How to Replace Intake Manifold On Ford F Series Trucks And Lincoln Mark?

The procedure is similar for both ford and Lincoln car models:-----

Intake Manifold

REMOVAL & INSTALLATION Details for ford Truck and Lincoln Mark LT car models.

For All engine models 4.2L,4.6L,5.4L,6.0L & 6.8L.

NOTE

When the battery is disconnected and reconnected, some abnormal drive symptoms may occur while the vehicle relearns its adaptive strategy. The vehicle may need to be driven 10 miles (16 km) or more to relearn the strategy.

4.2L Engine
Lower

1. Before servicing the vehicle, refer to the Precautions Section.
2. Relieve the fuel system pressure.
3. Disconnect the fuel supply spring lock coupling.
4. Remove the upper intake manifold. See the procedure above.
5. Disconnect the fuel charging wiring harness-to-main engine wiring harness and the intake manifold runner control (IMRC) actuator electrical connectors.
6. Remove the bolts and the fuel rail, the fuel charging wiring harness and the engine vacuum hose harness as an assembly.
7. Release the clamp and disconnect the heater outlet hose.
8. Release the clamp and disconnect the upper radiator hose.
9. Release the clamp and disconnect the bypass hose.
10. Release the clamp and disconnect the heater inlet hose.
11. Remove the 6 long and 8 short bolts, the lower intake manifold, the lower intake manifold gaskets and the front and rear seals.

To install:

WARNING

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.

1. Using a plastic scraping tool, silicone gasket remover and metal surface prep, clean the gasket mating surfaces. Follow the directions on the packaging.
   
   NOTE

   If the lower intake manifold is not secured within 4 minutes, the sealant must be removed and the sealing area cleaned. To clean the sealing area, use silicone gasket remover and metal surface prep. Follow the directions on the packaging. Failure to follow this procedure can cause future oil leakage.
2. Apply a bead of silicone gasket and sealant to the intake manifold front and rear seal mounting points as indicated.
3. Install the lower intake manifold front and rear seals. 
   
   
   
   Fig. Intake manifold seal RTV sealer application points-4.2L engine
   
   
   
   
   Fig. Intake manifold bolt torque sequence-4.2L engine

Upper

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the engine cooling system.
3. Disconnect the battery ground cable.
4. Remove the air cleaner outlet pipe.
5. Remove the bolt and position the heater hoses aside.
   
   WARNING

   It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.
   
   
   
   NOTE

   Spark plug wires must be connected to the correct ignition coil terminal. Mark the spark plug wires for installation reference.
6. Disconnect the 3 left spark plug wires from the ignition coil, disconnect the 2 spark plug wire retainers from the upper intake manifold and position the left spark plug wires aside.
7. Disconnect the exhaust gas recirculation (EGR) system module electrical and vacuum connectors.
8. Disconnect the exhaust manifold-to-EGR system module tube from the EGR system module.
9. Disconnect the electronic throttle body electrical connector.
10. Release the clamp and disconnect the fuel vapor tube from the upper intake manifold.
11. Disconnect the 5 wiring harness retainers from the upper intake manifold.
12. Release the clamp and disconnect the brake booster vacuum hose from the upper intake manifold.
13. Disconnect the vacuum hose connector from the rear of the upper intake manifold.
14. Release the clamps and disconnect the 2 heated positive crankcase ventilation (PCV) coolant hoses from the rear of the upper intake manifold.
15. Disconnect the PCV valve hose from the rear of the upper intake manifold.
16. Detach the fuel charging wiring harness-to-main engine wiring harness electrical connector retainer from the rear of the upper intake manifold.
17. Remove the 8 bolts and the upper intake manifold.

To install:

Fig. Upper intake manifold torque sequence-4.2Lengine

1. Inspect the 6 upper intake manifold gaskets. Install new gaskets, if necessary.
2. Position the upper intake manifold and install the bolts. Tighten the bolts in the sequence shown in 2 stages.
   
   
   Stage 1: Tighten to 6 Nm (53 inch lbs.).

   Stage 2: Tighten to 10 Nm (89 inch lbs.).
3. Attach the fuel charging wiring harness-to-main engine wiring harness electrical connector retainer to the rear of the upper intake manifold.
4. Connect the PCV valve hose to the rear of the upper intake manifold.
5. Connect the 2 heated PCV coolant hoses to the rear of the upper intake manifold and position the clamps.
6. Connect the vacuum hose connector to the rear of the upper intake manifold.
7. Connect the brake booster vacuum hose to the upper intake manifold and position the clamp.
8. Connect the 5 wiring harness retainers to the upper intake manifold.
9. Connect the fuel vapor hose to the upper intake manifold and position the clamp.
10. Connect the electronic throttle body electrical connector.
11. Connect the exhaust manifold-to-EGR system module tube to the EGR system module. Tighten to 40 Nm (30 ft. lbs.).
12. Connect the EGR system module electrical and vacuum connectors.
    
    NOTE

    Apply silicone brake caliper grease and dielectric compound to the inside of the spark plug wire boots.
    
    
    
    NOTE

    Spark plug wires must be connected to the correct ignition coil terminals.
13. Position the spark plug wires, connect the 2 spark plug wire retainers to the upper intake manifold and connect the 3 spark plug wires to the ignition coil.
14. Position the heater hoses and install the bolt. Tighten to 5 Nm (44 inch lbs.).
15. Install the air cleaner outlet pipe.
16. Connect the battery ground cable.
17. Fill and bleed the engine cooling system.

5.4L Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Drain the cooling system.
3. Release the fuel system pressure.
4. Remove the alternator.
5. Remove the air cleaner.
6. Disconnect the upper radiator hose from the thermostat housing.
7. Disconnect the heater coolant hose from the coolant bypass tube.
8. Disconnect the quick connect coupling and remove the evaporative emissions (EVAP) tube from the intake manifold.
9. Disconnect the quick connect coupling and remove the positive crankcase ventilation (PCV) tube.
10. Disconnect the fuel supply spring lock coupling from the fuel rail.
11. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
12. Disconnect the 8 fuel injector electrical connectors.
13. Disconnect the throttle position (TP) sensor and electronic throttle control electrical connectors.
14. Disconnect the heated PCV element electrical connector.
15. Disconnect the brake booster vacuum hose from the intake manifold vacuum tube.
16. Remove the 10 intake manifold bolts.
    
    WARNING

    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.
17. Remove the 3 bolts, the coolant bypass tube and discard the gaskets.
18. Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.
19. Disconnect the charge motion control valve (CMCV) electrical connector.
20. Disconnect the intake manifold vacuum tube from the valve cover stud and the support bracket.
21. Disconnect the cylinder head temperature (CHT) sensor jumper harness electrical connector.
22. Disconnect the LH and RH knock sensor (KS) electrical connectors.
23. Remove the nut and disconnect the engine wiring harness retainer from the CMCV stud.
    
    WARNING

    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.
24. Remove the intake manifold and discard the gaskets.
25. Clean and inspect the sealing surfaces with metal surface prep. Follow the directions on the packaging.

To install:

NOTE

Electrical and vacuum harnesses must not restrict movement of the CMCV control rods at the rear of the intake manifold. Use extreme care on installation of the intake manifold to prevent any pinching of electrical and vacuum harnesses.

1. Using new intake manifold gaskets, position the intake manifold.
2. Using new gaskets, position the coolant crossover and install the 3 bolts. Tighten to 10 Nm (89 inch lbs.).
3. Install the intake manifold bolts and tighten in 2 stages in the sequence shown.
   
   
   Stage 1: Tighten to 2 Nm (18 inch lbs.).

   Stage 2: Tighten to 10 Nm (89 inch lbs.).
   
   

   

   

   Fig. Intake manifold bolt tightening sequence-5.4L engine
4. Connect the engine wiring harness retainer to the CMCV stud and install the nut. Tighten to 10 Nm (89 inch lbs.).
5. Connect the CMCV electrical connector.
6. Connect the CHT sensor jumper harness electrical connector.
7. Connect the LH and RH KS electrical connectors.
8. Connect the intake manifold vacuum tube to the support bracket and the valve cover stud.
9. Connect the brake booster vacuum hose to the intake manifold vacuum tube.
10. Connect the heated PCV element electrical connector.
11. Connect the TP sensor and electronic throttle control electrical connectors.
12. Connect the 8 fuel injector electrical connectors.
13. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
14. Connect the fuel supply spring lock coupling to the fuel rail.
15. Position the PCV tube and connect the quick connect coupling.
16. Position the EVAP tube and connect the quick connect coupling to the intake manifold.
17. Connect the heater coolant hose to the coolant bypass.
18. Connect the upper radiator hose to the thermostat housing.
19. Install the alternator.
20. Install the air cleaner.
21. Fill and bleed the engine cooling system.

6.0L Diesel Engine

1. Before servicing the vehicle, refer to the Precautions Section.
2. Remove the auxiliary battery.
3. Remove the cooling fan stator.
4. Remove the degas bottle (coolant reservoir).
5. Remove the upper radiator hose.
6. Remove the turbocharger-to-charge air cooler duct.

Vehicles with dual alternators

1. Remove the accessory drive belt.
2. Remove the bolt and the accessory drive belt tensioner.
3. Remove the accessory drive belt.
4. Remove the bolts, bracket and accessory drive belt idler pulley.
5. Remove the bolts and the accessory drive belt tensioner.
6. Disconnect the wire retainer, alternator electrical connector and B+ wire.
7. Remove the bolts and the alternator with mounting bracket.

Vehicles with single alternator

1. Remove the accessory drive belt.

All vehicles

1. Position the boot back and disconnect the alternator B+ wire and electrical connector.
2. Remove the three bolts and the alternator.
3. Remove the turbocharger and the turbocharger pedestal.

Early build

1. Loosen the clamps and remove the charge air cooler duct.

Late build

1. Loosen the clamps and remove the charge air cooler duct.
2. Remove the bolts and position the heater hose tube aside.
3. Remove and discard the O-ring.
4. Disconnect the manifold absolute pressure (MAP) sensor hose.
5. Disconnect the engine coolant vent hose.
6. Remove the fuel injector control module.
7. Remove or position aside the heat insulating wrap.
8. Disconnect the wiring retainer, injector pressure regulator valve and injector control pressure (ICP) sensor (if equipped) electrical connectors.
9. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
10. Disconnect the engine oil pressure (EOP) sensor electrical connector.
11. Disconnect the engine oil temperature sensor electrical connector.
12. Disconnect the exhaust gas recirculation (EGR) throttle position control module electrical connector.
13. Disconnect the EGR throttle position sensor electrical connector.
14. Disconnect the pin-type retainer and engine coolant temperature (ECT) sensor.
15. Disconnect the intake air temperature (IAT2) sensor electrical connector and wiring connector.
16. Disconnect the exhaust backpressure sensor and retaining clip.
17. Disconnect the eight fuel injectors electrical connectors. Remove the nut and the fuel injector wiring harness.
    
    NOTE

    It is necessary to remove the fuel filter and drain the housing.
18. Disconnect the fuel line fittings.
    
    NOTE

    It is necessary to remove the oil filter and drain the housing.
19. Remove the four bolts and the oil filter housing.
20. Remove the bolt and the oil filter return tube.
21. Remove the fuel line.
22. Remove the bolt, and the banjo fitting from the fuel line.
23. Discard the sealing washers and remove the fuel line.
    
    NOTE

    Align the flat edge with the index feature located on the coolant supply port.
24. Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.

Early build

1. Remove the nuts and the turbocharger heat shield.
   
   NOTE

   Intake removed for clarity.
2. Remove the EGR cooler V-clamp and gasket.
3. Remove the bolts and the intake manifold.

Late build

1. Remove the nuts and the turbocharger heat shield.
2. Remove the EGR cooler V-clamp and gasket.
3. Remove the bolts and the intake manifold.

All vehicles

1. Remove the intake manifold gaskets.
2. Clean and inspect the gaskets. Install new gaskets if necessary.
3. Clean and inspect the sealing surfaces.
4. Remove and discard the front module O-ring seal.

To install:

All vehicles

Fig. Intake manifold torque sequence-6.0L Diesel Engine

NOTE

The locating tabs on the gaskets must be up and toward the center of the engine, or a leak will occur.

1. Install the intake manifold gaskets and front module O-ring seal.

Late build

1. Install the intake manifold and bolts and tighten in the following sequence.
   1. Loosely install bolts 1-8.
   2. Tighten bolts 9-16 to 11 Nm (8 ft. lbs.).
   3. Tighten all bolts to 11 Nm (8 ft. lbs.) in the sequence shown.
2. Install the gasket and the EGR cooler V-clamp.
3. Install the turbocharger heat shield and the nuts.

Early build

1. Install the intake manifold and bolts and tighten in the following sequence.
   1. Loosely install bolts 1-8.
   2. Tighten bolts 9-16 to 11 Nm (8 ft. lbs.).
   3. Tighten all bolts to 11 Nm (8 ft. lbs.) in the sequence shown.
2. Install the gasket and the EGR cooler V-clamp.
3. Install the turbocharger heat shield and the nuts.

All vehicles

1. Slide the EGR cooler hose forward and rotate flat to lock.
   
   
   

   

   Fig. Reposition and connect the fuel tubes at the fuel filter housing
2. Install the fuel line.
3. Install new sealing washers.
4. Install the fuel line.
5. Install the banjo fitting and the bolt.
6. Install the oil filter return tube and bolt.
7. On new oil filter return tubes, tighten to 6 Nm (53 inch lbs.).
8. On used oil filter return tubes, tighten to 3 Nm (27 inch lbs.).
9. Install the oil filter housing and the four bolts.
10. Clean and inspect the housing O-rings. Install new O-rings if necessary.
11. Connect the fuel line fittings.
12. Position the fuel injector harness and install the retaining nut. Connect the eight fuel injectors electrical connectors.
13. Connect the retaining clip and exhaust backpressure sensor electrical connector.
14. Connect the wiring retainer and the IAT2 sensor electrical connector.
15. Connect the engine coolant temperature (ECT) sensor and the pin-type retainer.
16. Connect the EGR throttle position sensor electrical connector.
17. Connect the EGR throttle position control module electrical connector.
18. Connect the engine oil temperature (EOT) sensor electrical connector.
19. Connect the engine oil pressure (EOP) sensor electrical connector.
20. Connect the EGR valve electrical connector.
21. Connect the wiring retainer, injector pressure regulator and ICP sensor (if equipped) electrical connectors.
22. Position back or install the heat insulating wrap.
23. Install the fuel injector control module.
24. Connect the engine coolant vent hose and clamp.
25. Connect the MAP sensor hose.
    
    NOTE

    Install a new O-ring on the heater hose tube.
26. Install the heater hose tube and bolts.

Early build

1. Install the charge air cooler duct and tighten the clamps.

Late build

1. Install the charge air cooler duct and tighten the clamp.
2. Install the turbocharger pedestal and turbocharger.
3. Install the alternator and the three bolts.
4. Connect the alternator B+ wire land electrical connector and position the boot back.

Vehicles with single alternator

1. Install the accessory drive belt.

Vehicles with dual alternators

1. Install the alternator with mounting bracket and bolts.
2. Connect the B+ wire, alternator electrical connector and wire retainer.
3. Install the accessory drive belt tensioner and bolts.
4. Position the accessory drive belt idler pulley. Install the bracket and bolts.
5. Install the accessory drive belt.
6. Install the accessory drive belt tensioner and bolt.
7. Install the accessory drive belt.

All vehicles

1. Install the turbocharger-to-charge air cooler duct.
2. Install the upper radiator hose.
3. Install the degas bottle (coolant reservoir).
4. Install the auxiliary battery.
5. Install the cooling fan stator

6.8L Engine

WARNING

Fuel in the fuel system remains under high pressure, even when the engine is not running.

1. Before servicing the vehicle, refer to the Precautions Section.
2. Relieve the fuel system pressure.
3. Disconnect the fuel supply spring lock coupling from the fuel rail.
4. Drain the cooling system.
5. Remove the alternator. See the -Alternator- section.
6. Remove the air cleaner outlet pipe.
7. Disconnect the upper radiator hose from the thermostat housing.
8. Disconnect the heater coolant hose from the coolant crossover assembly.
9. Disconnect the intake manifold runner control (IMRC) actuator electrical connector.
10. Disconnect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
11. Disconnect the 10 fuel injector electrical connectors.
12. Disconnect the positive crankcase ventilation (PCV) tube quick connect coupling from the intake manifold.
13. Disconnect the quick connect couplings and remove the evaporative emissions (EVAP) tube.
14. Disconnect the brake booster and engine vacuum hose connections from the rear of the intake manifold and position aside.
15. Disconnect the 2 heated PCV coolant hoses from the intake manifold.
16. Disconnect the throttle position (TP) sensor and electronic throttle control electrical connectors.
17. Disconnect the engine wiring harness position retainers from the intake manifold.
18. Remove the 12 intake manifold bolts.
    
    CAUTION

    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.
19. Remove the 2 bolts, the coolant crossover tube and discard the gaskets.
20. Clean and inspect the sealing surfaces with metal surface prep and silicone gasket remover. Follow the directions on the packaging.
21. Remove the intake manifold and discard the gaskets.
22. Clean and inspect the sealing surfaces with metal surface prep and silicone gasket remover.

To install:

1. Using new intake manifold gaskets, position the intake manifold.
2. Using new gaskets, position the coolant crossover tube and install the 2 bolts. Tighten to 89 inch lbs. (10 Nm).
3. Install the intake manifold bolts and tighten in 2 stages in the sequence shown, to the following:
   1. Stage 1: Tighten to 2 Nm (18 lb-in).
   2. Stage 2: Tighten to 89 inch lbs. (10 Nm).
      
      
      

      

      Fig. Intake manifold bolt tightening sequence-6.8L engine
4. Connect the throttle position (TP) sensor and electronic throttle control electrical connectors.
5. Connect the engine wiring harness position retainers to the intake manifold.
6. Connect the brake booster and engine vacuum hose connections to the rear of the intake manifold.
7. Connect the positive crankcase ventilation (PCV) tube quick connect coupling to the intake manifold.
8. Position the evaporative emissions (EVAP) tube and connect the quick connect couplings.
9. Connect the 2 heated PCV coolant hoses to the intake manifold.
10. Connect the 10 fuel injector electrical connectors.
11. Connect the fuel rail pressure and temperature sensor electrical connector and vacuum connector.
12. Connect the intake manifold runner control (IMRC) actuator electrical connector.
13. Connect the fuel supply spring lock coupling to the fuel rail.
14. Connect the heater coolant hose to the coolant crossover assembly.
15. Connect the heated PCV coolant hose to the coolant crossover assembly.
16. Connect the upper radiator hose to the thermostat housing.
17. Install the alternator.
18. Install the air cleaner outlet pipe.
19. Fill and bleed the engine cooling system.

These details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html