Intake Manifold

Tools Required:

• Spark Plug Wire Remover T74P-6666-A

Removal

1. Drain the cooling system.

2. Disconnect the accelerator cable and speed control linkage, if so equipped, from the throttle body. Disconnect transmission TV cable if so equipped. Remove accelerator cable bracket. Disconnect vacuum lines at the intake manifold fitting.

3. Disconnect the spark plug wires from the spark plugs using Spark Plug Wire Remover T74P-6666-A. Do not pull on the wire. Remove the wires and bracket assembly from the rocker arm cover attaching stud. Remove the distributor cap, adapter and spark plug wire assembly.

    WARNING: RELIEVE FUEL LINE PRESSURE BEFORE DISASSEMBLING CONNECTIONS. DISCONNECT AND CAP FUEL SUPPLY AND RETURN LINES. REFER TO SECTION 03-13 FOR PROCEDURES.

4. Disconnect supply and return fuel lines.

5. Disconnect the distributor wiring connector. Remove the distributor hold-down bolt and remove the distributor.

6. Disconnect the radiator upper hose from the coolant outlet housing, and the water temperature sending unit wire at the sending unit. Disconnect the air inlet hose from the intake manifold. Disconnect two throttle body cooler hoses on Mustang only.

7. Loosen the clamp on the water pump bypass hose at the coolant outlet housing and slide the hose off the outlet housing. Disconnect wires at ECT, IAT, TP, IAC solenoid and EGR sensors. Disconnect injector wire connections. Disconnect fuel charging assembly wiring.

8. Pull the PCV valve out of the grommet at rear of lower intake manifold. Disconnect fuel evaporative purge hose from the plastic connector at the front of the upper intake manifold.

   NOTE: On Mustang only, the cover plate must be removed to access the upper intake manifold retainer bolts.

9. Remove the upper intake manifold.

10. Remove heater tube assembly from lower intake manifold.

     CAUTION: It may be necessary to pry the intake manifold away from the cylinder head(s). Use caution to avoid possible damage to the gasket sealing surfaces. Remove the intake manifold gaskets and seals.

11. Remove lower intake manifold.

12. If the manifold assembly is to be disassembled, identify all vacuum hoses before disconnecting them. Remove the coolant outlet housing, gasket and thermostat.

Installation

1. If the intake manifold assembly was disassembled, install the temperature sending unit (threads coated with electrical conductive sealer). Position the thermostat in the coolant outlet housing. Coat the thermostat gasket with Perfect Seal Sealing Compound B5A-19554-A (ESR-M18P2-A and ESE-M4G115-A) or equivalent, and position it on the coolant outlet housing. Install the coolant outlet housing.

2. Clean the mating surfaces of the intake manifold, cylinder heads and cylinder block. Use a solvent such as lacquer thinner, chlorothane or equivalent. Apply a 3.2mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-AA or BA (ESB-M4G92-A and ESE-M4G195-A) or equivalent, at the points shown.

3. Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Ensure the holes in the gaskets are aligned with the holes in the cylinder heads.

   NOTE: This sealer sets up in 15 minutes, so it is important that assembly be completed promptly. Do not drip any sealer into the engine valley.

4. Apply a 1.6mm (1/16 inch) bead of sealer to the outer end of each intake manifold seal for the full width of the seal (four places).
   
   
   
   

5. Using guide pins to ease installation, carefully lower the intake manifold into position on the cylinder block and cylinder heads. After the intake manifold is in place, run a finger around the seal area to ensure the seals are in place. If the seals are not in place, remove the intake manifold and reposition the seals.

6. Ensure the holes in the manifold gaskets and manifold are in alignment. Remove guide pins. Install the intake manifold retaining bolts. Tighten the intake manifold bolts in three steps:
   1. Tighten in sequence to 11 Nm (8 lb-ft).
   2. Tighten in sequence to 22 Nm (16 lb-ft).
   3. Tighten in sequence to 31-34 Nm (23-25 lb-ft).

7. Install heater tube assembly to lower intake manifold.

8. Install the water pump bypass hose on the coolant outlet housing. Slide the clamp into position and tighten the clamp. Install hoses to heater tubes and tighten clamps.

9. Connect the radiator upper hose. Connect the heater hose at the intake manifold.

10. Install the fuel lines.

11. Rotate the crankshaft until the No. 1 piston is at TDC at the end of the compression stroke. Align the correct initial timing mark on the damper with the pointer. Position the distributor in the block with the rotor at the No. 1 firing position and install the hold-down clamp.
    
    
    
    

12. Install the distributor cap. Position the spark plug wires in the harness brackets on the valve rocker arm cover attaching stud and connect the wires to the spark plugs.

13. Install upper intake manifold.

14. Connect the crankcase vent tube.

15. Connect the accelerator cable and accelerator cable bracket. Connect TV cable and speed control, if equipped, to the throttle body.

16. Connect all electrical connections disconnected during removal.

17. Connect any vacuum lines that were disconnected from the intake manifold during removal. Connect coolant hoses to EGR spacer on Mustang only.

18. Fill and bleed the cooling system.

19. Install the air intake duct assembly and crankcase vent hose.

20. Start the engine. Check and adjust the ignition timing.

21. Operate the engine at fast idle and check all hose connections and gaskets for leaks. When engine temperatures have stabilized, check intake manifold bolt torques.