Diesel Data: Automotive Repair

Lower




Removal

1. Drain engine cooling system.
2. Remove upper intake manifold as outlined.






3. Remove fuel injectors (9F593) and fuel injection supply manifold (9F792).
4. Remove heater water outlet hose.
5. Remove lower intake manifold retaining bolts/studs.

CAUTION: The lower intake manifold is sealed at each end with silicone sealer. To break the seal, it may be necessary to pry on the front of the lower intake manifold with a prybar. If it is necessary to pry on the lower intake manifold, use care to prevent damage to machined surfaces.

6. Remove lower intake manifold.
7. Remove and discard intake manifold gaskets (9439) and end seals.






8. If lower intake manifold is to be disassembled, perform the following:
- Remove clutch pressure plate (7563) and water thermostat (8575).
- Remove engine coolant temperature sensor (ECT sensor) (12A648).
- Remove heater elbow.
- Remove all vacuum and electrical fittings.

Installation

NOTE: Lightly oil all retaining bolt and stud threads before installation with clean engine oil meeting Ford specification ESE-M2C153-E.

1. The lower intake manifold cylinder head and cylinder block mating surfaces should be clean and free of old gasketing material. Use a suitable solvent to clean these surfaces.
2. If lower intake manifold was disassembled:
a. Apply Pipe Sealant with Teflon� D8AZ-19554-A or equivalent meeting Ford specification WSK-M2G350-A2 and ESR-M18P7-A to the threads of the engine coolant temperature sensor, all vacuum fittings, heater elbows, and electrical fittings (if equipped).
b. Install clutch pressure plate (note direction) and water thermostat. Install water hose connection (8592). Tighten retaining bolts to 8-11 Nm (71-97 lb-in).

NOTE: Prior to applying sealer, clean sealing surfaces of cylinder heads (6049) and lower intake manifold with Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to remove all residues that may interfere with the sealer's ability to adhere.

NOTE: When the lower intake manifold is removed, always use new intake manifold gaskets upon reassembly.

NOTE: When using silicone sealer, assembly must occur within 15 minutes after sealer application. After this time, the sealer may start to set up, and its sealing effectiveness may be reduced.

3. Apply a 3-4 mm (0.125 inch) bead of Silicone Rubber D6AZ-19562-AA (clear) or equivalent meeting Ford specifications ESB-M4G92-A and ESE-M4G195-A or F4AZ-19562-B (black) meeting Ford specification WSE-M4G323-A1 at each corner where the cylinder head joins the cylinder block (6010).
4. Install new front and rear intake manifold end seals.






5. Install new intake manifold gaskets.
6. Carefully lower intake manifold into position on cylinder block and cylinder head. Use locating pins as necessary to guide lower intake manifold.






7. Install bolts and stud bolt in their original locations.






8. Tighten bolts and stud bolts in numerical sequence to the following specifications in two steps:
a. 8 Nm (71 lb-in).
b. 12 Nm (106 lb-in).
9. Install front crankcase ventilation tube so that the mounting bracket sits over the lower intake manifold stud. Tighten nut on stud to 20-30 Nm (15-22 lb-ft).
10. Install fuel injectors and fuel injection supply manifold. Tighten fuel injection supply manifold to lower intake manifold bolts to 8-11 Nm (71-97 lb-in). Tighten fuel pressure bracket bolt to 20-30 Nm (15-22 lb-ft).
11. Install upper intake manifold as outlined.

CAUTION: This engine has aluminum cylinder heads and requires a special corrosion inhibiting coolant to avoid cooling system damage.

12. Fill engine cooling system.
13. Start engine and check for leaks.