Intake Manifold: Service and Repair

REMOVAL

NOTE: The intake manifold is a four-piece assembly consisting of the upper intake manifold, the throttle body, the fuel injection supply manifold and the lower intake manifold.

WARNING: Residual pressure remains in fuel system after engine is shut off. This could result in injury or fire when fuel lines are disconnected. Disconnect inertia fuel shutoff switch and crank engine until fuel in lines is used up.

1. Disconnect the battery ground cable at the battery.
2. Remove the air cleaner outlet tube from the throttle body.
3. Remove the accelerator control splash shield and disconnect the throttle cable and bracket assembly.
4. Disconnect all vacuum hoses from the fittings on the upper intake manifold.
5. Disconnect the electrical connections at the throttle body, upper intake manifold, lower intake manifold and fuel injector nozzle tip.
6. Disconnect the fuel supply and return lines at the fuel supply manifold.
7. Remove the bolts securing the ignition coil and bracket assembly to the upper intake manifold.
8. Remove the EGR valve, the intake manifold to EGR valve tube, and the EGR transducer vacuum lines.
9. Remove the six nuts securing the upper intake manifold and remove the upper manifold.
10. Remove the valve covers.
11. Remove the intake manifold attaching bolts. Tap the intake manifold lightly with a plastic mallet to break the gasket seal, and lift off the intake manifold assembly.
12. Remove all old gasket material, and sealing compound.

INSTALLATION

Application Of Sealer To Intake Manifold:

1. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to the block and cylinder head mating surfaces at the four corners. Install the intake manifold gasket and again apply sealer to the four corner locations.

NOTE: Once applied, the silicone sealer will set up in approximately 15 minutes. The intake manifold must be installed immediately after the sealer is applied.

Lower Intake Manifold Installation:

2. Position the intake manifold with the aid of two guide studs and install the bolts hand-tight. Then remove the two guide studs and replace with bolts.

Lower Intake Manifold Bolt Tightening Sequence:

3. Tighten the intake manifold bolts in three stages following the sequence shown.
a. 8 Nm (6 ft lb)
b. 15 Nm (11 ft lb)
c. 22 Nm (16 ft lb)
4. Apply Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to the four locations at the joint where the intake manifold and the cylinder heads meet.
5. Install valve covers and tighten bolts to 6-8 Nm (4.5-5.9 ft lb).
6. Install the upper intake manifold and tighten the nuts to 20-25 Nm (15-18 ft lb) in sequence.
7. Install the EGR valve, the intake manifold to EGR valve tube, and the EGR transducer vacuum lines.

Ignition Coil Installation:

7. Install the ignition coil and tighten screws to 5-7 Nm (3.7-5.2 ft lb). Install ignition coil mounting strap assembly and tighten bolts to 20-25 Nm (15-19 ft lb).
8. Connect the fuel supply and return lines at the fuel injection supply manifold.
9. Connect the electrical connections at the throttle body, upper intake manifold, lower intake manifold and fuel injectors.
10. Connect all vacuum hoses to the fittings on the upper intake manifold.
11. Install the throttle cable and bracket assembly and the accelerator control splash shield to the throttle body.
12. Connect the air cleaner outlet tube to the throttle body.
13. Fill and bleed the cooling system.

NOTE: It is important to follow the coolant filling procedure.

14. Connect the battery ground cable at the battery.
15. Check the fuel system for leaks.