Intake Manifold

Upper

Removal

1. Remove air cleaner outlet tube (9B659). Refer to Section 03-12.

2. Disconnect accelerator cable (9A758) at throttle body (9E926) . Disconnect speed control actuator (9A825) , if equipped.

3. Remove retaining bolts from accelerator cable bracket (9723) and position cables aside.

4. Disconnect vacuum lines at intake manifold (9424) .

5. Disconnect necessary electrical connectors.

6. Disconnect one crankcase ventilation tube (6758) at the upper intake manifold and at positive crankcase ventilation valve (PCV valve) (6A666) .

7. Remove throttle body, if necessary.

8. Remove the EGR valve (EGR valve) (9D475) from the upper intake manifold . Refer to Section 03-08.

9. Remove the nut and bolt retaining engine support and wiring retainer bracket located at the LH front of the intake manifold and set aside with ignition wires.

10. Remove upper intake manifold retaining bolts/studs.

11. Remove upper intake manifold and intake manifold upper gasket (9H486) .
    
    
    
    
    

    Item	Part Number	Description
    1A	N804839-S2	Bolt (6 Req'd)
    2	9424	Lower Intake Manifold
    3	—	Locating Pins (2 Req'd)
    4	9H486	Intake Manifold Upper Gasket
    5	9424	Upper Intake Manifold
    A		Tighten in sequence in three steps: · 10 Nm (8 Lb-Ft) · 20 Nm (15 Lb-Ft) · 32 Nm (24 Lb-Ft)

Installation

NOTE: Use locating pins to secure position of intake manifold upper gasket between intake manifolds .

1. Position intake manifold upper gasket and intake manifold on top of lower intake manifold.

2. Install bolts and stud bolts in original locations.

   Tighten in sequence as listed under Step 18 in three steps:

   • 10 Nm (8 Lb-Ft)
   • 20 Nm (15 Lb-Ft)
   • 32 Nm (24 Lb-Ft)

3. Install engine support and wiring bracket and retaining nut and bolt to LH front of the intake manifold. Tighten retainers to 20-30 Nm (15-22 lb-ft).

4. Install the EGR valve as outlined in Section 03-08.

5. Install throttle body, if removed. Cross-tighten retaining nuts to 20-30 Nm (15-22 lb-ft).
   
   
   
   
   

   Item	Part Number	Description
   1	9424	Upper Intake Manifold
   2	—	Stud (Part of 9424)
   3	9E936	Throttle Body Gasket
   4	9E926	Throttle Body
   5A	N805620	Stud Bolt
   6A	N804178	Nut (3 Req'd)
   A		Tighten to 20-30 Nm (15-22 Lb-Ft)

6. Connect rear crankcase ventilation tube at positive crankcase ventilation valve on the upper intake manifold .
   
   
   
   
   

   Item	Part Number	Description
   1A	N805117-S8M	Bolt (4 Req'd)
   2	9F792	Fuel Injection Supply Manifold
   3	9424	Intake Manifold
   4B	N606691-S2	Bolt
   5	6049	Cylinder Head
   A		Tighten to 8-11.5 Nm (6-8.5 Lb-Ft)
   B		Tighten to 20-30 Nm (15-22 Lb-Ft)

7. Connect necessary fuel charging wiring connectors.

8. Connect necessary vacuum hoses.

9. Position accelerator cable bracket . Install and tighten retaining bolts to 14-20 Nm (10-15 lb-ft).

10. Connect accelerator cable at throttle body . Connect speed control actuator , if so equipped.

11. Install air cleaner outlet tube. Refer to Section 03-12.

12. Check and, if necessary, adjust engine idle airflow. Refer to Powertrain Control/Emissions Diagnosis Manual.

13. Check and adjust accelerator cable if necessary. Refer to Section 10-02.

14. Check and adjust speed control actuator if necessary. Refer to Section 10-03.

Lower

1. Drain engine cooling system as outlined in Section 03-03.

2. Remove upper intake manifold as outlined.

3. Remove fuel injector (9F593) and fuel injection supply manifold (9F792) . Refer to Section 03-04A.

4. Remove heater water outlet hose.

5. Remove lower intake manifold retaining bolts/studs.

    CAUTION: The intake manifold is sealed at each end with RTV-type sealer. To break the seal, it may be necessary to pry on the front of the intake manifold with a screwdriver blade. If it is necessary to pry on the intake manifold use care to prevent damage to machined surfaces.

6. Remove lower intake manifold .

7. Remove and discard intake manifold gasket (9439) and end seals.

8. If lower intake manifold is to be disassembled, perform the following:
   • Remove water outlet connection (8592) and water thermostat (8575) .

     NOTE: The water bypass tube is pressed-in, and is not serviceable.

   • Remove engine coolant temperature sensor (ECT sensor) (12A648).
   • Remove heater elbow.
   • Remove all vacuum and electrical fittings.
   
   
   
   
   
   

   Item	Part Number	Description
   1A	—	Bolt (2 Req'd)
   2	8592	Water Outlet Connection
   3	8255	Water Outlet Connection Gasket
   4	8575	Water Thermostat
   A		Tighten to 20-30 Nm (15-22 Lb-Ft)

Installation

NOTE: Lightly oil all retaining bolt and stud threads before installation.

NOTE: When using silicone rubber 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.

1. The lower intake manifold, cylinder head (6049) , and cylinder block mating surfaces should be clean and free of old gasketing material. Use a suitable solvent to clean these surfaces.

2. If intake manifold was disassembled:
   1. Apply a coat of Pipe Sealant with Teflon® D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-AZ and ESR-M18P7-A to the threads of the engine coolant temperature sensor , all vacuum fittings, heater elbows, and electrical fittings, if equipped. Refer to Specifications.
   2. Install water outlet connection (note direction) and water outlet connection gasket (8255) . Install water outlet connection . Tighten retaining bolts to 20-30 Nm (15-22 lb-ft).

      NOTE: Using solvent, clean sealing surfaces of cylinder heads and intake manifold before applying Silicone Sealer.

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.

4. Apply a 3-4mm (1/8 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 block (6010) .

5. Install front and rear intake manifold end seals.
   
   
   
   
   

   Item	Part Number	Description
   1	9439	Intake Manifold Gasket
   2	—	End Seal (Part of 9439)
   3	6049	Cylinder Head
   4	—	Locating Pin (4 Req'd)
   5	6051	Head Gasket

6. Carefully lower intake manifold into position on cylinder block and cylinder head . Use locating pins as necessary to guide intake manifold .

7. Install bolts and stud bolt in their original locations.
   
   
   
   
   

   Item	Part Number	Description
   1	M8X1.25X81	Stud Bolt (2 Req'd)
   2	M8X1.25X55	Bolt (12 Req'd)
   3	9424	Lower Intake Manifold
   4	9439	Intake Manifold Gasket
   5	—	End Seal (Part of 9439)

8. Tighten bolts and stud bolt in numerical sequence to the following specifications in two steps:
   1. 11 Nm (8 lb-ft).
   2. 20 Nm (15 lb-ft).
      
      
      
      

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 lb-ft).

10. Install fuel injector and fuel injection supply manifold . Tighten screws to 8-11 Nm (6-8 lb-ft).

11. Install upper intake manifold as outlined.

     CAUTION: This engine has aluminum cylinder heads and requires a special corrosion inhibiting coolant to avoid cooling system damage. Refer to Section 03-03 for the coolant specifications.

12. Fill engine cooling system as outlined in Section 03-03.

13. Start engine and check for leaks.