Intake Manifold: Service and Repair
REMOVAL1. Disconnect battery ground cable.
2. Drain engine cooling system.
3. Remove crankcase ventilation tube from valve cover and air cleaner outlet tube.
4. Remove air cleaner outlet tube.
WARNING: COVER FUEL PRESSURE RELIEF VALVE WITH A SHOP CLOTH TO PREVENT ACCIDENTAL FUEL SPRAY INTO EYES.
5. Carefully relieve fuel system pressure at the fuel pressure relief valve (Schrader valve).
6. Remove fuel line safety clips. Disconnect fuel lines.
7. Mark locations of vacuum lines and remove.
8. Disconnect fuel charging wiring from intake air temperature sensor (IAT sensor), camshaft position sensor (CMP sensor) throttle position sensor (TP sensor), idle air control valve (IAC valve), engine coolant temperature sensor (ECT sensor), ignition coil, water temperature indicator sender unit and EGR backpressure transducer.
9. Disconnect upper radiator hose from water hose connection. After loosening retaining clamp, carefully use a twisting motion on upper radiator hose to loosen from water hose connection.
10. Remove brace spanning from generator mounting bracket to throttle body stud bolt.
11. Remove throttle body.
12. Remove EGR tube at exhaust manifold connector and EGR valve.
13. Disconnect fuel charging wiring retainers from valve cover stud bolts. Carefully disconnect electrical connections to each fuel injector and remove fuel charging wiring from engine.
14. Disconnect heater water hoses.
15. Remove ignition wires from spark plugs. Remove harness retainer-to-valve cover stud bolts.
16. Remove camshaft position sensor.
17. Remove ignition coil from rear of LH cylinder head.
18. Remove valve covers.
19. Loosen cylinder No. 3 intake valve rocker arm seat retaining bolt. Rotate rocker arm off of push rod and away from top of valve stem. Remove push rod.
20. Remove lower intake manifold retaining bolts using a Torch head socket. Before attempting to remove intake manifold, break seal between intake manifold and cylinder block. Wedge a large pry bar or similar tool between intake manifold and cylinder block. Pry upward on tool using area between water hose connection and transaxle as a leverage point.
NOTE: Lower intake manifold may be removed with fuel injection supply manifold and fuel injectors in place as an assembly.
INSTALLATION
1. Clean mating gasket surfaces of lower intake manifold and cylinder head. Lay a clean cloth or shop cloth in valve tappet valley to catch any gasket material. After scraping, carefully lift cloth from valve tappet valley, preventing any particles from entering oil drain holes or cylinder head. Use a suitable solvent to remove old silicone sealant.
CAUTION: Aluminum components gouge easily which may cause gasket leaks. Always use care when scraping aluminum gasket surfaces.
NOTE: Lightly oil all retaining bolt and stud bolt threads before installation.
2. If installing a new lower intake manifold, transfer engine coolant temperature sensor, water thermostat, water hose connection, heater hose elbow and water temperature indicator sender unit to new lower intake manifold.
3. If removed, install fuel injection supply manifold.
- Apply clean engine oil XO-10W30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C 153-E lightly to fuel injector O-rings before installation.
- Install fuel injectors into fuel injection supply manifold.
- Carefully align fuel injection supply manifold to intake manifold fuel injector bores.
- Push one side into place at a time until fuel injection supply manifold clicks into place.
- Install fuel injection supply manifold retaining bolts and tighten to 8-12 Nm (71-106 inch lbs.).
4. Apply a 5-6 mm (0.25 inch) drop of Silicone Rubber D6AZ-19562-AA or BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A to intersection of cylinder block and cylinder head at four corners as shown in the Intake Manifold Gasket illustration.
NOTE: Prior to applying sealer, clean sealing surfaces of cylinder block and cylinder head with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
5. Position intake manifold gasket onto cylinder heads. Align intake manifold gasket locking tabs to provisions on head gaskets as shown.
6. Install front and rear intake manifold end seals as shown. Secure with retainers.
7. Carefully position lower intake manifold, aligning intake manifold bolt holes to those in cylinder head. Use care to prevent disturbing silicone sealer which can cause sealing voids.
- Install bolts No.1, 2, 3, and 4 and hand tighten.
- Install remaining bolts and tighten in a two step process.
- Tighten in numerical sequence to 20-30 Nm (15-22 ft. lbs.).
- Tighten again in sequence to 26-32 Nm (20-23 ft. lbs.).
8. Coat entire drive gear on CMP sensor housing with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A. Install camshaft position sensor.
CAUTION: If a new camshaft position sensor housing is installed, ALWAYS add the rest of the Engine Assembly Lubricant D9AZ-19579-D or equivalent (pint) meeting Ford specification ESR-M99C80-A to the engine oil by pouring it through the hole onto the camshaft drive gear. Run engine at idle for five minutes prior to driving vehicle.
9. Apply clean engine oil XO-1OW30-QSP or -DSP or equivalent meeting Ford specification ESE-M2C153-E to cylinder No. 3 intake valve, push rod and rocker arm. Install push rod. Move rocker arm into position with push rod and snug rocker arm seat retaining bolt. Rotate crankshaft to position camshaft lobe straight down and away from valve tappet.
- Tighten rocker arm seat retaining bolt to 7-15 Nm (62-132 inch lbs.).
- Final tighten rocker arm seat retainer bolt to 26-38 Nm (19-28 ft. lbs.) in any position.
NOTE: Rocker arm seat must be fully seated into cylinder head and push rod must be fully seated in rocker arm and valve tappet sockets prior to final tightening.
10. Install valve covers.
11. Install fuel charging wiring to each fuel injector. Secure retainers for fuel charging wiring to inboard valve cover stud bolts.
12. Install ignition coil to rear of LH cylinder head. Tighten retaining bolts to 40-55 Nm (30-41 ft. lbs.).
13. Connect ignition wires to spark plugs and ignition coil.
14. Install throttle body and new intake manifold upper gasket.
15. Reinstall EGR tube at exhaust manifold connector and EGR valve.
16. Install fuel lines.
17. Install fuel line safety clips.
18. Install upper radiator hose and heater water hoses. Tighten retaining clamps securely.
19. Connect vacuum lines to premarked locations.
20. Connect fuel charging wiring to intake air temperature sensor, camshaft position sensor to idle air control valve, throttle position sensor engine coolant temperature sensor, EGR backpressure transducer, ignition coil and water temperature indicator sender unit.
21. Fill and bleed engine cooling system with specified coolant mixture.
22. Fill crankcase with correct viscosity and amount of engine oil XO-10W30-QSP or -DSP meeting Ford specification ESE-M2C153-E.
CAUTION: Engine coolant is corrosive to all engine bearing material. Replacing oil after removal of a coolant carrying component prevents damage.
23. Install air cleaner outlet tube.
24. Install crankcase ventilation tube to valve cover and air cleaner outlet tube.
25. Connect battery ground cable.
26. Start engine and check for coolant, oil, fuel and vacuum leaks.