OEM 2009 Ford E-250 Intake Manifold

2009 Ford E-250 Intake Manifold Parts Questions & Experts Answers

• Q: How to remove and replace the intake manifold on a 4.6L (2V) engine on 2009 Ford E-250?

  A: The process of replacing an intake manifold on 4.6L (2V) engines starts with disconnecting the ground cable from the battery and following with engine cover and air cleaner assembly removal plus disconnecting and setting aside the outlet pipe. Start by draining the coolant from the system before disconnecting the quick connect ending of the fuel supply tube along with the PCV tube. The first step includes removing the bolt that holds the transmission fluid filler tube support bracket and carefully setting the filler tube to the side. The procedure requires separating the auxiliary heater hoses when they are present. To access the throttle body you must first disconnect ETC and PCV heater element electrical connectors before removing the four throttle body bolts and its gasket and the throttle body itself. The technician disconnects the EVAP canister purge valve tube at three points: the EVAP purge valve, brake booster vacuum hose and EGR system module vacuum connector. Then they remove the EGR system module with its corresponding gasket. Start by disconnecting eight ignition coils, the generator support bracket and next proceed with heater coolant hose and eight fuel injector electrical connectors. The Knock Sensor (KS) electrical connector along with its retainers need to be disconnected before removing the upper radiator coolant hose. Start by removing the thermostat housing combined with its O-ring seal before proceeding to detach the thermostat while removing the nine intake manifold bolts. It is necessary to pull out the intake manifold carefully through the passenger section while removing both right-hand and left-hand intake manifold gaskets. Before installing the parts you must clean the sealing areas using a plastic tool and metallurgical treatment. The intake manifold should be replaced if metal fragments are discovered inside its structure. The installation requires the placement of new gaskets between the intake manifold and its positioning followed by a loose procedure for placing nine bolts and a 10 Nm (89 lb-in) torque sequence according to specification. Place the thermostat along with its new O-ring and install the thermostat housing while tightening its bolts to 25 Nm (18 lb-ft). Connect the upper radiator hose along with KS electrical connector and eight fuel injector electrical connectors. The heater coolant hose should be connected first followed by generator support bracket installation with four bolts tightened to 10 Nm (89 lb-in). Finally, reinstall the eight ignition coils. Clean the EGR valve sealing area and apply a new EGR system module gasket before screwing the EGR system module with two bolts that reach a torque of 25 Nm (18 lb-ft) first and then 90 degrees additional tightening. Install the exhaust manifold-to-EGR system module tube then fasten it to 42 Nm (31 lb-ft) torque specification before connecting the vacuum tube assembly along with the EGR system module electrical connector. You should install the throttle body with new gasket while securing four bolts by following a two-step procedure of positioning them to 9 Nm (80lb in) before adding a 90 degree turn. Reconnect all electrical wires for the ETC and PCV heater element together with any necessary auxiliary heater hoses equipped to the system. The technician should place the transmission fluid filler tube in position before tightening the transmission bolt to 10 Nm (89 lb-in) and the front transmission fluid filler tube support bracket bolt to 28 Nm (21 lb-ft). Reattach the PCV tube and fuel supply tube quick connect coupling followed by return of the engine cover as well as air cleaner assembly and outlet pipe. Complete the procedure by reconnecting the battery ground cable then executing engine cooling system fillup with bleeding procedure.