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Home >> Mercury >> 2008 >> Grand Marquis V8-4.6L Flex Fuel >> Repair and Diagnosis >> Engine, Cooling and Exhaust >> Engine >> Intake Manifold >> Service and Repair

Intake Manifold: Service and Repair

Intake Manifold


























Removal

1. WARNING: Before serving a vehicle equipped with a fire suppression system, depower the system by following the procedure in Fire Suppression System. Failure to follow the instructions may result in serious personal injury.

With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Maintenance/Service and Repair.
2. Disconnect the fuel tube spring lock coupling. For additional information, refer to Fuel Delivery and Air Induction.
3. Disconnect the battery ground cable. For additional information, refer to Battery.
4. Drain the engine cooling system. For additional information, refer to Cooling System.
5. Remove the air cleaner and outlet pipe. For additional information, refer to Fuel Delivery and Air Induction.
6. Remove the wiper mounting arm and pivot shaft. For additional information, refer to Wiper and Washer Systems.
7. Disconnect the 8 fuel injector electrical connectors.
8. Remove the 8 ignition coil-on-plugs. For additional information, refer to Ignition System.
9. Remove the 2 bolts and the intake manifold shield.
10. Disconnect the brake booster vacuum hose from the intake manifold.
11. Disconnect the quick connect coupling evaporative emission (EVAP) canister purge valve hoses from the throttle body (TB) spacer and from the EVAP canister purge valve. For additional information, refer to Fuel Delivery and Air Induction.
12. Disconnect the quick connect coupling PCV tube from the TB spacer. For additional information, refer to Fuel Delivery and Air Induction.
13. Disconnect the EGR system module vacuum and electrical connectors.
14. Disconnect the intake manifold-to-TB spacer vacuum hose.
15. Disconnect the generator electrical connector.
16. Remove the 4 generator bracket bolts and the bracket.
17. Remove the coolant thermostat. For additional information, refer to Cooling System.
18. Disconnect the throttle control and the throttle position (TP) sensor electrical connectors.
19. Release the heater hose spring clamp and disconnect the heater hose.
20. Remove the EGR system module tube. For additional information, refer to Emission Control Systems.
21. If equipped, detach the wire harness retainer from the intake manifold crash bracket.
22. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.





23. Remove the intake manifold crash bracket bolt.
24. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
25. Remove the wire harness retainer from the LH front fuel rail stud.
26. Remove the wire harness retainer from the rear of the intake manifold.
27. Disconnect the ground connector from the RH rear fuel rail stud bolt.
28. Remove the 8 bolts and the intake manifold.
^ Remove and discard the intake manifold gaskets.
29. Clean the sealing surfaces.

Installation

1. NOTE: Align the gasket locator tabs with the slots in the cylinder head.

Install new intake manifold gaskets.





2. Install the intake manifold and hand-tighten the 8 bolts.
3. Install the 8 ignition coil-on-plugs.
4. Position the intake manifold crash bracket and loosely install the bolt and stud bolt.
5. Tighten the bolts in the sequence shown.
^ Tighten to 25 Nm (18 ft. lbs.).





6. Tighten the intake manifold crash bracket bolt.
^ Tighten to 25 Nm (18 ft. lbs.).
7. Install the EGR system module tube.
8. Install the intake manifold shield and the 2 bolts.
^ Tighten to 10 Nm (89 inch lbs.).
9. Connect the throttle control and the TP sensor electrical connectors.
10. Install the coolant thermostat.
11. Install the generator bracket and the 4 bracket bolts.
^ Tighten to 10 Nm (89 inch lbs.).
12. Connect the generator electrical connector.
13. Connect the EVAP canister purge valve hoses to the TB and the EVAP canister purge valve.
14. Connect the intake manifold vacuum hose to the TB spacer.
15. Connect the EGR system module vacuum and electrical connectors.
16. Connect the PCV tube quick connect coupling to the TB spacer.
17. Connect the brake booster vacuum hose to the intake manifold.
18. Install the heater hose and spring clamp.
19. Connect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
20. Connect the 8 fuel injector electrical connectors.
21. Install the wire harness retainer to the rear of the intake manifold.
22. Attach the wire harness retainer to the LH front fuel rail stud.
23. If equipped, attach the wire harness retainer to the intake manifold crash bracket.
24. Connect the ground connector to the RH rear fuel rail stud bolt.
25. Install the wiper mounting arm and pivot shaft.
26. Connect the fuel spring lock coupling.
27. Install the air cleaner and outlet pipe.
28. Connect the battery ground cable. For additional information, refer to Battery.
29. Fill and bleed the engine cooling system.

30. WARNING: If the vehicle is equipped with a fire suppression system, repower the system. For important safety warnings and procedures, refer to Fire Suppression System. Failure to follow these instructions may result in serious personal injury.

If equipped with fire suppression system, repower the system.
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