10/20/ Ford E 250 Engine Mechanical > Engine, 4.6L and 5.4L > IN VEHICLE REPAIR > Intake Manifold 5.4L

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1 2005 Ford E 250 : Engine Mechanical > Engine, 4.6L and 5.4L > IN VEHICLE REPAIR > Intake Manifold 5.4L Intake Manifold 5.4L Listen SECTION A: Engine 4.6L and 5.4L 2005 E Series Workshop Manual IN VEHICLE REPAIR Procedure revision date: 11/20/2008 INTAKE MANIFOLD 5.4L Removal 1. Remove the engine cover. For additional information, refer to Interior Trim and Ornamentation. 2. Disconnect the fuel hose spring lock couplings. For additional information, refer to Fuel System General Information Gasoline and Diesel. 3. Disconnect the battery ground cable. For additional information, refer to Battery, Mounting and Cables. 4. Drain the cooling system. For additional information, refer to Engine Cooling. 5. Position the engine air cleaner (ACL). Remove the four bolts. Loosen the clamp. Position the ACL to gain access to the mass airflow (MAF) sensor electrical connector. 6. Disconnect the MAF sensor electrical connector and remove the ACL Rjnq5XZM5czck2 1/22

2 7. Disconnect the engine vent tube. Loosen the clamp and remove the air cleaner outlet pipe. 8. NOTE: The red clip must be pulled out before disconnecting the electrical connector. Disconnect the electronic throttle body (TB) electrical connector. 9. Disconnect the throttle position (TP) sensor electrical connector Rjnq5XZM5czck2 2/22

3 10. Compress and slide the hose clamp and disconnect the upper radiator hose. 11. Disconnect the coolant hose. 12. If equipped, disconnect the coolant hoses from the TB Rjnq5XZM5czck2 3/22

4 13. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system. Disconnect the electrical connector. Disconnect the two hoses. 14. Remove the differential pressure feedback EGR system bracket. 15. Remove the bolts and the generator upper support bracket. 16. Remove the retaining bolt for the transmission fluid indicator and tube Rjnq5XZM5czck2 4/22

5 17. Remove the nut for the transmission fluid indicator and tube. Position the transmission fluid indicator and tube aside. 18. Disconnect the evaporative emissions hose. 19. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to Climate Control System General Information and Diagnostics Rjnq5XZM5czck2 5/22

6 20. Disconnect the EGR vacuum regulator solenoid connections. 21. NOTE: Valve shown disconnected for clarity. Press the tab, remove and position aside the evaporative emission canister purge valve. 22. Disconnect the EGR valve vacuum hose Rjnq5XZM5czck2 6/22

7 23. Disconnect the brake booster and main engine vacuum harness and position aside. 24. Remove the exhaust manifold to EGR valve tube. Disconnect the upper fitting. Disconnect the lower fitting and remove the tube. 25. Remove the four bolts, and the throttle body and adapter as an assembly. Discard the throttle body adapter gasket Rjnq5XZM5czck2 7/22

8 26. Disconnect and remove the positive crankcase ventilation (PCV) hose. 27. Disconnect the fuel pressure sensor vacuum hose and the electrical connector. 28. NOTE: LH shown; RH similar. Disconnect the eight ignition coil electrical connectors Rjnq5XZM5czck2 8/22

9 29. NOTE: LH shown; RH similar. Disconnect the eight fuel injector electrical connectors. 30. Remove the eight bolts and the eight ignition coils. 31. Remove the bolts, the thermostat housing and the thermostat. Disconnect the O ring seal Rjnq5XZM5czck2 9/22

10 32. Remove the nine bolts retaining the intake manifold. 33. Remove the intake manifold. Discard the intake manifold gaskets Rjnq5XZM5czck 10/22

11 34. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. Installation Inspect the throttle body, the intake manifold and their sealing surfaces for damage. 1. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or any other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which can cause leak paths. Use a plastic scraping tool to clean sealing surfaces. Clean and inspect all sealing surfaces. 2. Position the intake manifold gaskets and the intake manifold Rjnq5XZM5czck 11/22

12 3. Loosely install the nine bolts. 4. Install the thermostat. Install the thermostat. Install a new O ring seal Rjnq5XZM5czck 12/22

13 5. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts. Loosely install the thermostat housing and bolts. 6. Tighten the bolts in two stages, in the sequence shown. Stage 1: Tighten to 2 Nm (18 lb in). Stage 2: Tighten to 25 Nm (18 lb ft) Rjnq5XZM5czck 13/22

14 7. Install the eight ignition coils and bolts. 8. NOTE: LH shown; RH similar. Connect the eight fuel injector electrical connectors. 9. NOTE: LH shown; RH similar. Connect the eight ignition coil electrical connectors. 10. Connect the fuel pressure sensor vacuum hose and electrical connector Rjnq5XZM5czck 14/22

15 11. Install the PCV hose and valve. 12. Install the new throttle body adapter gasket. 13. Install the throttle body and adapter assembly. Install the four bolts Rjnq5XZM5czck 15/22

16 14. Install the exhaust manifold to EGR valve tube and tighten the fitting in two stages. Stage 1: Hand tighten the fittings. Stage 2: Tighten to 50 Nm (37 lb ft). 15. Connect the brake booster and the main engine vacuum harnesses. 16. Connect the EGR vacuum hose Rjnq5XZM5czck 16/22

17 17. Install the evaporative emission canister purge valve. 18. Connect the EGR vacuum regulator solenoid connections. 19. If equipped, connect the auxiliary heater hoses. For additional information, refer to Climate Control System General Information and Diagnostics Rjnq5XZM5czck 17/22

18 20. Connect the evaporative emissions hose on the intake manifold. 21. Position back the transmission fluid indicator and tube. Install the retaining nut. 22. Install the transmission fluid filler tube bracket and bolt. 23. Install the generator upper support bracket Rjnq5XZM5czck 18/22

19 24. Install the differential pressure feedback EGR system bracket. 25. Connect the differential pressure feedback EGR sensor. Connect the electrical connector. Connect the two hoses. 26. If equipped, connect the coolant hoses to the TB Rjnq5XZM5czck 19/22

20 27. Connect the coolant hose. 28. Connect the upper radiator hose. 29. Connect the TP sensor electrical connector. Push back the red clip Rjnq5XZM5czck 20/22

21 30. Connect the electronic TB electrical connector. Push back the red clip. 31. Install the air cleaner outlet pipe and tighten the clamp. Connect the engine vent tube. 32. Connect the MAF sensor and position the ACL. 33. Install the ACL. Install the four bolts. Tighten the clamp Rjnq5XZM5czck 21/22

22 34. Connect the fuel hose spring lock couplings. For additional information, refer to Fuel System General Information Gasoline and Diesel. 35. Install the engine cover. For additional information, refer to Interior Trim and Ornamentation. 36. Connect the battery ground cable. For additional information, refer to Battery, Mounting and Cables. 37. Fill and bleed the engine cooling system. For additional information, refer to Engine Cooling Rjnq5XZM5czck 22/22

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