Intake Manifold Assembly

Intake Manifold Assembly - 5.4L








Disassembly

WARNING: Do not smoke, carry lighted tobacco or have an open flame of any type when working on or near any fuel-related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in serious personal injury.

1. Remove the 2 bolts and the fuel rail pressure and temperature sensor.
^ Discard the O-ring seal.
2. Remove the 4 fuel rail bolts and the fuel rail and injectors as an assembly.
3. Remove the 8 fuel injectors from the fuel rail.
4. Discard the 2 O-ring seals from each fuel injector.
5. Remove the engine noise shield.





6. Remove the 6 bolts and the coolant crossover tube.
^ Discard the gaskets.

7. CAUTION: If the engine has been internally damaged and metal or other foreign material has entered the manifold, it is recommended the manifold be discarded. Failure to follow these instructions may result in engine damage.

Inspect all external and internal surfaces of the intake manifold.
^ Inspect for cracks or other damage.
^ Inspect for foreign material inside of the manifold.
^ Clean the upper intake manifold sealing surfaces.

Assembly
1. Position new gaskets, the coolant crossover tube and install the 6 bolts.
^ Tighten to 10 Nm (89 lb-in).
2. Install the engine noise shield.





3. NOTE: When installing the fuel injectors, make sure that the injectors are fully engaged in the fuel injector cups.

NOTE: Lubricate the new O-ring seals with clean engine oil prior to installation.

Install the 8 fuel injectors into the fuel rail.
4. Position the rail and install the 4 bolts.
^ Tighten to 10 Nm (89 lb-in).
5. Using a new O-ring seal, position the fuel rail pressure and temperature sensor and install the 2 bolts.
^ Tighten to 7 Nm (62 lb-in).