Ford 5.0 Engine Intake manifold replacing?

Intake Manifold

REMOVAL & INSTALLATION

5.0L Engine
Lower

1. Before servicing the vehicle, refer to the Precautions section.
2. Drain the cooling system.
3. Remove or disconnect the following:
   
   
   Negative battery cable

   Radiator overflow hose and set it aside

   Upper intake manifold

   Water bypass hose

   Engine Coolant Temperature (ECT) electrical connector

   Wire harness retainer nut

   Heater hoses

   Positive Crankcase Ventilation (PCV) hoses

   Upper radiator hose

   Fuel injector electrical connectors

   Ground strap at the rear of the lower intake manifold

   Water temperature indicator sender electrical connector

   Camshaft Position (CMP) sensor and the camshaft synchronizer

   Bolts from the lower intake manifold

   Lower intake manifold and discard the gaskets

To install:

1. Ensure that all of the gasket mating surfaces are clean and free of grease, oil or dirt. Also ensure that the EGR passages in the manifolds and heads are clear.
2. Apply a ¹ / ₁₆ in. (1.6mm) bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads.
3. Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the cylinder heads.
4. Apply a ¹ / ₁₆ in. (1.6mm) bead of sealer to the outer end of each intake manifold seal for the full width of the seal. Make sure the silicone sealer will not fall into the engine and possibly block oil passages. 
   
   
   

   

   Fig. Tighten the lower manifold bolts in the sequence shown-5.0L engine
5. Install the lower intake manifold and tighten the bolts in 2 steps as follows:
   1. 89 inch lbs. (10 Nm).
   2. 24 ft. lbs. (32 Nm).
6. Install or connect the following:
   
   
   CMP sensor and camshaft synchronizer

   Water temperature indicator sender electrical connector

   Fuel injector electrical connectors

   Fuel line

   Water bypass hose

   Upper radiator hose

   Heater hoses

   Wire harness retainer nut. Torque to the bolt to 18 ft. lbs. (25 Nm).

   ECT electrical connector

   Water heater bypass hose to the heater tube

   PCV hoses to the heater tube

   Upper intake manifold

   Radiator overflow hose

   Negative battery cable
7. Fill the cooling system.
8. Start the vehicle and check for leaks, repair if necessary.

Upper

1. Before servicing the vehicle, refer to the Precautions section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Air cleaner outlet tube

   Idle Air Control (IAC) valve electrical connector

   Accelerator control splash shield

   Throttle Position (TP) sensor electrical connector

   Accelerator cable and if equipped, speed control cable from the throttle linkage

   Accelerator cable bracket

   Fuel pressure regulator vacuum connection

   Pressure transducer hoses

   Upper Exhaust Gas Recirculation (EGR) valve-to-exhaust manifold tubing

   Engine Vacuum Regulator (EVR) electrical connector

   EVR vacuum connector

   EGR back pressure electrical connector

   Ignition coil bracket

   Accelerator cable from the upper intake manifold clips

   Intake cover plate
   
   

   

   

   Fig. Loosen the upper manifold bolts in the sequence shown-5.0L engine

   Vacuum connections from the front of the manifold

   Vapor Management Valve (VMV) purge line

   Brake booster vacuum supply line

   Positive Crankcase Ventilation (PCV) hose

   PCV heater hoses

   Upper intake manifold and discard the gasket

To install:

1. Ensure that all of the gasket mating surfaces are clean and free of grease, oil or dirt. Also ensure that the EGR passages in the manifolds and heads are clear.
2. Apply a ¹ / ₁₆ in. (1.6mm) bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads.
3. Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the cylinder heads.
4. Apply a ¹ / ₁₆ in. (1.6mm) bead of sealer to the outer end of each intake manifold seal for the full width of the seal. Make sure the silicone sealer will not fall into the engine and possibly block oil passages.
5. Using guide pins to ease installation, carefully lower the intake manifold into position on the cylinder block and cylinder heads. Also, ensure that the water pump bypass hose is installed at the same time.
6. Install or connect the following:
   
   
   Intake manifold and new gasket and hand tighten the bolts

   Upper intake vacuum connections

   PCV tube and heater hoses

   Brake booster vacuum supply line
   
   

   

   

   Fig. Tighten the upper manifold bolts in the sequence shown-5.0L engine

   Torque the intake manifold bolts to 18 ft. lbs. (25 Nm).

   Intake manifold cover plate. Torque the bolts to 15 ft. lbs. (20 Nm).

   Accelerator cable bracket. Torque the upper bolt to 15 ft. lbs. (20 Nm) and lower bolt to 80 inch lbs. (9 Nm).

   Accelerator cable and speed control cable to the throttle linkage, if equipped

   Ignition coils and bracket

   EVR electrical connector

   EVR vacuum connector

   EGR valve vacuum connector

   Fuel pressure regulator vacuum connector

   Upper EGR valve-to-exhaust manifold connector. Torque the fastener to 25 ft. lbs. (34 Nm).

   EGR back pressure transducer electrical connector

   TP sensor electrical connector

   IAC valve electrical connector

   Accelerator control splash shield. Torque the bolt to 89 inch lbs. (10 Nm).

   Air cleaner outlet tube

   Negative battery cable

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
2. Remove or disconnect the following:
   
   
   Negative battery cable

   Air cleaner outlet tube

   Idle Air Control (IAC) valve electrical connector

   Accelerator control splash shield

   Throttle Position (TP) sensor electrical connector

   Accelerator cable and if equipped, speed control cable from the throttle linkage

   Accelerator cable bracket

   Fuel pressure regulator vacuum connection

   Pressure transducer hoses

   Upper Exhaust Gas Recirculation (EGR) valve-to-exhaust manifold tubing

   Engine Vacuum Regulator (EVR) electrical connector

   EVR vacuum connector

   EGR back pressure electrical connector

   Ignition coil bracket

   Accelerator cable from the upper intake manifold clips

   Intake cover plate
   
   

   

   

   Fig. Loosen the upper manifold bolts in the sequence shown-5.0L engine

   Vacuum connections from the front of the manifold

   Vapor Management Valve (VMV) purge line

   Brake booster vacuum supply line

   Positive Crankcase Ventilation (PCV) hose

   PCV heater hoses

   Upper intake manifold and discard the gasket

To install:

1. Ensure that all of the gasket mating surfaces are clean and free of grease, oil or dirt. Also ensure that the EGR passages in the manifolds and heads are clear.
2. Apply a ¹ / ₁₆ in. (1.6mm) bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads.
3. Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the cylinder heads.
4. Apply a ¹ / ₁₆ in. (1.6mm) bead of sealer to the outer end of each intake manifold seal for the full width of the seal. Make sure the silicone sealer will not fall into the engine and possibly block oil passages.
5. Using guide pins to ease installation, carefully lower the intake manifold into position on the cylinder block and cylinder heads. Also, ensure that the water pump bypass hose is installed at the same time.
6. Install or connect the following:
   
   
   Intake manifold and new gasket and hand tighten the bolts

   Upper intake vacuum connections

   PCV tube and heater hoses

   Brake booster vacuum supply line
   
   

   

   

   Fig. Tighten the upper manifold bolts in the sequence shown-5.0L engine

   Torque the intake manifold bolts to 18 ft. lbs. (25 Nm).

   Intake manifold cover plate. Torque the bolts to 15 ft. lbs. (20 Nm).

   Accelerator cable bracket. Torque the upper bolt to 15 ft. lbs. (20 Nm) and lower bolt to 80 inch lbs. (9 Nm).

   Accelerator cable and speed control cable to the throttle linkage, if equipped

   Ignition coils and bracket

   EVR electrical connector

   EVR vacuum connector

   EGR valve vacuum connector

   Fuel pressure regulator vacuum connector

   Upper EGR valve-to-exhaust manifold connector. Torque the fastener to 25 ft. lbs. (34 Nm).

   EGR back pressure transducer electrical connector

   TP sensor electrical connector

   IAC valve electrical connector

   Accelerator control splash shield. Torque the bolt to 89 inch lbs. (10 Nm).

   Air cleaner outlet tube

   Negative battery cable