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Removal & Installation (4.2L - Lower Intake Manifold)

WARNING: This page is about a different car, the 2002 Lincoln Navigator, 2002 Lincoln Blackwood, 2002 Ford Pickup, and 2002 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove upper intake manifold. See REMOVAL (4.2L - UPPER INTAKE MANIFOLD) . See Figure. Remove intake manifold spacer. See REMOVAL & INSTALLATION (4.2L - INTAKE MANIFOLD SPACER) . Disconnect injector harness connectors. Disconnect wiring harness from fuel supply lines. Disconnect EGR valve vacuum hose and upper tube fitting. Disconnect upper radiator hose from engine. Disconnect fuel lines, IMRC harness connector and fuel pressure regulator hose.
  2. Disconnect by-pass hose and PCV heater hose from lower intake manifold. Remove lower intake manifold bolts, noting position of short and long bolts. See Fig 1. Remove lower intake manifold. Clean all mating surfaces.
  3. Install lower manifold with short bolts and long bolts in proper positions. See Fig 1. To complete installation, reverse removal procedure. Tighten fasteners to specification. See Fig 2. See TORQUE SPECIFICATIONS . Fill and bleed the engine cooling system. See COOLING SYSTEM BLEEDING  under COOLING SYSTEMS.
Fig 1: Identifying Short & Long Bolt Locations (4.2L)
G00132435Courtesy of FORD MOTOR CO.
Fig 2: Lower Intake Manifold Tightening Sequence (4.2L)
G00132436Courtesy of FORD MOTOR CO.
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