Removal & Installation (5.4 4V - 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.
- Remove upper intake manifold. See REMOVAL & INSTALLATION (5.4L 4V - UPPER INTAKE MANIFOLD) . 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.
- Disconnect by-pass hose and PCV heater hose from lower intake manifold. Remove and discard lower intake manifold bolts. Remove lower intake manifold.
- Clean all mating surfaces. Install lower manifold gaskets. Install NEW bolts by hand in positions 7-12 first, then in positions 1-6. See Fig 1. Tighten fasteners in order to specification. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure. Fill and bleed the engine cooling system. See COOLING SYSTEM BLEEDING under COOLING SYSTEMS.
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. Lower intake gaskets may be reused, if undamaged. Lower intake manifold bolts must be replaced.