Intake Manifold Replacing on Ford E series Vans?

The details to replace Intake Manifold on Ford E series Van models is as follows:---


Intake Manifold
REMOVAL & INSTALLATION Procedure:------

4.6L Engine

Specific to:

Ford E-150 2008-2009

Ford E-250 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Release the engine cover latches and remove the engine cover.
4. Remove the air intake assembly.
5. Drain the engine cooling system.
6. Disconnect the fuel supply line.
7. Disconnect the PCV tube.
8. Remove the front transmission fluid filler tube support bracket bolt.
9. Remove bolt and position the transmission fluid filler tube aside.
10. Disconnect the auxiliary heater hoses and position them aside, if equipped.
11. Disconnect the Electronic Throttle Control (ETC) and the PCV heater element electrical connectors and the wiring harness retainer.
12. Remove the throttle body mounting bolts, throttle body and discard the gasket.
13. Disconnect the electrical connector and the Evaporative Emission (EVAP) canister-to- EVAP canister purge valve tube quick connect coupling from the EVAP purge valve.
14. Disconnect the brake booster vacuum hose from the intake manifold.
15. Disconnect the EGR system module vacuum connector and position the vacuum tube assembly aside.
16. Disconnect the EGR system module electrical connector.
17. Disconnect the upper and lower fittings and remove the exhaust manifold-to-EGR system module tube.
18. Remove the two bolts and the EGR system module.
19. Discard the EGR system module gasket.
20. Remove the ignition coils.
21. Remove the four bolts and the generator support bracket.
22. Disconnect the heater coolant hose and position aside.
23. Disconnect the fuel injector electrical connectors.
24. Disconnect the Knock Sensor (KS) electrical connector, electrical connector retainer and the 2 engine wiring harness retainers from the rear of the intake manifold.
25. Disconnect the upper radiator coolant hose and position aside.
26. Remove the 2 thermostat housing bolts and the thermostat housing and discard the O-ring seal.
27. Remove the thermostat.
28. Remove the intake manifold mounting bolts.
29. Remove the intake manifold through the passenger compartment and discard the RH and LH intake manifold gaskets.

To install:

1. Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep and silicone gasket remover.
2. Install new intake manifold gaskets and position the intake manifold. Loosely install the 9 intake manifold bolts.
3. Tighten the intake manifold mounting bolts in the sequence shown to 89 inch lbs. (10 Nm).
   
   
   

   

   Fig. Intake manifold torque sequence-4.6L Engine
4. Install the thermostat, seal and tighten the thermostat housing bolts to 18 ft. lbs. (25 Nm).
5. Connect the upper radiator coolant hose.
6. Connect the KS electrical connector, electrical connector retainer and the 2 engine wiring harness retainers to the rear of the intake manifold.
7. Connect the fuel injector electrical connectors.
8. Connect the heater coolant hose.
9. Position the alternator support bracket and tighten the bolts to 89 inch lbs. (10 Nm).
10. Install the ignition coils.
11. Carefully clean both sealing surfaces and install a new EGR system module gasket with the side with the raised ring facing the intake manifold.
12. Install the EGR system module and tighten the bolts to 18 ft. lbs. (25 Nm) plus 90°.
13. Position the exhaust manifold-to-EGR system module tube and connect the upper and lower fittings.
14. Position the vacuum tube assembly and connect the EGR system module vacuum connector.
15. Connect the EGR system module electrical connector.
16. Connect the brake booster vacuum hose to the intake manifold.
17. Connect the electrical connector and the EVAP canister-to- EVAP canister purge valve tube quick connect coupling to the EVAP purge valve.
18. Install the throttle body with a new gasket and tighten the bolts to 80 inch lbs. (9 Nm) plus 90°.
19. Connect the auxiliary heater hose quick connect couplings, if equipped.
20. Install the transmission fluid filler tube and tighten the bolt to 89 inch lbs. (10 Nm).
21. Install the front transmission fluid filler tube support bracket bolt and tighten to 21 ft. lbs. (28 Nm).
22. Position the PCV tube and connect the quick connect couplings.
23. Connect the fuel supply tube quick connect coupling.
24. Install the engine cover.
25. Install the air intake assembly.
26. Connect the battery ground cable.
27. Refill the engine cooling system to the correct level.

5.4L Engine

Specific to:

Ford E-150 2008-2009

Ford E-250 2008-2009

Ford E-350 Super Duty 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Release the engine cover latches and remove the engine cover.
4. Remove the air intake assembly.
5. Drain the engine cooling system.
6. Disconnect the fuel supply line.
7. Disconnect the quick connect coupling and remove the crankcase ventilation tube from the LH valve cover.
8. Remove the throttle body spacer. For additional information, refer to the following section, -Throttle Body, Removal & Installation.-
9. Disconnect the upper radiator hose.
10. Disconnect the heater coolant hose.
11. Disconnect the Electronic Throttle Control (ETC) wiring harness retainer.
12. Disconnect the generator wiring harness retainer from the generator support bracket stud bolt.
13. Remove the 2 bolts, the 2 stud bolts and the alternator upper support bracket.
14. Remove the front transmission fluid filler tube support bracket bolt.
15. Remove the rear transmission fluid filler tube support bracket nut and position the transmission fluid filler tube aside.
16. Disconnect the electrical connector and the Evaporative Emission (EVAP) canister-to- EVAP canister purge valve tube quick connect coupling from the EVAP purge valve.
17. Remove the bolt and the EVAP canister purge valve.
18. Disconnect the auxiliary heater hoses and position aside, if equipped.
19. Disconnect the quick connect coupling and remove the PCV tube from the RH valve cover.
20. Disconnect the fuel injector electrical connectors.
21. Disconnect the ignition coil electrical connectors.
22. Remove the ignition coils.
23. Remove the bolts, the thermostat housing and the thermostat and discard the O-ring seal.
24. Remove the mounting bolts, the intake manifold assembly and discard the intake manifold gaskets.

To install:

1. Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep and silicone gasket remover.
2. Install new intake manifold gaskets and position the intake manifold. Loosely install the intake manifold bolts.
3. Using a new O-ring seal, install the thermostat. Loosely install the thermostat housing and bolts.
4. Tighten the intake manifold bolts in two stages, in the sequence shown as follows:
   1. Tighten to 18 inch lbs. (2 Nm).
   2. Tighten to 18 ft. lbs. (25 Nm).
      
      
      

      

      Fig. Intake manifold torque sequence-5.4L Engine
5. Install the ignition coils.
6. Connect the ignition coil electrical connectors.
7. Connect the fuel injector electrical connectors.
8. Position the PCV tube and connect the quick connect couplings.
9. Connect the auxiliary heater hoses, if equipped.
10. Install the EVAP canister purge valve and tighten the bolt to 89 inch lbs. (10 Nm).
11. Connect the electrical connector and the EVAP canister-to- EVAP canister purge valve tube quick connect coupling to the EVAP purge valve.
12. Position the transmission fluid filler tube and tighten the rear retaining nut to 21 ft. lbs. (28 Nm).
13. Install the transmission fluid filler tube front support bracket bolt and tighten to 89 inch lbs. (10 Nm).
14. Position the generator support bracket and tighten the two bolts and the two stud bolts to 89 inch lbs. (10 Nm).
15. Connect the generator wiring harness retainer to the generator support bracket stud bolt.
16. Connect the ETC wiring harness retainer to the generator support bracket stud bolt.
17. Connect the heater coolant hose.
18. Connect the upper radiator hose.
19. Install the TB spacer.
20. Position the crankcase ventilation tube and connect quick connect coupling to the LH valve cover.
21. Connect the fuel supply tube quick connect coupling.
22. Install the engine cover.
23. Connect the negative battery cable.
24. Refill the engine cooling system to the correct level.

6.0L Engine

Specific to:

Ford E-350 Super Duty 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the battery ground cable.
3. Remove the cooling fan stator.
4. Remove the turbocharger pedestal.

Vehicles with dual alternator

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 alternator electrical connector and the 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. Remove the bolt and position the ground wire aside. Disconnect the electrical connector push pin.
2. Remove the conduit and position the wiring aside.
3. Disconnect the locking tab.
4. Remove the bolts.
5. Disconnect the push pin and remove the wiring harness from the conduit.
6. Remove the bolts for the charge air cooler tube and oil fill tube.
7. Disconnect the oil fill tube at the valve cover.
8. Remove the retaining nuts, charge air cooler tube, oil fill tube and bracket.
9. Disconnect the alternator electrical connector and the B+ wire. Disconnect the wiring push pin.
10. Remove the retaining nut for the transmission fluid indicator and tube.
11. Disconnect the push pin retainer. Remove the retaining nut and position the transmission fluid indicator and tube aside.
12. Remove the three bolts, ground wire and the alternator.
13. Remove the bolts and position the heater hose tube aside.
14. Remove and discard the O-ring.
    
    NOTE

    It will be necessary to position back or remove the heat insulating wrap.
15. Remove the retaining nut and disconnect the wiring retainer and the injection pressure regulator valve electrical connector.
16. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
17. Disconnect the engine oil pressure (EOP) sensor electrical connector.
18. Disconnect the engine oil temperature (EOT) sensor electrical connector.
19. Disconnect the EGR throttle position control module electrical connector.
20. Disconnect the EGR throttle position sensor electrical connector.
21. Disconnect the pin-type retainer and engine coolant temperature (ECT) sensor.
22. Remove the ECT sensor.
23. Plug or cap the opening as needed.
24. Disconnect the Intake Air Temperature (IAT2) sensor electrical connector.
25. Remove the IAT2 sensor.
26. Plug or cap the opening as needed.
27. Disconnect the eight fuel injector electrical connectors and wiring connectors.
28. Disconnect the harness retainers. Position the engine wiring harness as needed for intake manifold removal.
29. Disconnect the manifold absolute pressure (MAP) sensor hose.
30. Disconnect the engine coolant vent hose.
31. Remove the secondary fuel filter and remove all fuel from the filter housing.
32. Disconnect the fuel tube fittings at the secondary fuel filter.
33. Remove and discard the copper sealing washers.
34. Disconnect the fuel tube at the fuel filter housing. Remove the retaining nut.
35. Remove the banjo bolt and fuel tube.
36. Discard the copper sealing washers.
37. Remove the bolts and the secondary fuel filter assembly.
38. Remove the nuts and turbocharger heat shield.
    
    NOTE

    Align the flat edge with the index feature located on the coolant supply port.
39. Pull the EGR cooler clamp forward, twist and then slide the EGR cooler hose rearward to remove.
40. Remove the bolts and the intake manifold.
41. Remove the intake manifold gaskets.
42. Clean and inspect the gaskets. Install new gaskets if necessary.
43. Clean and inspect the sealing surfaces.
44. Remove and discard the front module O-ring seal.

To install:

NOTE

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

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

   

   Fig. Intake manifold torque sequence-6.0L engine
2. 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.).
3. Slide the EGR cooler hose forward and rotate the flat to lock.
4. Install the turbocharger heat shield and nuts.
5. Install the secondary fuel filter assembly and bolts. Toque to 18 ft. lbs. (25 Nm).
   
   NOTE

   Install new copper sealing washers.
6. Install the fuel line and banjo bolt. Torque to 28 ft. lbs. (38 Nm).
7. Install the retaining nut and connect the fuel tube at the fuel filter assembly. Torque to 19 ft. lbs. (26 Nm).
   
   NOTE

   Install new copper sealing washers on the banjo fitting.
8. Reposition and connect the fuel tubes at the fuel filter housing.
   
   
   

   

   Fig. Reposition and connect the fuel tubes at the fuel filter housing
9. Install the secondary fuel filter and cover. Torque to 10 ft. lbs. (14 Nm).
10. Connect the engine coolant vent hose.
11. Connect the MAP sensor hose.
12. Position back the engine wiring harness as needed. Connect the harness retainers.
13. Connect the eight fuel injector electrical connectors.
14. Remove the plug or cap. Install the IAT2 sensor.
15. Connect the IAT2 sensor electrical connector.
16. Remove the plug or cap. Install the ECT sensor.
17. Connect the ECT sensor electrical connector and the pin-type retainer.
18. Connect the EGR throttle position sensor electrical connector.
19. Connect the EGR throttle position control module electrical connector.
20. Connect the EOT sensor electrical connector.
21. Connect the EOP sensor electrical connector.
22. Connect the EGR valve electrical connector.
23. Connect the injector pressure regulator valve electrical connector and position back the heat insulating wrap. Install the wiring retainer and retaining nut.
    
    NOTE

    Install a new O-ring seal and apply clean engine coolant
24. Install the heater tube and bolts.
25. Install the alternator, ground wire and the three bolts.
26. Position back the transmission fluid indicator and tube and install the retaining nut.
27. Connect the push pin retainer.
28. Install the retaining nut for the transmission fluid indicator and tube.
29. Connect the alternator B+ wire and electrical connector. Position back the boot. Connect the wiring push pin.
30. Position the charge air cooler tube, oil fill tube and bracket. Install the retaining nuts.
31. Connect the oil fill tube at the valve cover.
32. Install the bolts for the charge air cooler tube and oil fill tube.
33. Install the conduit and bolts.
34. Install the wiring harness into the conduit and connect the push pin.
35. Install the bolts.
36. Connect the locking tab.
37. Connect the electrical connector push pin. Position back the ground wire and install the bolt.

Vehicles with single alternator

1. Install the accessory drive belt.

Vehicles with dual alternator

1. Install the alternator with mounting bracket and bolts.
2. Connect the alternator B+ wire and electrical connector. Position the boot.
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 cooling fan stator.
2. Install the turbocharger pedestal and turbocharger.
3. Connect the battery ground cable.

6.8L Engine

Specific to:

Ford E-350 Super Duty 2008-2009

1. Before servicing the vehicle, refer to the Precautions Section.
2. Disconnect the negative battery cable.
3. Drain the engine cooling system.
4. Remove the air intake assembly.
5. Disconnect the fuel supply hose.
6. Disconnect the alternator wiring harnesses.
7. Remove the mounting bolts and remove the alternator support bracket.
8. Compress and slide the hose clamp and disconnect the coolant hose.
9. Disconnect the Electronic Throttle Control (ETC) electrical connector.
10. Disconnect the Throttle Position (TP) sensor electrical connector.
    
    NOTE

    The red clip must be pulled out before disconnecting the electrical connectors.
11. Disconnect the quick connect couplings and remove the PCV tube
12. Disconnect the two coolant heated PCV fitting coolant hoses and the body vacuum tube connector.
13. Disconnect the brake booster vacuum hose and the Evaporative Emission (EVAP) hose quick connect coupling.
14. Disconnect the electrical connector, remove the bolt and position the EVAP canister purge valve aside.
15. Remove the bolts and the Throttle Body (TB) and TB spacer as an assembly.
16. Disconnect the heater coolant hose.
17. Disconnect the fuel injector electrical connectors.
18. Disconnect the ignition coil electrical connectors.
19. Remove the transmission fluid indicator and tube support bracket nut.
20. Remove the transmission fluid level indicator tube support bracket nut and position the tube aside.
21. Disconnect the RH engine wiring harness retainers and position the harness aside.
22. Disconnect the LH engine wiring harness retainers and position the harness aside.
23. Remove the bolt and position the engine wiring harness support bracket aside.
24. Remove the bolts and the ignition coils.
25. Remove the bolts, thermostat housing and thermostat. Discard the O-ring seal.
26. Remove the mounting bolts, the intake manifold and the intake manifold gaskets. Discard the gaskets.

To install:

1. Clean the mating surfaces of the cylinder head and the intake manifold with metal surface prep and silicone gasket remover.
2. Install new intake manifold gaskets and position the intake manifold. Loosely install the intake manifold bolts.
3. Using a new O-ring seal, install the thermostat. Loosely install the thermostat housing and bolts.
4. Tighten the intake manifold bolts in two stages, in the sequence shown as follows:
   1. Tighten to 18 inch lbs. (2 Nm).
   2. Tighten to 18 ft. lbs. (25 Nm).
      
      
      

      

      Fig. Intake manifold torque sequence-6.8L Engine
5. Install the ignition coils.
6. Connect the pushpin retainer to the intake manifold bracket.
7. Position the engine harness and connect the three LH engine wiring harness retainers.
8. Position the engine harness and connect the two RH engine wiring harness retainers.
9. Position back the transmission fluid level indicator tube and tighten the nut to 21 ft. lbs. (28 Nm).
10. Connect the 10 ignition coil electrical connectors.
11. Connect the 10 fuel injector electrical connectors.
12. Connect the heater coolant hose.
13. Install the throttle body assembly. For additional information, refer to the following section, -Throttle Body, Removal & Installation.-
14. Position the EVAP canister purge valve and install the bolt and the electrical connector.
15. Connect the brake booster vacuum hose and the EVAP hose quick connect coupling.
16. Connect the 2 coolant heated PCV fitting coolant hoses and the body vacuum tube connector.
17. Position the PCV tube and connect the quick connect couplings.
18. Connect the TP sensor electrical connector and wiring harness retainer.
19. Connect the ETC electrical connector.
20. Install the upper radiator hose.
21. Position the alternator harness and the generator B+ terminal and install the nut and protective boot.
22. Connect the alternator electrical wiring harness retainer and the alternator electrical connector.
23. Connect the fuel hose quick connect coupling.
24. Install the air intake assembly.
25. Install the engine cover.
26. Connect the negative battery cable.
27. Refill the engine cooling system to the correct level.

This details will help.

Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

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