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9.
Disconnect the vapor management valve hose.
SECTION 303-01A: Engine — 4.6L and 5.4L 2000 Expedition/Navigator Workshop Manual
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IN-VEHICLE REPAIR
Procedure revision date: 06/17/1999
Intake Manifold — 5.4L
Removal
WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly
flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury.
1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01.
2. Relieve the fuel system pressure. For additional information, refer to Section 310-00.
3. Drain the engine cooling system. For additional information, refer to Section 303-03.
4. Remove the engine air cleaner (ACL)(9600) and the air cleaner outlet tube (9B659). For additional information, refer to Section 303-12.
5. Compress and slide the hose clamp and disconnect the upper radiator hose.
6. Remove the accelerator cable snow shield.
1. Remove the bolts.
2. Remove the accelerator cable snow shield.
7. Disconnect the throttle body cam.
1. Disconnect the accelerator cable (9A758).
2. Disconnect the speed control actuator cable.
3. Remove the accelerator return spring.
8. Remove the accelerator cable bracket bolts and position the bracket and cables aside.
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10. Remove the crankcase ventilation tube and the idle air control (IAC) valve fresh air tube.
11. Disconnect the exhaust gas recirculation (EGR) valve vacuum line and the main vacuum harness.
12. Disconnect the throttle position sensor electrical connector and the engine vacuum regulator connector.
13. Disconnect the fuel pressure regulator vacuum line.
14. Disconnect the vapor management valve vacuum line.
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15. Disconnect the differential pressure feedback EGR.
20.
Remove the four bolts and remove the throttle body adapter.
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16. Remove the nut and disconnect the brake booster vacuum line and bracket.
17. Disconnect the fuel lines. For additional information, refer to Section 310-01 .
18. Disconnect the idle air control motor electrical connector.
19. Position the EGR valve to exhaust manifold tube aside.
Disconnect the upper fitting.
Loosen the lower fitting.
Disconnect the two vacuum lines.
Position the tube aside.
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26.
Disconnect the heater hose.
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21. Disconnect and remove the positive crankcase ventilation (PCV) hose.
22. Position the power steering reservoir aside.
Remove the upper bolt.
Remove the lower bolts.
Position the reservoir aside.
23. Disconnect the eight fuel injectors.
24. Disconnect and remove the eight ignition coils. For additional information refer to Section 303-07B.
25. Remove the generator. For additional information, refer to Section 414-02.
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27. Disconnect the two radio interference capacitors.
28. Remove the water thermostat. For additional information, refer to Section 303-03.
29. Remove the nine bolts.
30. Remove the upper intake manifold.
1. Lift the intake manifold.
2. Disconnect the intake manifold tuning valve connector.
3. Remove the intake manifold and discard the gaskets.
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31. If required, remove the bolts and the water crossover.
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Installation
1. CAUTION: Do not use metal scrapers, power abrasive discs or any abrasive means to clean the sealing surfaces. These tools cause
scratches and gouges that make leak paths. Use a plastic scraper only.
Clean all the sealing surfaces.
2. If removed, install the water crossover.
3. Install the intake manifold.
1. Position the new intake manifold gaskets.
2. Position the upper intake manifold.
3. Loosely install nine bolts.
4. Install the water thermostat. For additional information, refer to Section 303-03.
5. Tighten the 11 bolts in two stages in the sequence shown.
Stage 1: Tighten to 2 Nm (18 lb-in).
Stage 2: Tighten to 10 Nm (89 lb-in).
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6. Connect the two radio ignition interference capacitor electrical connectors.
7. Connect the heater hose.
8. Install the generator. For additional information, refer to Section 414-02.
9. Install and connect eight ignition coils. For additional information, refer to Section 303-07B.
10. Connect the eight fuel injector electrical connectors.
11. Install the power steering reservoir.
Position the reservoir.
Install the two lower bolts.
Install the upper bolt.
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12. Install the PCV hose.
13. Install the throttle body adapter and the four bolts. Tighten the bolts in two stages.
Stage 1: Tighten to 10 Nm 89 (lb-in)
Stage 2: Tighten an additional 90 degrees.
14. Install the EGR valve to exhaust manifold tube.
Hand-tighten the fittings.
Tighten the upper fitting.
Tighten the lower fitting.
Connect the two vacuum hoses.
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15. Connect the idle air control motor.
16. Connect the fuel lines. For additional information, refer to Section 310-00 .
17. Connect the brake booster vacuum line and bracket and install the nut.
18. Connect the differential pressure feedback EGR connections.
19. Connect the vapor management valve vacuum line.
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20. Connect the fuel pressure regulator vacuum line.
25.
Install the accelerator cable bracket and the bolts.
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21. Connect the throttle position sensor connector and the engine vacuum regulator connector.
22. Connect the EGR valve the main vacuum harness vacuum connections.
23. Install the crankcase ventilation tube and the IAC fresh air tube.
24. Connect the vapor management hose.
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26. Connect the throttle body cam.
1. Connect the accelerator cable.
2. Connect the speed control actuator cable.
3. Install the throttle return spring.
27. Install the accelerator cable snow shield and the bolts.
28. Connect the upper radiator hose and position the clamp.
29. Install the engine air cleaner and the air cleaner outlet tube. For additional information, refer to Section 303-12.
30. Connect the battery ground cable. For additional information, refer to Section 414-01.
31. Fill and bleed the engine cooling system. For additional information, refer to Section 303-03.
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