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1997 ford f150 4.2L V6-how do I remove the intake manifold?


Upper Intake Manifold

Upper Intake Manifold

Removal

Remove the engine air cleaner outlet tube (9B659).

Disconnect the following ignition coil electrical connections.
Ignition coil electrical connector (A).
Radio ignition interference capacitor electrical connector (B).

Remove the bolts and remove the ground strap.
Caution: Spark plugs wires must be connected to the proper ignition coil terminal. Mark locations before removing spark plug wires.

Note: Refer to the cylinder to coil tower relation indicated.

Disconnect and remove the six spark plug wires.

Disconnect idle air control (IAC) valve electrical connector.

Remove the accelerator control splash shield.
Remove the two accelerator control splash shield bolts.
Remove the accelerator control splash shield.

Disconnect the (A) accelerator cable end and, if equipped, the (B) speed control actuator cable end.

Remove the (A) accelerator cable to bracket bolt and, if equipped, the (B) speed control actuator cable to bracket bolt and position the (C) accelerator cable (9A758) and, if equipped, the (D) speed control actuator cable (9A825) aside.

Disconnect the vapor management valve (VMV) hose.

Disconnect the brake booster vacuum hose.

Disconnect the manifold vacuum connection.

Remove the PCV valve.

Position the EVR bracket aside.
Remove the two engine vacuum regulator (EVR) bracket stud bolts.
Position the EVR bracket aside.

Disconnect the following electrical connection:
Throttle position (TP) sensor electrical connector.

Remove the breather.

Remove the twelve bolts and the upper intake manifold.

REmove and discard the intake manifold upper gasket (9H486).
Installation

Install a new intake manifold upper gasket.
Note: Make sure to tighten the upper intake manifold bolts in two steps.

Position the upper intake manifold and tighten the upper intake manifold bolts in the sequence shown.

Tighten the upper intake manifold bolts in the sequence shown.

Install the breather.

Connect the following electrical connection:
Throttle position (TP) sensor electrical connector.

Install the EVR bracket.
Position the EVR bracket.
Install the two EVR bracket stud bolts.

Connect the manifold vacuum connection.

Install the PCV valve.

Connect the brake booster vacuum hose.

Connect the vapor management valve (VMV) hose.

Position the (A) accelerator cable and, if equipped, the (B) speed control actuator cable and install the (C) accelerator cable to bracket bolt and, if equipped, the (D) speed control actuator cable to bracket bolt.

Connect the (A) accelerator cable end and, if equipped, the (B) speed control actuator cable end.

Position the (A) accelerator control splash shield and install the three (B) accelerator control splash shield bolts.
Caution: Spark plug wires must be connected to the proper ignition coil terminal.

Note: Refer to the cylinder to coil tower relation indicated.

Install and connect the six spark plug wires.

Install the ground strap and bolts.

Connect the following ignition coil electrical connections.
Ignition coil electrical connector (A).
Radio ignition interference capacitor electrical connector (B).

Connect the idle air control (IAC) valve electrical connector.
Install the engine air cleaner outlet tube.

Lower Intake Manifold

Removal

Remove the upper intake manifold.

Disconnect the six fuel injector electrical connectors.

Disconnect the (B) engine coolant temperature (ECT) sensor and the (B) water temperature indicator sending unit electrical connectors.

Disconnect the exhaust gas recirculation (EGR) valve vacuum hose.

Remove the EGR valve tube upper fitting.
Remove the upper radiator hose from the lower intake manifold.
NOTE: Discard the plastic retainer when removing the linkage.

Disconnect the vacuum hoses and linkage from the intake manifold runner control (IMRC).
Disconnect the two linkages.
Disconnect the vacuum hoses.
Disconnect the Intake Manifold Runner Control (IMRC) Vacuum and electrical connections.

Disconnect the fuel pressure regulator vacuum line.
Disconnect the fuel lines.

Disconnect the water pump bypass hose.
Release and slide the hose clamp.
Disconnect the water pump bypass hose.
Disconnect the two heater water hoses (18472).

Remove the heater water outlet tube (18663).
NOTE: Remove the lower intake manifold including the fuel injection supply manifold (9F792) and the fuel injectors.

Remove the 14 intake manifold bolts and the lower intake manifold.

Remove and discard the lower intake manifold sealing components.
Installation

Refer to the illustration for intake manifold sealing component locations.

Install the lower intake manifold front and rear end seals.
Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated.
Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A1.
Install the lower intake manifold front and rear end seals.

Install the intake manifold gaskets (9439).
NOTE: The lower intake manifold must be installed within 4 minutes of applying sealant.

Position the lower intake manifold.
Apply a bead of sealant to the lower intake manifold mounting at the points indicated.
Use Silicone Gasket and Sealant F6AZ-19562-AA or equivalent meeting Ford specification WSE-M4G323-A1.
Position the lower intake manifold.
NOTE: Refer to the location note made during removal and make sure the bolts are installed in the correct location.

Install the 14 long lower intake manifold bolts.

Install the 14 short lower intake manifold bolts.
NOTE: Make sure to tighten the lower intake manifold bolts in two steps.

Tighten the lower intake manifold bolts in the sequence shown.

Tighten the lower intake manifold bolts in the sequence shown.

Install heater water outlet tube (18663).
Connect the two heater water hoses (18472).

Connect the water pump bypass hose.
Position the water pump bypass hose.
Position the hose clamp.
Connect the fuel lines, if necessary.

Connect the fuel pressure regulator vacuum line.
Connect the IMRC vacuum and electrical connections.
NOTE: Install the new plastic retainer when installing the linkage.

Connect the IMRC hoses and linkage.
Connect the linkage.
Connect the vacuum hoses.
Install the upper radiator hose to the lower intake manifold.

Connect the EGR valve vacuum hose.

Install the EGR valve tube upper fitting.

Connect the (B) engine coolant temperature (ECT) sensor and the (A) water temperature indicator sending unit electrical connectors.

Connect the six fuel injector electrical connectors.
Install the upper intake manifold.

Try www.autozone.com for the

Try www.autozone.com for the step-by step guide along with pictures for this procedure.
Once at the site identify you car under the heading "current Vehicle"
Next click "Repair Info" on the tabs below the AutoZone logo.
At the middle of the page go to "Your Ride, Your Guide" and click "Become a member" set you username and password
Log-in and click "Vehicle repair guide"
Select the category for the repair needed.
Select (on the left) type of repair needed.
Page opens to your repair info.


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