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2000 Ford Windstar Intake Manifold-Lower Removal And installation manual

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Filed Under (Ford Manuals) by admin on 25-06-2012

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Intake Manifold—Lower Removal 1. Partially drain the cooling system. For additional information, refer to Section 303-03 . 2. Remove the upper intake manifold (9424). For additional information, refer to Intake Manifold—Upper in this section. 3. Remove the fuel supply manifold (9F792). For additional information, refer to Section 303-04B . 4. Disconnect the EGR vacuum tube (9E498). 5. Disconnect the EGR-to-exhaust manifold tube (9D477). * Loosen the nut. 6. Disconnect the upper radiator hose (8260). * Reposition the clamp. * Disconnect the hose. 7. Disconnect the heater hose (18472). * Compress the fitting * Disconnect the hose. 8. Disconnect the intake manifold runner control (IMRC). 9. Position the water bypass tube (8555) aside. 1. Remove the bolts. 2. Position the tube aside. 10. NOTE: Note the location of the six long bolts. Remove the lower intake manifold (9J447). 1. Remove the bolts. 2. Remove the intake manifold. 11. Remove the intake manifold runner control (IMRC) if necessary. For additional information, refer to Section 303-14 . 12. Remove and discard the lower intake manifold sealing components. Installation 1. Refer to the illustration for intake manifold sealing component locations. 2. Install the lower intake manifold front and rear end seals. 1. Apply a bead of sealant to the intake manifold front and rear end seal mounting points as indicated. * Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 3. Install the lower intake manifold front and rear end seals. 3. Install the intake manifold gaskets (9439). 4. Install the intake manifold runner control (IMRC) if required. For additional information, refer to Section 303-14 . 5. NOTE: The lower intake manifold must be installed within four minutes of applying sealant. Position the lower intake manifold. 1. Apply a bead of sealant to the lower intake manifold mounting at the points indicated. * Use Silicone Gasket and Sealant F7AZ-19554-EA or equivalent meeting Ford specification WSE-M4G323-A4. 3. Position the lower intake manifold.

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1997 Ford Explorer/ Mountaineer Intake Manifold Upper Repair Manual

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Filed Under (Ford Manuals) by admin on 09-05-2012

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Intake Manifold — Upper 1. Disconnect the battery ground cable. 2. Remove the air cleaner outlet tube; refer to Section 303-12 3. Disconnect the ignition coil electrical connector and the noise suppressor electrical connector. 4. Disconnect the idle air control (IAC) electrical connector. 5. Disconnect the EGR backpressure transducer electrical connector. 6. Disconnect the EVR solenoid electrical and vacuum connectors. 7. Disconnect the brake booster vacuum hose from the upper intake manifold. 8. Disconnect the vacuum connector from the upper intake manifold 9. Disconnect the vacuum connector from the fuel pressure regulator and remove the vacuum harness from the engine. 10. Disconnect the throttle position (TP) sensor electrical connector. 11. Disconnect the hoses from the EGR backpressure transducer ports. 12. Disconnect the six spark plug wires from the spark plugs. 13. Disconnect the spark plug wires from the seven retaining clips. 14. Remove the four ignition coil bolts and the ignition coil from the upper intake manifold. 15. Raise and support the vehicle; refer to Section 100-02 . 16. Access the LH exhaust manifold through the wheel well and disconnect the EGR inlet tube from the exhaust manifold (9430). 17. Lower the vehicle. 18. Disconnect the EGR inlet tube from the EGR valve and remove the EGR inlet tube. 19. Remove the EGR valve bolts and the EGR valve and gasket. 20. Remove the oil level indicator tube bracket nut and remove the oil level indicator tube (6754). 21. Remove the EGR outlet tube bracket stud bolt and remove the EGR outlet tube from the upper intake manifold. 22. Disconnect the accelerator cable assembly from the upper intake manifold bracket. 23. Remove the upper intake manifold nuts and remove the upper intake manifold and gasket. Installation 1. NOTE: Before installing the upper intake manifold, the EGR port must be clean and free of obstruction. Use combustion chamber cleaner and a suitable wire brush to remove carbon buildup from the EGR passages. Clean and inspect all surfaces. Install new seals and new gaskets. Use Metal Surface Cleaner F4AZ-19A536-RA or equivalent meeting Ford specification WSE-M5B392-A to clean the upper and lower intake manifold gasket surfaces. Position the upper intake manifold gasket on the fuel injection supply manifold. 2. Position the upper intake manifold and install the six nuts.

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2006 Ford Five Hundred SE UPPER INTAKE MANIFOLD REMOVAL AND INSTALLATION MANUAL

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Filed Under (Ford Manuals) by admin on 30-11-2011

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Removal All vehicles 1. Drain the cooling system. For additional information, refer to DRAINING . 2. Disconnect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION . 3. Remove the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION . 4. Remove the 4 transaxle roll restrictor cross brace bolts 5. Remove the bolt and the transaxle roll restrictor cross brace. 6. Disconnect the evaporative emissions (EVAP) canister purge valve tube from the upper intake manifold and detach the retainer. 7. Disconnect the positive crankcase ventilation (PCV), brake booster and vacuum harness tubes from the upper intake manifold. 8. Detach the fuel tube retainer from the upper intake manifold. 9. Disconnect the exhaust gas recirculation (EGR) system module electrical connector and vacuum tube. 10. Detach the vacuum tube from the upper intake manifold vacuum tube retainer. 11. Disconnect the EGR system module tube from the EGR system module. Early build 12. Disconnect and plug the throttle body and PCV coolant hoses. Late build 13. Disconnect and plug the 2 PCV coolant hoses. All vehicles 14. Disconnect the throttle body electrical connector. 15. If equipped, remove and discard the 4 upper-to-lower intake manifold screws. 16. Remove the 8 bolts and the upper intake manifold. * Remove and discard the gaskets. Installation All vehicles Fig. 4: Identifying Tightening Sequence Of Bolts Courtesy of FORD MOTOR CO. NOTE: Clean and inspect all sealing surfaces. Install new gaskets 1. Position the upper intake manifold and install the 8 bolts. * Tighten in the sequence shown to 10 N.m (89 lb-in). 2. Connect the throttle body electrical connector. Late build 3. Connect the 2 PCV coolant hoses. Early build 4. Connect the throttle body and PCV coolant hoses. All vehicle 5. Connect the EGR system module tube to the EGR system module. * Tighten to 40 N.m (30 lb-ft). 6. Attach the vacuum tube to the upper intake manifold vacuum tube retainer. 7. Connect the EGR system module electrical connector and vacuum tube. 8. Attach the fuel tube retainer to the upper intake manifold. 9. Connect the PCV, brake booster and vacuum harness tubes to the upper intake manifold. 10. Connect the EVAP canister purge valve tube to the upper intake manifold and attach the retainer. 11. Clean the 4 transaxle roll restrictor cross brace bolts using a wire brush and apply new threadlock to the threads. 12. Position the transaxle roll restrictor cross brace and install the 4 new bolts. * Tighten to 55 N.m (41 lb-ft). 13. Clean the transaxle roll restrictor cross brace-to-roll restrictor bolt using a wire brush and apply new threadlock to the threads. 14. Install a new transaxle roll restrictor cross brace-to-roll restrictor bolt. * Tighten to 48 N.m (35 lb-ft). 15. Install the air cleaner outlet pipe. For additional information, refer to REMOVAL AND INSTALLATION . 16. Connect the battery ground cable. For additional information, refer to REMOVAL AND INSTALLATION . 17. Fill and bleed the cooling system.

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Chevrolet V8 With General Duty Oval Port Cylinder Heads STREET TUNNEL RAM INTAKE MANIFOLD INSTALLATION INSTRUCTIONS

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Filed Under (Chevrolet Manuals) by admin on 28-12-2011

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CAMSHAFT AND HEADERS: The Street Tunnel Ram manifold is compatible with aftermarket camshafts and headers. Use Edelbrock Torker-Plus camshaft #5062 for more low RPM torque, or the Edelbrock Performer RPM camshaft #7162 for more high RPM power. Header primary tube diameter should be 1-7/8″. This may vary depending upon your particular engine specifications. PREP AND TUNING FOR POWER: 1. Specific applications may show an increase in performance through additional carburetor tuning. 2. Aftermarket distributor curve kits and aftermarket ignitions may be used with the Street Tunnel Ram intake manifold. 3. Use modified or high performance cylinder heads such as our Performer RPM, and port match the intake manifold to the heads. 3. The engine’s compression ratio should be at least 9.5:1 to work properly with Torker-Plus or Performer RPM camshafts. INSTALLATION PROCEDURE INTAKE MANIFOLD BASE 1. Use only recommended intake gaskets set when installing this intake manifold. 2. Fully clean the cylinder head intake flanges and the engine block end seal surfaces. 3. Apply Edelbrock Gasgacinch sealant P/N 9300 to both cylinder head flanges and to the cylinder head side of the gaskets, allow to air dry, and attach the intake gaskets. 4. Do not use cork or rubber end seals. Use RTV silicone sealer instead. Apply a ¼” high bead across each block end seal surface, overlapping the intake gasket at the four corners. This method will eliminate end seal slippage. 5. Install the intake manifold hold-down bolts. Hand tighten all bolts to approximately 5 ft./lbs. to center the manifold on the engine. WARNING: There is no gasket support for the manifold under the four bolt holes which are numbered 13,14,15, and 16 in Figure 1 below. Damage to the manifold will occur if these four bolts are over tightened. Hand tighten these bolts with a 6″ box-end wrench. DONOT use a torque wrench. 6. Torque all of the remaining manifold bolts in two steps by the sequence shown in Figure 1 to 25 ft/lbs. INTAKE MANIFOLD TOP 1. Apply Edelbrock Gasgacinch sealant P/N 9300 to the gasket mating surface and install the gasket and manifold top. 2. Install and tighten the supplied hold down bolts to 15-18 ft./lbs.

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2002 Chevrolet Impala Intake Manifold Replacement (Lower) Removal And Installation Manual

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Filed Under (Chevrolet Manuals) by admin on 30-04-2012

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Intake Manifold Replacement (Lower) Notes Intake Manifold Replacement – Lower Removal Procedure 1. Disconnect the negative bakery. 2. Remove the upper intake manifold. 3. Remove the left valve rocker arm cover. 4. Remove the right valve rocker arm cover. 5. Disconnect the Engine Coolant Temperature ( ECT ) sensor electrical connector. 6. Disconnect and remove the fuel injector and the Manifold Absolute Pressure (MAP) sensor wiring harnesses. 7. Remove the fuel pipe clip bolt. 8. Remove the fuel pipe clip. 9. Remove the fuel feed pipe from the fuel injector rail. 10. Remove the fuel return pipe from the fuel injector rail. 11. Remove the fuel injector rail. 12. Remove the power steering pump from the front engine cover and reposition. 13. Remove the heater inlet pipe with heater hose from the lower intake manifold and reposition. 14. Remove the radiator inlet hose from the engine. 16. Remove the lower intake manifold bolts. 17. Remove the lower intake manifold. 18. Remove the valve rocker arms and pushrods. 19. Remove the lower intake manifold gaskets and seals. 20. Clean the lower intake manifold gasket mating surfaces. 21. Remove and clean all the RTV sealant from the lower intake manifold and the engine block (1).

Chrysler V8 DUAL QUAD INTAKE MANIFOLD INSTALLATION INSTRUCTIONS

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Filed Under (Chrysler Manuals) by admin on 24-02-2012

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PREP AND TUNING FOR POWER: NOTE: This manifold will produce optimum power and drivability when used with #1405 carburetors. Please refer to Edelbrock Performer Series Carburetor Owner’s Manual for tuning procedures. 1. Edelbrock has found, while dyno testing on a Performer level engine at our location, the best calibration to be: Metering Rods – .070″ x .047″ (stock 1405), Primary Jets – .098″ (provided with intake manifold), and Secondary Jets – .086″ (provided with intake manifold). This will vary according to engine build and atmospheric conditions. Use it as a starting point. However, if used for racing or marine installation, further tuning may be necessary. 2. Aftermarket distributor curve kits may be used with this intake manifold. A basic ignition curve of 12° to 14° initial and a total of 36° to 38° advance is a good starting point. 3. Use modified or high performance cylinder heads such as our Performer RPM. 4. Installation of aftermarket headers, camshafts or both may lean carburetor calibration. Should this condition occur, recalibrate with a richer jet. • CAMSHAFT AND HEADERS: Dual Quad manifolds are compatible with aftermarket camshafts and headers. Header primary tube diameter should be 1-7/8″, depending on the specific engine combination. Edelbrock has developed two camshafts for use with this intake manifold – Performer-Plus #2192 or Performer RPM #7194. Please check the catalog or website for rpm and application guidelines. INSTALLATION 1. Use only recommended intake gaskets set when installing this intake manifold. For ease of installation, we recommend Edelbrock Manifold Bolt and Washer Kit, #8594. 2. Fully clean the cylinder head intake flanges and the engine block end seal surfaces. 3. Use a factory style valley pan along with the recommended gaskets. 4. Apply Edelbrock Gasgacinch sealant P/N 9300 to both cylinder head flanges and to the cylinder head side of the gaskets, allow to air dry, and attach the intake gaskets. 5. Install the intake manifold and hold-down bolts. Torque all of the manifold bolts in two steps by the sequence shown in Figure 1 to 25 ft/lbs

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305-400 C.I.D. Chevrolet V8 STREET TUNNEL RAM INTAKE MANIFOLD INSTALLATION INSTRUCTIONS

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Filed Under (Chevrolet Manuals) by admin on 27-12-2011

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INSTALLATION PROCEDURE INTAKE MANIFOLD BASE 1. Use only recommended intake gaskets set when installing this intake manifold. 2. Fully clean the cylinder head intake flanges and the engine block end seal surfaces. 3. Apply Edelbrock Gasgacinch sealant P/N 9300 to both cylinder head flanges and to the cylinder head side of the gaskets, allow to air dry, and attach the intake gaskets. 4. Do not use cork or rubber end seals. Use RTV silicone sealer instead. Apply a ¼” high bead across each block end seal surface, overlapping the intake gasket at the four corners. This method will eliminate end seal slippage. 5. Install the intake manifold hold-down bolts (We offer an Intake Manifold Bolt Kit #8504 that includes small-head silver Cadmium-plated bolts and matching hardened washers). Apply a small amount of RTV silicone to the threads of the eight inner bolts (1,2,3,4,5,7,9, & 11) (See Figure 1) . This will prevent oil weepage, as generally these are not blind holes in the cylinder head. 6. Torque all of the manifold bolts in two steps by the sequence shown in Figure 1 to 25 ft/lbs. INTAKE MANIFOLD TOP 1. Apply Edelbrock Gasgacinch sealant P/N 9300 to the gasket mating surface and install the gasket and manifold top. 2. Install and tighten the supplied hold down bolts using a liquid thread-locking compound on the bolt threads. As an extra safety precaution, we suggest you drill a small safety wire hole in the head of each bolt and safety wire them together. Edelbrock Corporation expressly disclaims any liability for any and all consequential damages.

2001 Chevy Truck S10/ T10 Blazer Intake Manifold Replacement (Upper) Removal And Installation Manual

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Filed Under (Chevy Manuals) by admin on 05-06-2012

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Intake Manifold Replacement (Upper) Notes Intake Manifold Replacement – Upper Removal Procedure Important: The upper intake does not have to be removed to remove the lower intake manifold. 1. Disconnect the breather tube at the air cleaner outlet duct 2. Remove the air cleaner outlet duct retaining wingnut. 3. Disconnect the IAT sensor harness connector 4. Remove the air cleaner outlet duct from the throttle body. 5. Disconnect the accelerator cable from the throttle body 6. Remove the accelerator cable from the accelerator control cable bracket. 7. Disconnect the cruise control cable, if equipped from the throttle shaft and the accelerator cable bracket. 8. Disconnect the vacuum hose from the intake manifold for the vacuum tank. 9. Remove the power brake booster vacuum hose. 10. Disconnect the following electrical connectors: * The A/C compressor clutch (1) * The A/C compressor cutoff switch (5), if equipped * The Throttle Position (TP) sensor (2) * The Idle Air Control (IAC) motor (3) 11. Disconnect the following electrical connectors: * The fuel meter body assembly (1) * The Manifold Absolute Pressure (MAP) sensor(3) * The EVAP canister purge solenoid valve (2) 12. Remove the engine wire harness clip from the accelerator cable bracket. 13. Move the engine wiring harness aside. 14. Remove the accelerator cable bracket from the throttle body and the intake manifold. 15. Remove the accelerator and cruise control cable bracket from the throttle body. Leave the accelerator and cruise control cables on the bracket16. Remove the PCV valve hose assembly from the intake manifold and the valve rocker arm cover. 17. Remove the bracket for the engine wiring harness from the intake manifold stud. 18. Remove the fuel lines from the fuel meter body assembly. 19. Remove the EVAP canister purge solenoid valve.

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1996 Ford Truck E 350 Exhaust Manifold – Exhaust Leaks Service Manual

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Filed Under (Ford Manuals) by admin on 08-02-2012

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SERVICE PROCEDURE NOTE IF THE MANIFOLD IS TO BE RESURFACED, THE BOLTS MUST BE SHORTENED TO ACCOMMODATE THE EXHAUST MANIFOLD . THE BOLTS SHOULD HAVE THE LEADING “DOG POINT” REMOVED TO PREVENT BOTTOMING INTO THE HOLE. NOTE THERE SHOULD NOT BE ANY TYPE OF GASKET USED BETWEEN THE EXHAUST MANIFOLD AND THE CYLINDER HEAD. Parts Block OTHER APPLICABLE ARTICLES: NONE SUPERSEDES: 97-26-23 WARRANTY STATUS: Eligible Under The Provisions Of Bumper To Bumper 1. If an exhaust leak exists at the exhaust manifold due to a reduction in bolt torque, remove the manifold bolts and the exhaust manifold and check the overall flatness of the manifold. The manifold should not exceed 0.25 mm (0.010″) out- of-flat. Refer to the appropriate model/year Service Manual for manifold removal procedures. 2. If the vehicle is covered under the emissions warranty period, replace the manifold if it is out-of-flat. If the vehicle is out of the emissions warranty period, resurface the exhaust manifold 3. Install the manifold using new mounting hardware, but DO NOT USE WASHERS TO INSTALL THE MANIFOLD. Torque the bolts to 34-47 N.m (25- 35 lb-ft). 4. Check all exhaust system fittings loosened during repair for adequate tightness and allow engine to warm up. Recheck exhaust system for leaks and repair as required.

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1984-1995 Honda Civic/ CRX Positive Crankcase Ventilation (PCV) System Repair Manual

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Filed Under (Honda Manuals) by admin on 22-04-2012

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The PCV system is designed to prevent blow-by gas from escaping to the atmosphere by drawing it directly into the intake manifold. The PCV valve contains a spring-loaded plunger which is lifted in proportion to intake manifold vacuum. Under high vacuum, blow-by is returned directly to the manifold through the breather chamber and PCV valve with fresh air. When intake manifold vacuum decreases (wide open throttle) and vacuum in the air cleaner increases, the PCV valve closes and the blow-by is returned through the cylinder head cover breather hose and into the air cleaner. The PCV valve also acts as a check valve when the engine backfires to prevent crankcase explosion. Fig. 1: PCV system components-1984-87 1.5L engines Fig. 2: PCV system components-1988-91 1.6L engines Fig. 3: PCV system components-1992-95 engines Fig. 4: PCV system components-1984-87 carbureted engines SERVICE Positive Crankcase Ventilation (PCV) Valve For PCV valve removal, refer to Routine Maintenance of this information. 1. Locate the PCV valve. With the engine running at idle, use pliers to pinch the PCV hose between the valve and the intake manifold. It should be possible to hear the spring loaded valve click shut. 2. If no click is heard, remove the valve from the engine but leave it connected to the intake manifold. A hissing sound should be heard and vacuum should be felt at the valve inlet. 3. If no vacuum is felt, remove the valve from the intake manifold hose. The engine should stall or almost stall. This will indicate a stuck valve or clogged hose. Check the breather hose for clogging or leaks and replace any defective parts. Exhaust Gas Recirculation (EGR) System FUEL INJECTED ENGINES General Information See Figure 3 The Exhaust Gas Recirculation (EGR) system is used to control emissions measured at the tailpipe. Components included are the EGR valve and controls. The EGR system uses a poppet type valve to regulate the amount of exhaust gas flowing into the intake manifold. The flow path is cast into the cylinder head and does not use any external tubing. A control solenoid valve regulates the amount of vacuum to the EGR valve. A Constant Volume Control (CVC) valve provides a constant amount of vacuum to the control solenoid valve over a wide range of engine vacuum. When servicing or repairing any part of the emissions system, it is absolutely essential to check for any obvious mechanical faults or failures. Remember, a trouble code only indicates which sensor or circuit is affected by the problem. Simple mechanical faults such as a vacuum leak or poor electrical connection can cause a fault code. The EGR valve is not simply open or closed but is modulated by controlling the amount of engine vacuum to the valve diaphragm, up to a maximum of 8 in. Hg of vacuum. The EGR valve has a sensor in the top of the valve that reports valve lift to the ECU (same as ECM, 1992-95). The ECU modulates the position of the control solenoid valve to control the EGR valve lift according to an internal program. Upstream of the control solenoid valve, the CVC provides a constant supply of vacuum so EGR control is precise under all manifold vacuum conditions

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