Lower
REMOVAL1. Drain engine cooling system.
2. Remove upper intake manifold.
3. Remove fuel injectors and fuel injection supply manifold (9F792).
4. Remove heater water inlet hose.
5. Remove heater water outlet hose.
6. Remove lower intake manifold retaining bolts/studs.
7. Remove lower intake manifold.
CAUTION: The lower intake manifold is sealed at each end with silicone sealer. To break the seal, it may be necessary to pry on the front of the lower intake manifold with a prybar. If it is necessary to pry on the lower intake manifold, use care to prevent damage to machined surfaces.
8. Remove and discard water hose connections (8592) and end seals.
Part 1 Of 2:
Part 2 Of 2:
9. If lower intake manifold is to be disassembled, perform the following:
a. Remove water hose connection and water thermostat (8575).
b. Remove engine coolant temperature sensor (ECT)(12A648).
c. Remove heater elbow.
d. Remove all vacuum and electrical fittings.
INSTALLATION
1. The lower intake manifold cylinder head and cylinder block mating surfaces should be clean and free of old gasketing material. Use a suitable solvent to clean these surfaces.
NOTE: Lightly oil all retaining bolt and stud threads before installation.
2. If lower intake manifold was disassembled:
a. Apply Pipe Sealant with Teflon D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 to the threads of the engine coolant temperature sensor, all vacuum fittings, heater elbows, and electrical fittings (if equipped).
b. Install water hose connection (note direction and water thermostat. Install water hose connection. Tighten retaining bolts to 8-11 Nm (71-97 inch lbs.).
3. Apply a dab of Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specifications ESR-M11P17-A and ESE-M2G52-A to each cylinder head mating surface. Press new intake manifold gasket into place, using location pins as necessary to aid in assembly.
NOTE:
- Prior to applying sealer, clean sealing surfaces of cylinder heads (6049) and lower intake manifold with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residue that may interfere with the sealer's ability to adhere.
- When the lower intake manifold is removed, always use new intake manifold gaskets upon reassembly.
4. Apply a 3-4 mm (0.125 inch) bead of Silicone Rubber D6AZ-19562-BA or AA or equivalent meeting Ford specifications ESB-M4G92-A or ESE-M4G195-A at each corner where the cylinder head joins the cylinder blocks (6010).
NOTE: When using silicone sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set-up, and its sealing effectiveness may be reduced.
5. Install new front and rear intake manifold end seals.
6. Carefully lower intake manifold into position on cylinder blocks and cylinder head. Use locating pins as necessary to guide intake manifold.
7. Install bolts and stud bolt in their original locations.
8. Tighten bolts and stud bolt in numerical sequence to the following specifications in two steps:
Step 1 ... 5 Nm (44 inch lbs.).
Step 2 ... 8-12 Nm (71-106 inch lbs.).
9. Install front crankcase ventilation tube so that the mounting bracket sits over the lower intake manifold stud. Tighten nut on stud to 20-30 Nm (15-22 ft. lbs.).
10. Install fuel injectors and fuel injection supply manifold. Tighten fuel injection supply manifold to lower intake manifold bolts to 8-11 Nm (71-97 inch lbs.). Tighten fuel pressure bracket bolt to 20-30 Nm (15-22 lb-ft).
11. Install upper intake manifold.
CAUTION: This engine has aluminum cylinder heads and requires a special corrosion inhibiting coolant to avoid cooling system damage.
12. Fill engine cooling system.
13. Start engine and check for leaks.