AutoZone 1992 Toyota Corolla 1.6L EFI DOHC 4cyl | Repair Guides | Engine Mechanical | Engine Mechanical Components | Intake Manifold | AutoZone.com

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    1992 Toyota Corolla 1.6L EFI DOHC 4cyl

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    Lincoln Aviator, Ford Explorer, Exp Sport, Exp Sport-Trac, Mercury Mountaineer 2000-2005

    Intake Manifold

    Print

    Removal & Installation



    4.0L Engine
    VIN E Engine
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Air cleaner-to-intake tube
       
      Accelerator splash shield
       
      Accelerator and, if equipped with cruise control, speed control cables from the throttle control cam
       
      Accelerator cable retaining bracket from the upper intake manifold
       
      Label and disengage all vacuum and electrical connections on the intake manifold.
       
      Upper intake manifold attaching bolts
       
      Lift up on the manifold and remove both fuel Vapor Management Valve (VMV) hoses
       
      Intake manifold and discard the gasket
       

    4.  

    To install:


    NOTE
    Ford does not specify a sequence for either upper or lower intake manifolds, but it is recommended that you start tightening in the middle and work your way out to the ends. Repeat the tightening sequence several times until the bolts will no longer turn at the specified torque.

    1. Install the lower intake manifold. Torque the bolts to 10 ft. lbs. (13 Nm) for 2000, and 13 ft. lbs. (18 Nm) for 2001.
    2.  
    3. Position the upper manifold on the lower manifold.
    4.  
    5. Install or connect the following:

      Attach both VMV hoses to the manifold
       
      Upper manifold attaching bolts. Torque the bolts to 62 inch lbs. (7 Nm).
       
      Attach any vacuum and electrical connections that were removed
       
      Accelerator cable bracket to the intake and the cable (or cables if equipped with cruise control) to the throttle cam
       
      Accelerator splash shield
       
      Air cleaner-to-intake supply tube
       
      Negative battery cable
       

    6.  
    7. Start the vehicle and check for leaks, repair if necessary.
    8.  

    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Splash shield
       
      Air cleaner outlet pipe
       
      Accelerator and speed control cables from the throttle body
       
      Accelerator cable and the speed control cable from the bracket. Position the cables away from the intake manifold.
       
      All the vacuum hoses
       
      KS electrical connector
       
      IAC valve electrical connector
       
      TP sensor electrical connector
       
      EGR transducer electrical connector
       
      Wiring anchor
       
      EGR tube from the EGR valve
       
      Wiring harness pin-type retainer
       
      Spark plug wires
       
      Intake manifold retainers, then slightly reposition the manifold to access the EGR vacuum regulator (EVR) solenoid.
       
      EVR solenoid vacuum and electrical connections
       
      Intake manifold
       
      To install, reverse the removal procedure. Torque the bolts to 89 inch lbs. (10 Nm). There is no particular sequence.
       

    4.  



    Click image to see an enlarged view

    Fig. Parts to be removed prior to intake manifold removal-2003-05 4.0L SOHC engine



    Click image to see an enlarged view

    Fig. Intake manifold removal-2003-05 4.0L SOHC engine

    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    2.  
    3. Disconnect the battery ground cable.
    4.  
    5. Remove the air cleaner outlet pipe.
    6.  
    7. Remove the positive crankcase ventilation (PCV) tube
    8.  
    9. Remove the brake booster vacuum supply hose
    10.  
    11. Remove the engine main vacuum harness-to-intake manifold fitting
    12.  
    13. Remove the evaporative emissions (EVAP) return tube
    14.  
    15. Remove the EVAP tube pin-type retainer
    16.  
    17. Remove the exhaust gas recirculation (EGR) system module electrical connector
    18.  
    19. Remove the wiring harness pin-type retainer
    20.  
    21. Remove the engine main vacuum harness-to-EGR system module fitting
    22.  
    23. Remove the EGR tube fitting
    24.  
    25. Remove the throttle position (TP) sensor electrical connector
    26.  
    27. Remove the electronic throttle body electrical connector
    28.  
    29. Remove the electronic throttle body-to-intake manifold bolt
    30.  
    31. Remove the intake manifold mounting bolts
    32.  
    33. Remove the intake manifold
    34.  
    35. Remove the intake manifold gaskets
    36.  

    To install:

    1. Installation is the reverse of the removal procedure.
      CAUTION
      Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools can cause scratches and gouges which can make leak paths.

    2.  
    3. Clean the sealing surfaces, inspect the gaskets and install new gaskets if necessary. There is no special torque sequence.
    4.  

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

      Negative battery cable
       
      Splash shield
       
      Air cleaner outlet pipe
       
      Accelerator and speed control cables from the throttle body
       
      Accelerator cable and the speed control cable from the bracket. Position the cables away from the intake manifold.
       
      All the vacuum hoses
       
      KS electrical connector
       
      IAC valve electrical connector
       
      TP sensor electrical connector
       
      EGR transducer electrical connector
       
      Wiring anchor
       
      EGR tube from the EGR valve
       
      Wiring harness pin-type retainer
       
      Spark plug wires
       
      Intake manifold retainers, then slightly reposition the manifold to access the EGR vacuum regulator (EVR) solenoid.
       
      EVR solenoid vacuum and electrical connections
       
      Intake manifold
       
      To install, reverse the removal procedure. Torque the bolts to 89 inch lbs. (10 Nm). There is no particular sequence.
       

    4.  

    1. Before servicing the vehicle, refer to the -Precautions- section.
    2.  
    3. Disconnect the battery ground cable.
    4.  
    5. Remove the air cleaner outlet pipe.
    6.  
    7. Remove the positive crankcase ventilation (PCV) tube
    8.  
    9. Remove the brake booster vacuum supply hose
    10.  
    11. Remove the engine main vacuum harness-to-intake manifold fitting
    12.  
    13. Remove the evaporative emissions (EVAP) return tube
    14.  
    15. Remove the EVAP tube pin-type retainer
    16.  
    17. Remove the exhaust gas recirculation (EGR) system module electrical connector
    18.  
    19. Remove the wiring harness pin-type retainer
    20.  
    21. Remove the engine main vacuum harness-to-EGR system module fitting
    22.  
    23. Remove the EGR tube fitting
    24.  
    25. Remove the throttle position (TP) sensor electrical connector
    26.  
    27. Remove the electronic throttle body electrical connector
    28.  
    29. Remove the electronic throttle body-to-intake manifold bolt
    30.  
    31. Remove the intake manifold mounting bolts
    32.  
    33. Remove the intake manifold
    34.  
    35. Remove the intake manifold gaskets

      Click image to see an enlarged view

      Fig. Parts to be removed prior to intake manifold removal-2005 4.0L SOHC engine



      Click image to see an enlarged view

      Fig. Intake manifold removal-2005 4.0L SOHC engine

    36.  

    To install:

    1. Installation is the reverse of the removal procedure.
      CAUTION
      Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools can cause scratches and gouges which can make leak paths.

    2.  
    3. Clean the sealing surfaces, inspect the gaskets and install new gaskets if necessary. There is no special torque sequence.
    4.  

    1. Before servicing the vehicle, refer to the -Precautions- section.
    2.  
    3. Remove or disconnect the following:

      Battery ground cable
       
      Engine cover
       
      Air cleaner outlet pipe
       
      Accelerator and speed control cables
       
      Idle air control valve and TP sensor electrical connectors
       
      TP sensor wiring routing clip
       
      EGR vacuum hose and EGR tube from EGR valve
       
      EGR vacuum regulator solenoid connections
       
      Fuel vapor hose
       
      Brake booster vacuum hose
       
      Spark plug wires (mark locations prior to removal)
       
      Accelerator cable routing clip and wiring harness
       
      Ignition coil bracket lower, then upper, bolts; position coil aside
       
      Remaining vacuum hoses from intake manifold (mark for installation locations)
       
      Wiring harness retaining nut at bulkhead
       
      PCM connector
       
      Ground wires from body connections
       
      Knock sensor connector
       
      Intake manifold bolts, and lift up manifold
       
      Heated PCV hose retainers and PCV fitting
       

    4.  
    5. Remove intake manifold
    6.  

    To install:

    1. Clean the mating surfaces.
    2.  
    3. Position the intake manifold, while installing the PCV fitting and hose retainers.
    4.  
    5. With intake manifold fully in place, tighten the bolts to 89 inch lbs. (10 Nm).
    6.  
    7. Install or connect the following:

      Knock sensor connector
       
      Ground wires to body connections
       
      PCM connector
       
      Wiring harness retaining nut at bulkhead
       
      Vacuum hoses to intake manifold
       
      Ignition coil bracket lower, then upper, bolts
       
      Accelerator cable routing clip and wiring harness
       
      Spark plug wires
       
      Brake booster vacuum hose
       
      Fuel vapor hose
       
      EGR vacuum regulator solenoid connections
       
      EGR vacuum hose and EGR tube to EGR valve
       
      TP sensor wiring routing clip
       
      Idle air control valve and TP sensor electrical connectors
       
      Accelerator and speed control cables
       
      Air cleaner outlet pipe
       
      Engine cover
       

    8.  
    9. Connect the battery ground cable.
    10.  

    4.6L Engine
    VIN H DOHC Engine
    Lower


    Click image to see an enlarged view

    Fig. Lower intake manifold and related parts-4.6L DOHC engine

    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    2.  
    3. Remove the upper intake manifold.
    4.  
    5. Disconnect the spring lock couplings.
    6.  
    7. Remove the cooling fan.
    8.  
    9. Remove the accessory drive belt tensioner.
    10.  
    11. Remove the accessory drive belt.
    12.  
    13. Remove the wire harness retainer.
    14.  
    15. Remove the alternator.
    16.  
    17. Remove the alternator bracket studs.
    18.  
    19. Remove the upper coolant hose.
    20.  
    21. Remove the coolant bypass hose.
    22.  
    23. Remove the thermostat housing coolant hose.
    24.  
    25. Remove the engine coolant temperature (ECT) sensor electrical connector.
    26.  
    27. Remove the coolant crossover tube.
    28.  
    29. Remove the vacuum hose.
    30.  
    31. Remove the engine harness retainers.
    32.  
    33. Remove the fuel rail pressure (FRP) sensor electrical connector.
    34.  
    35. Remove the intake manifold runner control (IMRC) motor electrical connector.
    36.  
    37. Remove the fuel injector connectors.
    38.  
    39. Remove the lower intake manifold bolts.
    40.  
    41. Remove the lower intake manifold assembly.
    42.  
    43. Remove the intake manifold gaskets.
    44.  

    To install:

    1. Installation is the reverse of the removal procedure.
      NOTE
      Hand-start all fasteners.



      Click image to see an enlarged view

      Fig. Lower intake manifold torque sequence-4.6L DOHC engine

    2.  
    3. Tighten all fasteners in the sequence shown in the illustration to 89 inch lbs. (10 Nm).
    4.  

    1. Before servicing the vehicle, refer to the -Precautions- section.
    2.  
    3. Remove the upper intake manifold.
    4.  
    5. Disconnect the spring lock couplings.
    6.  
    7. Remove the cooling fan.
    8.  
    9. Remove the accessory drive belt tensioner.
    10.  
    11. Remove the accessory drive belt.
    12.  
    13. Remove the wire harness retainer.
    14.  
    15. Remove the alternator.
    16.  
    17. Remove the alternator bracket studs.
    18.  
    19. Remove the upper coolant hose.
    20.  
    21. Remove the coolant bypass hose.
    22.  
    23. Remove the thermostat housing coolant hose.
    24.  
    25. Remove the engine coolant temperature (ECT) sensor electrical connector.
    26.  
    27. Remove the coolant crossover tube.
    28.  
    29. Remove the vacuum hose.
    30.  
    31. Remove the engine harness retainers.
    32.  
    33. Remove the fuel rail pressure (FRP) sensor electrical connector.
    34.  
    35. Remove the intake manifold runner control (IMRC) motor electrical connector.
    36.  
    37. Remove the fuel injector connectors.
    38.  
    39. Remove the lower intake manifold bolts.
    40.  
    41. Remove the lower intake manifold assembly.
    42.  
    43. Remove the intake manifold gaskets.

      Click image to see an enlarged view

      Fig. Lower intake manifold and related parts-4.6L DOHC engine

    44.  
    45. Installation is the reverse of the removal procedure, noting the following:
      NOTE
      Hand-start all fasteners.

      1. Tighten all fasteners in the sequence shown in the illustration to 89 inch lbs. (10 Nm).

        Click image to see an enlarged view

        Fig. Lower intake manifold torque sequence-2005 4.6L (VIN H) DOHC engine

      2.  

    46.  

    Upper


    Click image to see an enlarged view

    Fig. Upper intake manifold and related parts-4.6L DOHC engine

    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    2.  
    3. Disconnect the battery ground cable.
    4.  
    5. Drain the cooling system.
    6.  
    7. Remove the air cleaner outlet pipe.
    8.  
    9. Remove the exhaust gas recirculation (EGR) system module.
    10.  
    11. Remove the positive crankcase ventilation (PCV) valve hose.
    12.  
    13. Remove the brake booster vacuum hose.
    14.  
    15. Remove the evaporative emissions (EVAP) hose.
    16.  
    17. Remove the coolant hose clamp.
    18.  
    19. Remove the PCV coolant hose.
    20.  
    21. Remove the coolant hose clamp.
    22.  
    23. Remove the PCV coolant hose.
    24.  
    25. Remove the accelerator cable.
    26.  
    27. Remove the speed control cable.
    28.  
    29. Remove the accelerator cable return spring.
    30.  
    31. Remove the accelerator cable pin-type retainer.
    32.  
    33. Remove the accelerator cable bracket.
    34.  
    35. Remove the idle air control (IAC) valve electrical connector.
    36.  
    37. Remove the throttle position (TP) sensor electrical connector.
    38.  
    39. Remove the fuel rail shield.
    40.  
    41. Remove the radio capacitor.
    42.  
    43. Remove the upper intake manifold bolts.
    44.  
    45. Remove the upper intake manifold studs.

      Click image to see an enlarged view

      Fig. Upper intake manifold bolt torque sequence-4.6L DOHC engine

    46.  
    47. Remove the upper intake manifold.
    48.  

    To install:

    1. Installation is the reverse of the removal procedure.
      NOTE
      Locations 5 and 9 use studs.

    2.  
    3. Tighten the bolts and studs in the sequence shown to 89 inch lbs. (10 Nm).
    4.  

    1. Before servicing the vehicle, refer to the -Precautions- section.
    2.  
    3. Disconnect the battery ground cable.
    4.  
    5. Drain the cooling system.
    6.  
    7. Remove the air cleaner outlet pipe.
    8.  
    9. Remove the exhaust gas recirculation (EGR) system module.
    10.  
    11. Remove the positive crankcase ventilation (PCV) valve hose.
    12.  
    13. Remove the brake booster vacuum hose.
    14.  
    15. Remove the evaporative emissions (EVAP) hose.
    16.  
    17. Remove the coolant hose clamp.
    18.  
    19. Remove the PCV coolant hose.
    20.  
    21. Remove the coolant hose clamp.
    22.  
    23. Remove the PCV coolant hose.
    24.  
    25. Remove the accelerator cable.
    26.  
    27. Remove the speed control cable.
    28.  
    29. Remove the accelerator cable return spring.
    30.  
    31. Remove the accelerator cable pin-type retainer.
    32.  
    33. Remove the accelerator cable bracket.
    34.  
    35. Remove the idle air control (IAC) valve electrical connector.
    36.  
    37. Remove the throttle position (TP) sensor electrical connector.
    38.  
    39. Remove the fuel rail shield.
    40.  
    41. Remove the radio capacitor.
    42.  
    43. Remove the upper intake manifold bolts.
    44.  
    45. Remove the upper intake manifold studs.

      Click image to see an enlarged view

      Fig. Upper intake manifold and related parts-4.6L DOHC engine

    46.  
    47. Remove the upper intake manifold.
    48.  
    49. Installation is the reverse of the removal procedure. Tighten the bolts and studs in the sequence shown to 89 inch lbs. (10 Nm).
      NOTE
      Locations 5 and 9 use studs.



      Click image to see an enlarged view

      Fig. Upper intake manifold bolt torque sequence-4.6L DOHC engine

    50.  

    VIN W SOHC Engine


    Click image to see an enlarged view

    Fig. Intake manifold and related parts-4.6L SOHC engine

    1. Before servicing the vehicle, please familiarize yourself with safety procedures.
    2.  
    3. Remove or disconnect the following:

      Negative battery cable
       
      Throttle body
       
      Ignition coils
       
      Fuel injection supply manifold
       
      Upper radiator hose and the heater hose
       
      Alternator
       
      Accelerator cable bracket
       
      Throttle body adapter
       
      Thermostat housing
       
      Intake manifold bolts
       
      Intake manifold. Tilt the manifold to slide it out from underneath the exhaust gas recirculation (EGR) tube.
       
      To install, reverse the removal procedure. Tighten retaining bolts is sequence shown.

      Click image to see an enlarged view

      Fig. Tighten the manifold bolts in the sequence shown-4.6L SOHC Engine

       

    4.  

    1. Before servicing the vehicle, refer to the -Precautions- section.
    2.  
    3. Relieve the fuel system pressure.
    4.  
    5. Drain the cooling system.
    6.  
    7. Remove or disconnect the following:

      Negative battery cable
       
      Air cleaner outlet pipe
       
      EGR tube
       
      Alternator
       
      Fuel tube spring lock coupling
       
      Upper radiator hose from the thermostat housing
       
      Brake booster vacuum tube bracket bolt and disconnect the tube from the throttle body adapter; position the tube aside
       
      Heater hose from the intake manifold
       
      Crankcase breather tube
       
      Heater control vacuum hose fitting
       
      Vacuum tube from the throttle body adapter
       
      EGR system module and fuel pressure sensor vacuum fittings
       
      PCV valve tube
       
      Thermostat housing cover, the O-ring seal and the thermostat
       
      Electronic throttle body and throttle position (TP) sensor electrical connectors
       
      Fuel pressure sensor electrical connector
       
      EVAP tube from the throttle body adapter
       
      Heated PCV coolant inlet hose
       
      Heated PCV coolant outlet hose
       
      Coolant outlet hose anchor from the fuel rail stud
       
      EGR system module electrical connector
       
      Ground wire connection
       
      RH fuel injector, coil pack electrical connectors and the wiring harness retainers
       
      LH fuel injector and coil pack electrical connectors and the fuel charging wiring harness retainers
       
      Wire harness locators and the knock sensor (KS) electrical connector from the back of the intake manifold
       
      All 8 ignition coils
       
      Intake manifold bolts and intake manifold

      Click image to see an enlarged view

      Fig. External hoses and related parts for intake manifold removal-2005 4.6L (VIN W) engine (1 of 3)



      Click image to see an enlarged view

      Fig. External related parts for intake manifold removal-2005 4.6L engine (VIN W) (2 of 3)



      Click image to see an enlarged view

      Fig. Intake manifold removal-2005 4.6L engine (VIN W) (3 of 3)

       

    8.  

    To install:

    1. Clean all mating surfaces.
    2.  
    3. Position the intake manifold and new gasket.
    4.  
    5. Tighten the intake manifold bolts, in sequence shown, to 18 ft. lbs. (25 Nm).

      Click image to see an enlarged view

      Fig. Intake manifold bolt tightening sequence-4.6L (VIN W) SOHC engine

    6.  
    7. Apply dielectric compound to the inside of the coil boots, then install all 8 ignition coils and the bolts.
    8.  
    9. Install or connect the following:

      Wire harness locators and the KS electrical connector to the back of the intake manifold
       
      LH fuel injector and coil pack electrical connectors and the fuel charging wiring harness retainers
       
      RH fuel injector, coil pack electrical connectors and the wiring harness retainers
       
      Ground wire
       
      EGR system module electrical connector
       
      Coolant outlet hose anchor to the fuel rail stud
       
      Heated PCV coolant outlet hose and position the clamp
       
      Heated PCV coolant inlet hose and position the clamp
       
      EVAP hose to the throttle body adapter
       
      Fuel pressure sensor electrical connector
       
      TP sensor and the electronic throttle body electrical connectors
       
      Thermostat, with a new O-ring; tighten housing bolts to 18 ft. lbs. (25 Nm)
       
      PCV valve tube
       
      Vacuum harness and connect the fuel pressure sensor and EGR system module vacuum fittings
       
      Vacuum tube to the throttle body adapter
       
      Heater control vacuum hose fitting
       
      Crankcase breather tube and connect it to the valve cover
       
      Heater hose and position the clamp
       
      Brake booster vacuum tube and connect it to the throttle body adapter, install the vacuum tube bracket bolt
       
      Upper radiator hose to the thermostat housing
       
      Fuel tube spring lock coupling
       
      Alternator
       
      EGR tube
       
      Air cleaner outlet pipe
       
      Battery ground cable
       

    10.  
    11. Refill and bleed the engine cooling system.
    12.  

    5.0L Engine
    Lower
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. Drain the cooling system.
    4.  
    5. 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
       

    6.  

    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.  
    3. Apply a 1 / 16 in. (1.6mm) bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads.
    4.  
    5. 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.
    6.  
    7. 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.

      Click image to see an enlarged view

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

    8.  
    9. Install the lower intake manifold and tighten the bolts in 2 steps as follows:
      1. 89 inch lbs. (10 Nm).
      2.  
      3. 24 ft. lbs. (32 Nm).
      4.  

    10.  
    11. 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
       

    12.  
    13. Fill the cooling system.
    14.  
    15. Start the vehicle and check for leaks, repair if necessary.
    16.  

    Upper
    1. Before servicing the vehicle, refer to the Precautions section.
    2.  
    3. 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

      Click image to see an enlarged view

      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
       

    4.  

    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.  
    3. Apply a 1 / 16 in. (1.6mm) bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads.
    4.  
    5. 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.
    6.  
    7. 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.
    8.  
    9. 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.
    10.  
    11. 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

      Click image to see an enlarged view

      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
       

    12.  

    1. Before servicing the vehicle, refer to the precautions in the beginning of this section.
    2.  
    3. 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

      Click image to see an enlarged view

      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
       

    4.  

    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.  
    3. Apply a 1 / 16 in. (1.6mm) bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads.
    4.  
    5. 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.
    6.  
    7. 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.
    8.  
    9. 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.
    10.  
    11. 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

      Click image to see an enlarged view

      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
       

    12.  

     
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