Removal and Replacement

Intake Manifold - 5.4L











Removal

WARNING: Do not smoke, carry lighted tobacco or have an 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 serious personal injury.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Remove the engine cover.
2. Disconnect the fuel supply tube 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. Remove the throttle body (TB) spacer. For additional information, refer to Fuel Delivery and Air Induction.
6. Compress and slide the hose clamp and disconnect the upper radiator hose.
7. Disconnect the coolant hose.





8. Remove the 3 bolts and the generator upper support bracket.
9. Remove the transmission fluid indicator and tube support bracket bolt.





10. Remove the nut and position the transmission fluid indicator and tube aside.





11. Disconnect the evaporative emissions (EVAP) tube quick connect coupling from the LH valve cover. For additional information, refer to Fuel Delivery and Air Induction.





12. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to Heating and Air Conditioning.
13. Disconnect the quick connect couplings and remove the PCV tube. For additional information, refer to Fuel Delivery and Air Induction.
14. Disconnect the fuel rail pressure and temperature sensor vacuum hose and the electrical connector.





15. NOTE: LH shown, RH similar.

Disconnect the 8 ignition coil electrical connectors.





16. NOTE: LH shown, RH similar.

Disconnect the 8 fuel injector electrical connectors.





17. Remove the 8 bolts and the 8 ignition coils.
18. Remove the 2 bolts, the thermostat housing and the thermostat.
^ Discard the O-ring seal.

19. 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 lb-in).
^ Stage 2: Tighten to 25 Nm (18 lb-ft).





6. Install the 8 ignition coils and the 8 bolts.
^ Tighten to 6 Nm (53 lb-in).

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.
11. If equipped, connect the auxiliary heater hoses.





12. Position the transmission fluid indicator and tube and install the retaining nut.
^ Tighten to 28 Nm (21 lb-ft).





13. Install the transmission fluid filler tube support bracket bolt.
^ Tighten to 10 Nm (89 lb-in).





14. Install the generator upper support bracket and the 3 bolts.
^ Tighten to 10 Nm (89 lb-in).

15. Connect the coolant hose.





16. Connect the upper radiator hose.
17. Position the crankcase ventilation tube and connect quick connect coupling to the LH valve cover.





18. Install the TB spacer.
19. Connect the fuel supply tube spring lock coupling.
20. Install the engine cover.
21. Connect the battery ground cable. For additional information, refer to Battery.
22. Fill and bleed the engine cooling system.