Variable Induction System: Service and Repair
NOTE: The Intake Manifold Runner Control (IMRC) system is a unique design and cannot be substituted for earlier versions. The actuator assembly's electromechanical drive, cables, and monitor switch cannot be serviced independently, but must be replaced as an assembly if diagnosis indicates that any of its components are the root cause of a DTC or engine performance concern.REMOVAL
1. Disconnect battery ground cable.
2. Drain engine cooling system.
Engine Appearance Cover:
3. Remove engine appearance cover.
4. Remove air cleaner outlet tube.
5. Relieve fuel system pressure and disconnect fuel lines from the fuel injection supply manifold.
6. Remove eight retaining nuts on RH and LH ignition wire covers and remove ignition wire covers.
7. Disconnect ignition wires from spark plugs with a gentle twist/pull motion on the spark plug boot.
CAUTION: Do not pull on ignition wire as it may separate from the connector in the ignition wire boot.
8. Disconnect ignition wires from ignition coils.
9. Detach two center ignition wire separators from retaining studs.
10. Remove ignition wires.
11. Disconnect generator wiring harness from generator at B+ terminal and disconnect stator connector plug. Remove wiring harness retaining clip from generator mounting bracket.
12. Remove two bolts and two nuts attaching generator mounting bracket to generator and intake manifold. Remove generator mounting bracket.
13. Disconnect upper radiator hose, heater water hose and water bypass tube to water thermostat hose at water bypass tube.
14. Disconnect engine control sensor wiring from engine coolant temperature sensor connector at water bypass tube.
Water Bypass Tube:
15. Remove two retaining nuts and spacers from water bypass tube hold-down braces to intake manifold studs and remove water bypass tube.
16. Disconnect accelerator cable and speed control actuator cable from throttle body and from accelerator cable bracket. Position accelerator cable and speed control actuator cable out of the way.
17. Disconnect chassis vacuum supply hose from intake manifold connector and move out of the way.
18. Disconnect vacuum harness from fuel pressure regulator, RH and LH secondary air injection diverter valves, EGR control valve, EGR vacuum regulator solenoid, and secondary air injection vacuum control solenoid and intake manifold connection. Remove vacuum harness.
19. Disconnect IMRC actuator from the IMRC assemblies at the levers. Remove IMRC actuator retainers and IMRC actuator.
Crankcase Vent Connector:
20. Disconnect crankcase vent connector and hose from throttle body. Remove positive crankcase ventilation valve) from LH valve cover. Move crankcase vent connector and hose and positive crankcase ventilation valve out of the way.
21. Disconnect engine wiring harness retaining clips from intake manifold studs.
22. Disconnect eight fuel-charging wiring connectors at fuel injectors.
23. Disconnect engine control sensor wiring from idle air control valve, throttle position sensor or throttle position sensors (if equipped with traction control) and position engine control sensor wiring out of the way.
24. Remove two retaining bolts attaching EGR valve and EGR valve gasket to intake manifold.
Intake Manifold De-torque Sequence:
25. Loosen and remove 20 bolts and studs retaining intake manifold to cylinder heads following the de-torque sequence shown in the illustration.
26. Lift engine control sensor wiring upward for intake manifold removal clearance.
27. Remove intake manifold.
28. Remove four fuel injection supply manifold retaining bolts from intake manifold. Remove fuel injection supply manifold from fuel injectors.
29. Remove four bolts retaining RH and LH IMRC housing assemblies to intake manifold and remove IMRC housing assemblies.
30. Remove intake manifold upper gaskets and all load limiting spacers from RH and LH IMRC assemblies and discard.
NOTE: Intake manifold upper gaskets must be replaced when intake manifold retaining bolts have been loosened.
31. Remove IMRC assemblies.
32. Remove lower intake manifold gaskets from cylinder heads and discard.
33. Remove EGR valve gasket and discard. Clean EGR valve gasket sealing surface on both EGR valve and intake manifold.
INSTALLATION
1. Clean and inspect all sealing surfaces. Upper sealing surfaces or IMRC housing assemblies and intake manifold mating surfaces should be cleaned with a suitable solvent to remove adhesive residue. Inspect intake manifold mating surfaces and upper IMRC assembly surfaces to ensure that no load limiting spacers (washers) are stuck to the sealing surfaces. The load limiting spacers are part of the intake manifold upper gasket. New load limiter spacers will be included with the replacement intake manifold upper gasket as an assembly.
NOTE: If a new intake manifold or IMRC housing assembly is being installed, transfer all necessary components onto new intake manifold or IMRC housing assembly using new gaskets.
2. Remove protective housing paper from adhesive backing on intake manifold upper gasket and install onto top of RH IMRC assembly using tapered pins at end bolt hole locations for proper gasket alignment. Repeat procedure for LH assembly.
3. Assemble IMRC assemblies to intake manifold and install four IMRC retaining bolts. Finger tighten bolts.
4. Install fuel injection supply manifold onto fuel injectors and install four retaining bolts. Tighten to 8-12 Nm (71-106 lb in).
5. Position new intake manifold gaskets onto cylinder heads using gaskets' integral locating pins to align gaskets.
6. Place intake manifold under engine control sensor wiring and connect fuel charging wiring to idle air control valve and throttle position sensor or throttle position sensors (depending upon application).
7. Move intake manifold into position and install new EGR valve gasket and two EGR valve retaining bolts. Finger tighten bolts.
8. Install longer bolts and stud bolts in outer bolt holes of intake manifold. Do not tighten.
9. Install shorter bolts and stud bolts in inner bolt holes of intake manifold. Hand tighten all 20 fasteners.
Fastener Torque Sequence:
10. Following sequence shown, tighten fasteners 1 through 20 in numerical sequence as follows:
- Fasteners 5, 7, 9 and 11 to 12-15 Nm (9-11 lb ft).
- All other fasteners to 18-22 Nm (13-16 lb ft).
- Then tighten all fasteners in numerical sequence by rotating an additional 85-95 degrees.
Fastener Torque Sequence:
11. Tighten four intake manifold to IMRC housing retaining bolts A through D to 8-10 Nm (71-89 lb in). Tighten fasteners A through D an additional 85-95 degrees.
12. Tighten two EGR valve retaining bolts to 20-30 Nm (15-22 lb ft).
13. Connect engine control sensor wiring to eight fuel injectors.
14. Connect fuel charging wiring harness retaining clips to intake manifold studs.
15. Connect crankcase vent connector and hose to throttle body connection and install positive crankcase ventilation valve into crankcase ventilation grommet on RH valve cover.
16. Install IMRC actuator to the IMRC assemblies at the levers. Position IMRC actuator on engine and install retainers. Tighten retainers to 8-12 Nm (71-106 lb in).
17. Connect vacuum harness to fuel pressure regulator, RH and LH secondary air injection diverter valves, EGR valve, ECR vacuum regulator solenoid and secondary air injectors vacuum control solenoids, and intake manifold vacuum at rear connection.
18. Connect chassis vacuum supply hose and spring clamp to intake manifold vacuum connection.
19. Connect accelerator cable and speed control actuator cable to throttle body. Connect cables to accelerator cable bracket.
20. Replace 0-ring seals on water bypass tube as required. Replace center 0-ring seal on water bypass tube if needed.
21. Clean 0-ring sealing surface on cylinder heads and coat water bypass tube sealing 0-rings with Ford Premium Cooling System Fluid E2FZ-19549-AA or B or equivalent meeting Ford specification ESE-M97B44-A. Insert water bypass tube support braces over intake manifold inner studs and install water bypass tube into position.
CAUTION: Do not cut 0-ring seal during water bypass tube installation into cylinder heads. Engine coolant leakage may occur.
22. Install two water bypass tube spacers and retaining nuts. Tighten nuts to 8-12 Nm (71-106 lb-in).
23. Connect engine control sensor wiring to the ECT connector.
24. Connect upper radiator hose, heater water hose and water bypass tube to water thermostat housing hose to the water bypass tube.
25. Position generator mounting bracket and install two front retaining bolts and two rear nuts. Tighten to 8-12 Nm (71-106 lb in).
26. Connect generator wiring harness connector plug and B+ terminal wire to generator. Install wiring harness retaining clip to generator mounting bracket. Tighten retaining screw securely.
Ignition Wiring:
Ignition Wiring:
27. Position ignition wires and connect two center ignition wire separators to retaining studs on intake manifold.
28. Connect ignition wires to ignition coils.
NOTE: Make sure ignition wire clips are fully seated to ignition coils.
29. Connect ignition wires as numbered to proper cylinder spark plugs.
30. Install ignition wires into valve cover slots and install ignition wire covers. Install eight retaining nuts and tighten to 2.0-4.0 Nm (18-35 lb in).
31. Connect fuel tubes to the fuel injection supply manifold.
32. Install air cleaner outlet tube. Tighten engine air cleaner tube clamps to 1.4-2.5 Nm (12-22 lb in).
33. Install engine appearance cover. Tighten retaining nuts to 7.0-9.0 Nm (61-79 lb in).
34. Close radiator draincock and fill engine cooling system.
CAUTION: Use extreme care to keep coolant mixture off drive belt and pulleys. If needed, remove drive belt and rinse with clear water. Clean pulleys and install drive belt. Drive belt squeal and early drive belt fatigue will occur otherwise.
35. Connect battery ground cable.
36. Start engine and check for leaks.