Lower
Removal1. Disconnect battery ground cable.
2. Drain engine cooling system.
3. Remove crankcase ventilation tube from valve cover and air cleaner outlet tube.
4. Remove aspirator hose from air cleaner outlet tube. Remove engine Air Cleaner (ACL) from throttle body and air cleaner outlet tube.
5. WARNING: COVER FUEL PRESSURE RELIEF VALVE WITH SHOP CLOTH TO PREVENT ACCIDENTAL. FUEL SPRAY INTO EYES.
Carefully relieve fuel system pressure at fuel pressure relief valve.
6. Remove fuel tube safety clips. Disconnect fuel tubes.
7. Mark locations of vacuum lines and remove.
8. Disconnect engine control sensor wiring from Camshaft Position (CMP) Sensor, throttle position sensor, idle air control valve, Engine Coolant Temperature (ECT) sensor, ignition coil, water temperature indicator sender unit, EGR backpressure transducer and EGR vacuum regulator solenoid connector.
9. Disconnect upper radiator hose from water hose connection. After loosening retaining clamp, use a twisting motion on upper radiator hose to loosen hose from water hose connection.
10. Remove upper intake manifold.
11. Loosen EGR valve to exhaust manifold tube retaining nut and remove EGR valve to exhaust manifold tube from EGR valve tube to manifold connector.
12. Disconnect engine control sensor wiring retainers from valve cover stud bolts. Carefully disconnect electrical connections to each fuel injector and position engine control sensor wiring out of the way.
13. Disconnect heater water hoses.
14. Remove ignition wires from spark plugs. Remove harness retainers to valve cover stud bolts.
15. Remove camshaft position sensor.
16. Remove ignition coil from rear of LH cylinder head.
17. Remove valve covers.
18. Loosen cylinder No. 3 intake valve rocker arm seat retaining bolt and rotate rocker arm off of push rod and away from top of valve stem. Remove push rod.
19. NOTE: Lower intake manifold may be removed with fuel injection supply manifold and fuel injectors in place as an assembly.
Remove lower intake manifold retaining bolts using a Torx head socket. Before attempting to remove intake manifold, break seal between intake manifold and cylinder block. Wedge a large pry bar or similar tool between intake manifold and cylinder block. Pry upward on tool using area between water hose connection and transaxle as a leverage point.
Installation
1. CAUTION: Aluminum components gouge easily which may cause gasket leaks. Always use care when scraping aluminum gasket surfaces.
NOTE: Lightly oil all retaining bolt and stud bolt threads with Motorcraft Super Premium 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G before installation.
Clean mating gasket surfaces of lower intake manifold and cylinder head. Lay a clean cloth or shop cloth in valve tappet valley to catch any gasket material. After scraping, carefully lift cloth from valve tappet valley, preventing any particles from entering oil drain holes or cylinder head. Use a suitable solvent to remove old silicone sealant.
2. If installing a new lower intake manifold, transfer engine coolant temperature sensor, water thermostat, water hose connection gasket and water hose connection, heater hose elbow and water temperature indicator sender unit to new lower intake manifold.
3. If removed, install fuel injection supply manifold.
- Apply Motorcraft Super Premium 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G lightly to fuel injector O-rings before installation.
- Install fuel injector into fuel injection supply manifold.
- Carefully align fuel injection supply manifold to intake manifold fuel injector bores.
- Push one side into place at a time until fuel injection supply manifold clicks into place.
- Install fuel injection supply manifold retaining bolts and tighten to 8-12 Nm (71-106 inch lbs.).
4. NOTE: Prior to applying sealer, clean sealing surfaces of cylinder block and cylinder head with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M513392-A, to remove all residues that may interfere with the sealer's ability to adhere.
Apply a 5-6 mm (1/4-inch) drop of Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specifications WSK-M2G343-A4 to intersection of cylinder block and cylinder head at four corners as shown.
5. Position intake manifold gasket onto cylinder heads. Align intake manifold gasket locking tabs to provisions on head gaskets as shown.
6. Install front and rear intake manifold end seals as shown. Secure with retainers.
7. Carefully position lower intake manifold, aligning intake manifold bolt holes, to those in cylinder head. Use care to prevent disturbing silicone sealer which can cause sealing voids.
- Install bolts No. 1, 2, 3, and 4 and hand-tighten.
- Install remaining bolts and tighten in sequence shown in two steps.
- Tighten in numerical sequence to 20-30 Nm (15-22 ft. lbs.).
- Tighten again in Sequence to 26-32 Nm (20-23 ft. lbs.).
8. CAUTION: If a new CKP sensor housing is installed, ALWAYS add the rest of the Engine Assembly Lubricant D9AZ-19579-D or equivalent (pint) meeting Ford specification ESR-M99C80-A to the engine oil by pouring it through the distributor hole onto the camshaft drive gear. Run engine at idle for five minutes prior to driving vehicle.
Coat entire drive gear on CMP sensor housing with Engine Assembly Lubricant D9AZ-19579-D or equivalent meeting Ford specification ESR-M99C80-A and install camshaft position sensor.
9. NOTE: Rocker arm seat must be fully seated into cylinder head and push rod must be fully seated in rocker arm and valve tappet sockets prior to final tightening.
Apply Motorcraft Super Premium SAE 5W30 Motor Oil XO-6W30-QSP or equivalent meeting Ford specification WSS-M2C153-G to cylinder No. 3 intake valve, push rod and rocker arm. Install push rod. Move rocker arm into position with push rod and snug rocker arm seat retaining bolt. Rotate crankshaft to position camshaft lobe straight down and away from valve tappet.
- Tighten rocker arm seat retaining bolt to 7-15 Nm (6-11 ft. lbs.).
- Final tighten rocker arm seat retainer bolt to 26-38 Nm (20-28 ft. lbs.) in any position.
10. Install valve covers.
11. Install engine control sensor wiring to each fuel injector. Secure retainers for engine control sensor wiring to valve cover stud bolts.
12. Install ignition coil to rear of LH cylinder head. Tighten retaining bolts to 40-55 Nm (30-40 ft. lbs.).
13. Install wire harness retainers to valve cover stud bolts and connect ignition wires to spark plugs and ignition coil.
14. Install upper intake manifold and new intake manifold upper gasket.
15. Install EGR valve to exhaust manifold tube from exhaust manifold to EGR valve.
16. Install fuel tubes.
17. Install fuel tube safety clips.
18. Install upper radiator hose and heater water hoses. Tighten retaining clamps securely.
19. Connect vacuum lines to premarked locations.
20. Connect engine control sensor wiring to camshaft position sensor, idle air control valve, throttle position sensor, engine coolant temperature sensor, EGR backpressure transducer, EGR vacuum regulator solenoid, ignition coil and water temperature indicator sender unit.
21. Fill and bleed engine cooling system.
22. CAUTION: Engine coolant is corrosive to all engine bearing material. Replacing oil after removal of a coolant carrying component prevents damage.
Fill crankcase to proper level with Motorcraft Super Premium SAE 5W30 Motor Oil XO-5W30-QSP or equivalent meeting Ford specification WSS-M2C153-G.
23. Install air cleaner outlet tube to throttle body and engine air cleaner.
24. Install crankcase ventilation tube to valve cover and air cleaner outlet tube. Install aspirator hose to air cleaner outlet tube.
25. Connect battery ground cable.
26. Start engine and check for coolant, oil, fuel and vacuum leaks.