system.