Removal and Installation
Intake Manifold - 5.4LMaterial:
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before servicing or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved to prevent accidental spraying of fuel, causing personal injury or a fire hazard.
1. Remove the engine cover.
2. Disconnect the fuel supply hose spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction.
3. Disconnect the battery ground cable. For additional information, refer to Battery.
4. Drain the cooling system. For additional information, refer to Cooling System.
5. Loosen the clamp, remove the 4 bolts and position the engine air cleaner (ACL) aside to gain access to the mass airflow (MAF) sensor electrical connector.
6. Disconnect the MAF sensor electrical connector and remove the ACL.
7. Disconnect the crankcase ventilation tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
8. Loosen the clamp and remove the air cleaner outlet Pipe.
9. NOTE: The red clip must be pulled out before disconnecting the electrical connector.
Disconnect the electronic throttle control electrical connector.
10. Disconnect the throttle position (TP) sensor electrical connector.
11. Compress and slide the hose clamp and disconnect the upper radiator hose.
12. Disconnect the coolant hose.
13. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system electrical connector and the 2 vacuum hoses.
14. Remove the 2 bolts and the differential pressure feedback EGR system bracket.
15. Remove the 3 bolts and the generator upper support bracket.
16. Remove the transmission fluid indicator and tube support bracket bolt.
17. Remove the nut and position the transmission fluid indicator and tube aside.
18. Disconnect the evaporative emissions (EVAP) hose quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
19. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to Heating and Air Conditioning.
20. Disconnect the EGR vacuum regulator solenoid electrical and vacuum connectors.
21. NOTE: Valve shown disconnected for clarity.
Press the tab, remove and position aside the EVAP canister purge valve.
22. Disconnect the EGR valve vacuum hose.
23. Disconnect the brake booster and main engine vacuum hoses and position aside.
24. Disconnect the upper and lower fittings and remove the exhaust manifold-to-EGR valve tube.
25. Remove the 4 bolts, and the an assembly. TB and adapter as an assembly.
^ Discard the TB adapter gasket.
26. Disconnect the quick connect remove the Positive couplings and Crankcase ventilation tube For additional information, refer to (PCV) Fuel Delivery and Air Induction.
27. Disconnect the fuel rail Pressure and temperature sensor vacuum electrical connector hose and the electrical connector.
28. NOTE: LH shown, RH similar.
Disconnect the 8 ignition coil electrical connectors.
29. NOTE: LH shown RH similar.
Disconnect the 8 fuel injector electrical connectors.
30. Remove the 8 bolts and the 8 ignition coils.
31. Remove the bolts, the thermostat housing and the thermostat.
^ Disconnect the O-ring seal.
32. Remove the 9 bolts, the intake manifold assembly and discard the intake manifold gaskets.
Installation
1. 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 can cause leak paths. Use a plastic scraping tool to clean sealing surfaces.
Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
2. Position new intake manifold gaskets, the intake manifold and loosely install the 9 bolts.
3. Using a new O-ring seal, install the thermostat.
4. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.
Loosely install the thermostat housing and the 2 bolts.
5. Tighten the 11 bolts in 2 stages in the sequence shown.
^ Stage 1: Tighten to 2 Nm (18 inch lbs.).
^ Stage 2: Tighten to 25 Nm (18 ft. lbs.).
6. Install the 8 ignition coils and the 8 bolts.
^ Tighten to 6 Nm (53 inch lbs.).
7. NOTE: LH shown, RH similar.
Connect the 8 fuel injector electrical connectors.
8. NOTE: LH shown, RH similar.
Connect the 8 ignition coil electrical connectors.
9. Connect the fuel rail pressure and temperature sensor vacuum hose and electrical connector.
10. Position the PCV tube and connect the quick connect couplings. For additional information, refer to Fuel Delivery and Air Induction.
11. Install a new TB adapter gasket, position the TB adapter assembly and tighten the 4 bolts in 2 stages.
^ Stage 1: Tighten to 9 Nm (80 inch lbs.).
^ Stage 2: Tighten an additional 90 degrees.
12. Install the exhaust manifold-to-EGR valve tube.
^ Hand-tighten the upper and lower fittings.
^ Tighten to 50 Nm (37 ft. lbs.).
13. Connect the brake booster and the main engine vacuum hoses.
14. Connect the EGR vacuum hose.
15. Install the EVAP canister purge valve.
16. Connect the EGR vacuum regulator solenoid electrical and vacuum connectors.
17. If equipped, connect the auxiliary heater hoses. For additional information, refer to Heating and Air Conditioning.
18. Connect the EVAP hose quick connect coupling to the intake manifold. For additional information, refer to Fuel Delivery and Air Induction.
19. Position the transmission fluid indicator and tube and install the retaining nut.
^ Tighten to 28 Nm (21 ft. lbs.).
20. Install the transmission fluid filler tube support bracket bolt.
^ Tighten to 10 Nm (89 inch lbs.).
21. Install the generator upper support bracket and the 3 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
22. Install the differential pressure feedback EGR system bracket and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
23. Connect the differential pressure feedback EGR system electrical connector and the 2 vacuum hoses.
24. Connect the coolant hose.
25. Connect the upper radiator hose.
26. Connect the TP sensor electrical connector.
^ Push back the red clip.
27. Connect the electronic throttle control electrical connector.
^ Push back the red clip.
28. Install the air cleaner outlet pipe and tighten the clamp.
29. Connect the crankcase ventilation tube quick connect coupling. For additional information, refer to Fuel Delivery and Air Induction.
30. Connect the MAF sensor and position the ACL.
31. Tighten the clamp and Install the 4 bolts.
^ Tighten to 7 Nm (62 inch lbs.).
32. Connect the fuel hose spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction.
33. Install the engine cover.
34. Connect the battery ground cable. For additional information, refer to Battery.
35. Fill and bleed the engine cooling system. For additional information, refer to Cooling System.