Removal and Replacement

Intake Manifold







Evaporative Emission (EVAP) Purge Valve, PCV Tube, Fuel Supply Tube Quick Connect Coupling, Transmission Fluid Level Indicator Tube and Electrical Connectors











Generator Support Bracket, Upper Radiator Hose, Heater Coolant Hose and Crankcase Ventilation Tube











Ignition Coils, Intake Manifold and Gaskets









Removal

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.

WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury.

1. Disconnect the battery ground cable.

2. Remove the engine cover. For additional information, refer to Interior Trim and Ornamentation Service and Repair.

3. Remove the Air Cleaner (ACL) assembly and the ACL outlet pipe. For additional information, refer to Intake Air Distribution and Filtering Intake Air System Components - Exploded View.

4. Drain the cooling system. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.

5. Disconnect the fuel supply tube quick connect coupling. For additional information, refer to Fuel System - General Information Service and Repair.

6. Disconnect the quick connect coupling and remove the crankcase ventilation tube from the LH valve cover. For additional information, refer to Fuel System - General Information Service and Repair.

7. Remove the Throttle Body (TB) spacer. For additional information, refer to Fuel Charging and Controls - 5.4L (2V) Service and Repair.

8. Disconnect the upper radiator hose.

9. Disconnect the heater coolant hose.

10. Disconnect the Electronic Throttle Control (ETC) wiring harness retainer.

11. Disconnect the generator wiring harness retainer from the generator support bracket stud bolt.





12. Remove the 2 bolts, the 2 stud bolts and the generator upper support bracket.

13. Remove the front transmission fluid filler tube support bracket bolt.

14. Remove the rear transmission fluid filler tube support bracket nut and position the transmission fluid filler tube aside.

15. Disconnect the electrical connector and the Evaporative Emission (EVAP) canister-to-EVAP canister purge valve tube quick connect coupling from the EVAP purge valve. For additional information, refer to Fuel System - General Information Service and Repair.

16. Remove the bolt and the EVAP canister purge valve.

17. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to Climate Control System - General Information and Diagnostics Heater Hose Coupling.





18. Disconnect the quick connect coupling and remove the PCV tube from the RH valve cover. For additional information, refer to Fuel System - General Information Service and Repair.

19. Disconnect the 8 fuel injector electrical connectors.

20. Disconnect the 8 ignition coil electrical connectors.

21. NOTE: Use a twisting motion while pulling up on the ignition coil.

Remove the 8 bolts and the 8 ignition coils.

22. Remove the 2 bolts, the thermostat housing and the thermostat.
- Discard the O-ring seal.

23. Remove the 9 bolts, the intake manifold assembly and discard the intake manifold gaskets.

Installation

1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep and silicone gasket remover. Follow the directions on the packaging.

2. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage.

Install the intake manifold in the following sequence.

1. Position the new intake manifold gaskets.

2. Position the intake manifold.

3. Loosely install the 9 intake manifold bolts.

3. Using a new O-ring seal, install the thermostat.

4. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.

Loosely install the thermostat housing and the 2 bolts.

5. Tighten the 11 bolts in 2 stages in the sequence shown.
- Stage 1: Tighten to 2 Nm (18 lb-in).

- Stage 2: Tighten to 25 Nm (18 lb-ft).





6. NOTE: Verify that the ignition coil spring is correctly located inside the ignition coil boot and that there is no damage to the tip of the boot.

Install the 8 ignition coils and the 8 bolts.

- Apply a light coat of dielectric compound to the inside of the coil boots prior to installation.

- Tighten to 6 Nm (53 lb-in).

7. Connect the 8 ignition coil electrical connectors.

8. Connect the 8 fuel injector electrical connectors.

9. Position the PCV tube and connect the quick connect couplings. For additional information, refer to Fuel System - General Information Service and Repair.

10. If equipped, connect the auxiliary heater hoses. For additional information, refer to Climate Control System - General Information and Diagnostics Heater Hose Coupling.





11. Position the EVAP canister purge valve and install the bolt.
- Tighten to 10 Nm (89 lb-in).

12. Connect the electrical connector and the EVAP canister-to-EVAP canister purge valve tube quick connect coupling to the EVAP purge valve. For additional information, refer to Fuel System - General Information Service and Repair.

13. Position the transmission fluid filler tube and install the rear retaining nut.
- Tighten to 28 Nm (21 lb-ft).

14. Install the transmission fluid filler tube front support bracket bolt.
- Tighten to 10 Nm (89 lb-in).

15. Position the generator support bracket and install the 2 bolts and the 2 stud bolts.
- Tighten to 10 Nm (89 lb-in).

16. Connect the generator wiring harness retainer to the generator support bracket stud bolt.





17. Connect the ETC wiring harness retainer to the generator support bracket stud bolt.

18. Connect the heater coolant hose.

19. Connect the upper radiator hose.

20. Install the TB spacer. For additional information, refer to Fuel Charging and Controls - 5.4L (2V) Service and Repair.

21. Position the crankcase ventilation tube and connect the quick connect coupling to the LH valve cover. For additional information, refer to Fuel System - General Information Service and Repair.

22. Connect the fuel supply tube quick connect coupling. For additional information, refer to Fuel System - General Information Service and Repair.

23. Install the engine cover. For additional information, refer to Interior Trim and Ornamentation Service and Repair.

24. Connect the battery ground cable.

25. Fill and bleed the engine cooling system. For additional information, refer to Engine Cooling Cooling System Draining, Filling and Bleeding.