Thunderbird V8-302 5.0L HO (1992)
Intake Manifold: Service and Repair
1.
Disconnect battery ground cable and drain cooling system, then disconnect accelerator cable and speed control linkage from throttle body.
2.
Disconnect transmission cable and remove accelerator cable bracket.
3.
Disconnect vacuum lines at intake manifold fitting.
4.
Disconnect spark plug wires. Remove wires and bracket assembly from rocker arm cover attaching stud. Remove distributor cap, adapter and
spark plug wire assembly.
5.
Relieve fuel system pressure, then disconnect fuel lines.
6.
Disconnect distributor wiring connector, then remove distributor hold-down bolt. Remove distributor.
7.
Disconnect upper radiator hose from coolant outlet housing and water temperature sending unit wire at sending unit.
8.
Disconnect hose from intake manifold and two throttle body cooler hoses.
9.
Loosen clamp on water pump bypass hose at coolant outlet housing and slide hose off of housing. Disconnect wires at ECT, ACT, TP, ISC
solenoid and EGR sensors.
10.
Disconnect injector wire connections and fuel charging assembly wiring.
11.
Pull PCV valve out of grommet at rear of lower intake manifold. Disconnect fuel evaporative purge hose from plastic connector at front of upper
intake manifold.
12.
Remove upper intake manifold.
13.
Remove heater tube assembly from lower intake manifold.
14.
Remove lower intake manifold. It may be necessary to pry manifold away from cylinder head.
15.
Avoid possible damage to gasket sealing surfaces. Remove intake manifold gaskets and seals.
16.
Reverse procedure to install, noting the following:
a. Apply a 1/16 inch bead of sealer to outer end of each intake manifold seal for the full width of seal (four places).
Intake Manifold Tightening Sequence
b. Torque intake manifold bolts to 15-20 ft lb in sequence.
c. Following installation, fill and bleed cooling system, then adjust ignition timing.
d. Operate engine at fast idle and check all hose connections and gaskets for leaks. When engine temperatures have stabilized, tighten intake
manifold bolts to 23-25 ft lb.
