Expedition 2WD V8-5.4L (2009)
12. Disconnect the Throttle Position (TP) sensor and Electronic Throttle Control (ETC) electrical connectors.
13. Disconnect the heated PCV element electrical connector.
14. Disconnect the 4 LH ignition coil and the LH Variable Camshaft Timing (VCT) solenoid electrical connectors and detach the 2 engine wiring
harness retainers from the LH valve cover studs.
15. Disconnect the intake manifold vacuum tube from the brake booster vacuum hose.
16. NOTE: The intake manifold vacuum tube must be removed with the intake manifold as an assembly.
Disconnect the intake manifold vacuum tube from the LH valve cover studbolt and the support bracket at the rear of the LH cylinder head.
17. Remove the 10 intake manifold bolts.
18. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
Remove the 3 bolts, the coolant crossover manifold assembly and discard the gaskets.
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Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
19. NOTE: The intake manifold vacuum tube must be positioned under the engine wiring harness and removed with the intake manifold as an
assembly.
Position the intake forward to gain access to the wiring harness retainers.
20. Disconnect the 2 engine wiring harness retainers from the rear of the intake manifold.
21. Disconnect the Cylinder Head Temperature (CHT) sensor jumper harness electrical connector retainer.
22. NOTICE: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools
cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.
NOTE: The intake manifold vacuum tube must be positioned under the engine wiring harness and removed with the intake manifold as an
assembly.
Remove the intake manifold and discard the gaskets.
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Clean and inspect the sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
Installation
1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the
intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in
engine damage.
NOTE: The intake manifold vacuum tube must be positioned under the engine wiring harness during installation of the intake manifold.
Using new intake manifold gaskets, position the intake manifold.
2. Position the intake manifold forward and connect the CHT sensor jumper harness electrical connector retainer.
3. Connect the 2 engine wiring harness retainers to the rear of the intake manifold and position back the intake manifold assembly.
4. Using new gaskets, position the coolant crossover manifold assembly and install the 3 bolts.
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Tighten to 10 Nm (89 lb-in).
5. Install the 10 intake manifold bolts and tighten in 2 stages in the sequence shown.
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Stage 1: Tighten to 2 Nm (18 lb-in).
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Stage 2: Tighten to 10 Nm (89 lb-in).
