Intake Manifold: Service and Repair
Intake ManifoldRemoval
1. Disconnect battery ground cable.
2. Drain engine cooling system.
3. Relieve fuel system pressure and disconnect fuel lines.
4. Remove air cleaner outlet tube.
5. Release drive belt tensioner and remove drive belt.
6. CAUTION: Do not pull on ignition wire as wire may separate from the connector in the ignition wire boot.
Disconnect all ignition wires from spark plugs.
7. Disconnect ignition wires and ignition wire separators from valve cover stud bolts.
8. Disconnect engine control sensor extension wire from both ignition coils and camshaft position sensor (CMP sensor).
9. Remove four bolts retaining ignition coil to ignition coil brackets.
10. Disconnect generator wiring harness from junction block at front fender apron and from generator (GEN).
11. Remove four bolts retaining generator mounting bracket to intake manifold.
12. Remove bolts retaining generator to cylinder block and remove generator.
13. Raise vehicle on a hoist.
14. Disconnect engine control sensor extension wire from the oil pressure sensor and electronic variable orifice sensor and position fuel charging wiring out of the way.
15. Disconnect EGR valve to exhaust manifold tube from RH exhaust manifold.
16. Lower vehicle.
17. Disconnect accelerator cable and speed control actuator cable from throttle body.
18. Remove accelerator cable bracket from intake manifold and position out of the way.
19. Disconnect vacuum hose from throttle body adapter vacuum port.
20. Disconnect heater water hose.
21. Note: Two water outlet connection retaining bolts also retain intake manifold.
Remove two bolts retaining water hose connection to intake manifold and position upper radiator hose and water hose connection out of the way.
22. Remove the remaining nine bolts retaining intake manifold to cylinder heads and remove intake manifold.
23. Remove intake manifold gaskets.
Installation
1. Note: If a new intake manifold is being installed, transfer all necessary components onto new intake manifold.
Clean sealing surfaces of intake manifold and cylinder heads.
2. Position new intake manifold gaskets on cylinder heads.
3. Position intake manifold on cylinder heads.
4. Note: Make sure alignment tabs on intake manifold gasket are aligned with holes in cylinder heads.
Install and tighten intake manifold retaining bolts one through nine in sequence shown to 20-30 N-m (15-22 lb-ft).
5. Replace O-ring seal on water hose connection. Position water hose connection and upper radiator hose and install two bolts and tighten to 20-30 N-m (15-22 lb-ft).
6. Connect heater water hose.
7. Connect vacuum hose to throttle body adapter vacuum port.
8. Install accelerator cable bracket on intake manifold and connect accelerator cable and speed control actuator cables to throttle body.
9. Raise vehicle.
10. Connect EGR valve to exhaust manifold tube to RH exhaust manifold and tighten nut to 35-45 N-m (26-33 lb-ft).
11. Connect the engine control sensor extension wire to the electronic variable orifice sensor and oil pressure sensor.
12. Lower vehicle.
13. Position generator and install two retaining bolts. Tighten to 20-30 N-m (15-22 lb-ft).
14. Install two bolts retaining generator rear mounting bracket to intake manifold and tighten to 8-12 N-m (71-106 lb-in).
15. Connect generator wiring harness to generator, RH front fender apron and junction block.
16. Position ignition wires and ignition wire separators on engine and install bolts retaining ignition coil to ignition coil brackets. Tighten bolts to 8-12 N-m (71-106 lb-in).
17. Connect all ignition wires to spark plugs.
18. Connect ignition wire separators on valve cover studs.
19. Connect the engine control sensor extension wire to both ignition coils and camshaft position sensor.
20. Install drive belt.
21. Install air cleaner outlet tube.
22. Connect fuel lines.
23. Connect battery ground cable.
24. Fill and bleed engine cooling system.
25. Check and fill crankcase to specified level with clean engine oil meeting Ford specification ESE-M2C153-E .
26. Start engine and check for leaks.