Intake Manifold: Service and Repair

This article has been updated by technical service bulletin (TSB) 94-10-10 dated 05/18/94.

Upper and Lower Intake Manifolds

Removal
1. Drain engine cooling system.
2. Remove air cleaner assembly including air intake duct and heat tube.
3. Disconnect accelerator cable at throttle body assembly. Disconnect speed control cable, if so equipped.
4. Disconnect the transaxle linkage at the upper intake manifold.
5. Remove retaining bolts from accelerator cable mounting bracket and position cables aside.
6. Disconnect Secondary Air Injection (AIR) air supply hose at the check valve.
7. Disconnect flexible fuel lines from steel lines over rocker arm cover.
8. Disconnect fuel lines at injector fuel rail assembly.
9. Disconnect radiator upper hose at thermostat housing.
10. Disconnect coolant bypass hose at intake manifold.
11. Disconnect heater tube at intake manifold. Remove tube support bracket retaining nut. Remove heater hose at rear of heater tube. Loosen hose clamp at heater elbow and remove heater tube with hose attached. Remove heater tube with fuel lines attached and set assembly aside.
12. Disconnect vacuum lines at fuel rail assembly and intake manifold.
13. Disconnect necessary electrical connectors.
14. If equipped with air conditioning, remove air compressor support bracket.






15. Disconnect PCV lines. One is located on upper intake manifold. The second is located at the LH rocker cover and the lower intake stud.
16. Remove throttle body assembly.
17. Remove the EGR valve assembly from the upper manifold.
18. Remove the retaining nut and remove wiring retainer bracket located at the LH front of the intake manifold and set aside with spark plug wires.
19. Remove upper intake manifold retaining bolts/studs.
20. Remove upper intake manifold.
21. Remove injectors and fuel injection supply manifold (9F792) assembly.
22. Remove heater water outlet hose.
23 Remove lower intake manifold retaining bolts.

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

24. Remove lower intake manifold.






25. Remove intake manifold to cylinder head gasket (9439) and end seals, and discard.
26. If lower intake manifold assembly is to be disassembled, perform the following:

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






a. Remove thermostat housing and thermostat.
b. Remove water temperature sending unit.
c. Remove heater elbow.
d. Remove all vacuum and electrical fittings.


Installation






NOTE: Lightly oil all retaining bolt and stud threads before installation. 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, 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:
- Apply a coat of Pipe Sealant with Teflon D8AZ- 19554-A (ESG-M4G 194-A and ESR-M18P7-A) or equivalent to the threads of the temperature sending unit, all vacuum fittings, heater elbows, electrical fittings, if equipped. Refer to Specifications.






- Install thermostat (note direction) and gasket. Install thermostat housing. Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.).

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-AA (ESR-11p 17-A and ESE-M2G52-A) or equivalent to each cylinder head mating surface. Press new intake manifold gaskets into place, using locating pins as necessary to aid in assembly.
4. Apply a 3-4mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-BA (ESB-M4G92-A and ESE-M4G195-A) or equivalent at each corner where the cylinder head joins the cylinder block.



5. Install front and rear intake manifold end seals.
6. Carefully lower intake manifold into position on cylinder block and cylinder heads. Use locating pins as necessary to guide manifold.
7. Install bolts in their original locations. Tighten in numerical sequence to the following specifications in two steps:
- 18N.m (13lb-ft)
- 22N.m (16lb-ft)
8. Connect rear PCV line to upper intake tube.
9. Install front PCV tube so the mounting bracket sits over the lower intake stud.
10. Install injectors and fuel rail assembly. Tighten screws to 8-11 Nm (6-8 ft. lbs.).
11. Position upper intake gasket and manifold on top of lower intake.

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

12. Install bolts and studs in original locations. Tighten four center bolts, then tighten the end bolts. Tighten bolts in three steps:
- 10N.m (8lb-ft)
- 20N.m (15lb-ft)
- 32N.m (24lb-ft)

13. Install EGR valve assembly on manifold. Tighten retaining nuts to 20-30 Nm (15-22 ft. lbs.).






14. Install throttle body. Cross-tighten retaining nuts to 20-30 Nm (15-22 ft. lbs.).






15. Connect rear PCV line at PCV valve and upper intake manifold.
16. If equipped with air conditioning, install compressor support bracket. Tighten retaining nut to 20-30 Nm (15-22 ft. lbs.).
17. Connect necessary electrical connectors.
18. Connect necessary vacuum hoses.
19. Connect heater tube hose to heater elbow.
20. Position heater tube support bracket and tighten retaining nut to 20-30 Nm (15-22 ft-lbs). Tighten hose clamp at heater elbow securely.
21. Connect heater hose to the rear of the heater tube and tighten hose clamp.
22. Connect coolant bypass hose. Tighten hose clamp securely.
23. Connect radiator upper hose. Tighten hose clamp securely.
24. Connect fuel line(s) at injector fuel rail assembly.
25. Connect flexible fuel lines to steel lines.
26. Position accelerator cable mounting bracket. Install and tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.).
27. Connect speed control cable, if so equipped.
28. Connect transaxle linkage at upper intake manifold.
29. Fill cooling system with specified coolant.

CAUTION: This engine has aluminum cylinder heads and requires a special corrosion Inhibiting coolant to avoid cooling system damage. Capacity is, 11.5 Liters (12.1 Quarts). Listed capacities include heater and coolant reservoir filled to add mark. Service refill recommendations are 50/50 mixture of water and coolant meeting Ford specifications ESE-M97b44-A, such as premium cooling system fluid E2FZ-19549-AA.

30. Start engine and check for coolant or fuel leaks.
31. Check and, if necessary, adjust engine idle speed. Refer to Powertrain Control/Emissions Diagnosis. Adjust transaxle throttle linkage and speed control. Based on the condition, the following steps are to be used for diagnoses following disconnection of the accelerator cable from the throttle body lever. (If the vehicle is equipped with speed control, disconnect the speed control cable from the accelerator cable.)
a. Accelerator pedal is hard to push down, or has a rough/raspy or sticky feel.
- Make sure that disconnected end of cable or its spring does not come into contact with any surrounding parts.
- Operate pedal by foot.
- If cable operation is smooth, cable is not damaged. Refer to Powertrain Control/Emission Diagnoses for other checks.
- If condition recurs (making sure disconnected end of cable has not come into contact with anything), check foot pedal assembly for free operation. If pedal operation is free, replace cable.
b. High engine idle speed.
- If cable ball stud extends beyond throttle lever ball stud (closed throttle plate direction), cable is not damaged. Refer to Powertrain Control/Emission Diagnoses for other checks.
- If ball socket does not extend beyond stud, check foot pedal assembly for free operation. If pedal operation is free, replace cable.
NOTE: Accelerator cable should not be lubricated and is not serviceable.
c. Linkage Actuator Cable
- Remove speed control actuator cable retaining clip.
- Push actuator cable through adjuster until slight tension is felt.
- Insert cable retaining clip and snap into place.
32. Install air cleaner assembly and air intake duct.