Lower
Lower Intake Manifold Removal
1. Drain engine cooling system.
2. Remove upper intake manifold as outlined.
3. Disconnect upper radiator hose (8260) from water hose connection (8592).
4. Disconnect heater water hose (18472) from lower intake manifold.
5. Disconnect heater water outlet tube (18663) from lower intake manifold.
6. Remove fuel injectors (9F593) and fuel injection supply manifold (9F792).
7. Remove lower intake manifold retaining bolts.
8. Remove lower intake manifold.
CAUTION: The lower intake manifold is sealed at each corner with sealer. To break the seal, it may be necessary to pry on the front of the intake manifold with a prybar. If it is necessary to pry on the lower intake manifold use care to prevent damage to machined surfaces.
9. Remove intake manifold gasket (9439) and end seals, and discard.
10. If lower intake manifold assembly is to be disassembled, perform the following:
a. Remove water hose connection and water thermostat (8575).
b. Remove water temperature indicator sender unit (10884).
c. Remove hot water heater elbow connection (18599).
d. Remove all vacuum and electrical fittings.
Lower Intake Manifold Installation
Lower Intake Manifold:
1. The mating surfaces of the lower intake manifold, cylinder head (6049), and cylinder block (6010) should be clean and free of old gasketing material. Use a suitable solvent to clean these surfaces.
Note: Lightly oil all retaining bolt and stud bolt threads before installation.
Note: 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.
2. If intake manifold was disassembled:
a. Apply a coat of Pipe Sealant with Teflon� D8AZ-19554-A or equivalent meeting Ford specifications WSK-M2G350-A2 to the threads of the water temperature indicator sender unit and tighten to 11-16 Nm (8-12 ft. lbs.), all vacuum fittings, hot water heater elbow connections, electrical fittings, if equipped.
b. Install water thermostat (note direction).
Install water hose connection.
Tighten retaining bolts to 20-30 Nm (15-22 ft. lbs.).
3. Apply a dab of Gasket and Trim Adhesive D7AZ-19B508-B or equivalent meeting Ford specifications M11P17-A and ESE-M2G52-A to each cylinder head mating surface.
Press new intake manifold gaskets into place, using locating pins as necessary to aid in assembly.
Note:Prior to applying sealer, clean sealing surfaces of cylinder heads and intake manifold with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A, to remove all residues that may interfere with the sealer's ability to adhere.
Note: When the lower intake manifold is removed, always use new intake manifold gaskets upon reassembly.
4. Apply a 3-4 mm (1/8 inch) bead of Silicone Rubber D6AZ-19562-BA or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A at each corner where the cylinder head joins the cylinder block.
5. Install front and rear intake manifold end seals.
6. Carefully install intake manifold into position on cylinder block and cylinder heads. Use locating pins as necessary to guide intake manifold.
7. Install bolts in their original locations. Tighten in numerical sequence to the following specifications in two steps:
a. 18 Nm (13 ft. lbs.)
b. 22 Nm (16 ft. lbs.)
8. Install fuel injectors and fuel injection supply manifold.
Tighten retaining bolts to 8-11 Nm (71-97 in. lbs.).
9. Connect heater water outlet tube to lower intake manifold.
Install hose clamp securely.
10. Connect heater water hose to lower intake manifold.
Install hose clamp securely.
11. Connect upper radiator hose to water hose connection.
Tighten hose clamp securely.
12. Install upper intake manifold as outlined.
13. Fill engine cooling system.
CAUTION: This engine has aluminum cylinder heads and requires a special corrosion inhibiting coolant to avoid cooling system damage.
14. Start engine and check for oil, coolant or fuel leaks.