How do you take off a intake manifold - 1997 Mercury Grand Marquis

5.0L Engine

Disconnect the negative battery cable.



Drain the cooling system. Relieve the fuel system pressure; refer to Section 5.






CAUTION


When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.






Disconnect the accelerator cable and cruise control linkage, if equipped, from the throttle body. Disconnect the throttle valve cable, if equipped. Label and disconnect the vacuum lines at the intake manifold fitting.



Label and disconnect the spark plug wires from the spark plugs. Remove the wires and bracket assembly from the rocker arm cover attaching stud. Remove the distributor cap and wires assembly.



Detach the fuel lines (see Section 5) and the distributor wiring connector. Mark the position of the rotor on the distributor housing and the position of the distributor housing in the block. Remove the hold-down bolt and remove the distributor.



Disconnect the upper radiator hose from the thermostat housing and the water temperature sending unit wire from the sending unit. Disconnect the heater hose from the intake manifold and disconnect the 2 throttle body cooler hoses.



Disconnect the water pump bypass hose from the thermostat housing. Label and detach the connectors from the engine coolant temperature, air charge temperature, throttle position and EGR sensors and the idle speed control solenoid. Detach the injector wire connections and the fuel charging assembly wiring.



Remove the PCV valve from the grommet at the rear of the lower intake manifold. Detach the fuel evaporative purge hose from the plastic connector at the front of the upper intake manifold.



Remove the upper intake manifold cover plate and upper intake bolts. Remove the upper intake manifold.



Remove the heater tube assembly from the lower intake manifold studs. Remove the alternator and air conditioner braces from the intake studs. Disconnect the heater hose from the lower intake manifold.



Remove the lower intake manifold retaining bolts and remove the lower intake manifold.


If it is necessary to pry the intake manifold away from the cylinder heads, be careful to avoid damaging the gasket sealing surfaces.






Lower intake manifold installation—5.0L engine








Lower intake manifold bolt torque sequence—5.0L engine






Upper intake manifold installation—5.0L engine






Apply sealer as shown during intake manifold installation—5.0L and 5.8L engines



To install:





Clean all gasket mating surfaces. Apply a 1/8 in. (3mm) bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads.



Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the cylinder heads.



Apply a 3/16 in. (5mm) bead of sealer to the outer end of each intake manifold seal for the full width of the seal.



Using guide pins to ease installation, carefully lower the intake manifold into position on the cylinder block and cylinder heads.


After the intake manifold is in place, run a finger around the seal area to make sure the seals are in place. If the seals are not in place, remove the intake manifold and position the seals.





Make sure the holes in the manifold gaskets and the manifold are in alignment. Remove the guide pins. Install the intake manifold attaching bolts and tighten, in sequence, to 23-25 ft. lbs. (31-34 Nm).



If required, install the heater tube assembly to the lower intake manifold studs.



Install the water pump bypass hose and upper radiator hose on the thermostat housing. Install the hoses to the heater tubes and intake manifold. Connect the fuel lines.



Install the distributor, aligning the housing and rotor with the marks that were made during removal. Install the distributor cap. Position the spark plug wires in the harness brackets on the rocker arm cover attaching stud and connect the wires to the spark plugs.



Install a new gasket and the upper intake manifold. Tighten the bolts to 12-18 ft. lbs. (16-24 Nm). Install the cover plate and connect the crankcase vent tube.



Connect the accelerator, throttle valve cable and cruise control cable, if equipped, to the throttle body. Connect the electrical connectors and vacuum lines to their proper locations.



Attach the coolant hoses to the EGR spacer. Fill the cooling system.



Connect the negative battery cable, start the engine and check for leaks. Check the ignition timing.



Operate the engine at fast idle. When engine temperatures have stabilized, tighten the intake manifold bolts to 23-25 ft. lbs. (31-34 Nm).



Connect the air intake duct and the crankcase vent hose.

5.0L Engine


Disconnect the negative battery cable.

Drain the cooling system. Relieve the fuel system pressure; refer to Section 5.

CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.


Disconnect the accelerator cable and cruise control linkage, if equipped, from the throttle body. Disconnect the throttle valve cable, if equipped. Label and disconnect the vacuum lines at the intake manifold fitting.

Label and disconnect the spark plug wires from the spark plugs. Remove the wires and bracket assembly from the rocker arm cover attaching stud. Remove the distributor cap and wires assembly.

Detach the fuel lines (see Section 5) and the distributor wiring connector. Mark the position of the rotor on the distributor housing and the position of the distributor housing in the block. Remove the hold-down bolt and remove the distributor.

Disconnect the upper radiator hose from the thermostat housing and the water temperature sending unit wire from the sending unit. Disconnect the heater hose from the intake manifold and disconnect the 2 throttle body cooler hoses.

Disconnect the water pump bypass hose from the thermostat housing. Label and detach the connectors from the engine coolant temperature, air charge temperature, throttle position and EGR sensors and the idle speed control solenoid. Detach the injector wire connections and the fuel charging assembly wiring.

Remove the PCV valve from the grommet at the rear of the lower intake manifold. Detach the fuel evaporative purge hose from the plastic connector at the front of the upper intake manifold.

Remove the upper intake manifold cover plate and upper intake bolts. Remove the upper intake manifold.

Remove the heater tube assembly from the lower intake manifold studs. Remove the alternator and air conditioner braces from the intake studs. Disconnect the heater hose from the lower intake manifold.

Remove the lower intake manifold retaining bolts and remove the lower intake manifold.

If it is necessary to pry the intake manifold away from the cylinder heads, be careful to avoid damaging the gasket sealing surfaces.


Lower intake manifold installation—5.0L engine



Lower intake manifold bolt torque sequence—5.0L engine


Upper intake manifold installation—5.0L engine


Apply sealer as shown during intake manifold installation—5.0L and 5.8L engines

To install:

Clean all gasket mating surfaces. Apply a 1/8 in. (3mm) bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads.

Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the cylinder heads.

Apply a 3/16 in. (5mm) bead of sealer to the outer end of each intake manifold seal for the full width of the seal.

Using guide pins to ease installation, carefully lower the intake manifold into position on the cylinder block and cylinder heads.

After the intake manifold is in place, run a finger around the seal area to make sure the seals are in place. If the seals are not in place, remove the intake manifold and position the seals.

Make sure the holes in the manifold gaskets and the manifold are in alignment. Remove the guide pins. Install the intake manifold attaching bolts and tighten, in sequence, to 23-25 ft. lbs. (31-34 Nm).

If required, install the heater tube assembly to the lower intake manifold studs.

Install the water pump bypass hose and upper radiator hose on the thermostat housing. Install the hoses to the heater tubes and intake manifold. Connect the fuel lines.

Install the distributor, aligning the housing and rotor with the marks that were made during removal. Install the distributor cap. Position the spark plug wires in the harness brackets on the rocker arm cover attaching stud and connect the wires to the spark plugs.

Install a new gasket and the upper intake manifold. Tighten the bolts to 12-18 ft. lbs. (16-24 Nm). Install the cover plate and connect the crankcase vent tube.

Connect the accelerator, throttle valve cable and cruise control cable, if equipped, to the throttle body. Connect the electrical connectors and vacuum lines to their proper locations.

Attach the coolant hoses to the EGR spacer. Fill the cooling system.

Connect the negative battery cable, start the engine and check for leaks. Check the ignition timing.

Operate the engine at fast idle. When engine temperatures have stabilized, tighten the intake manifold bolts to 23-25 ft. lbs. (31-34 Nm).

Connect the air intake duct and the crankcase vent hose.

5.8L Engine

Disconnect the negative battery cable and drain the cooling system.

Remove the air cleaner, crankcase ventilation hose and intake duct assembly. If equipped, disconnect the automatic choke heat tube.



Disconnect the accelerator cable and cruise control linkage, if equipped, from the carburetor. Disconnect the throttle valve rod, if equipped, and remove the accelerator cable bracket.



Tag and disconnect the vacuum lines at the intake manifold and the wires from the coil.



Tag and disconnect the spark plug wires from the spark plugs. Remove the wires and bracket assembly from the rocker arm cover attaching stud. Remove the distributor cap and spark plug wires assembly.



Remove the carburetor fuel inlet line.



Detach the vacuum hoses and the wiring connector from the distributor. Mark the position of the rotor on the distributor housing and the position of the distributor housing in the block. Remove the hold-down bolt and remove the distributor.



Disconnect the upper radiator hose at the thermostat housing and the water temperature sending unit wire at the sending unit. Disconnect the heater hose from the intake manifold. Disconnect the EGR cooler T-fitting from the heater return hose, if equipped.



Disconnect the water pump bypass hose at the thermostat housing. Disconnect the crankcase vent hose at the rocker arm cover. Disconnect the fuel evaporative purge tube, if equipped.



Remove the intake manifold and carburetor as an assembly.


If it is necessary to pry the intake manifold away from the cylinder heads, be careful to avoid damaging the gasket sealing surfaces.







Intake manifold and gaskets—5.8L engine






Intake manifold bolt torque sequence—5.8L engine



To install:





Clean all gasket mating surfaces. Apply a 1/8 in. bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads.



Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the cylinder heads.



Apply a 3/16 in. bead of sealer to the outer end of each intake manifold seal for the full width of the seal.



Using guide pins to ease installation, carefully lower the intake manifold into position on the cylinder block and cylinder heads.


After the intake manifold is in place, run a finger around the seal area to make sure the seals are in place. If the seals are not in place, remove the intake manifold and position the seals.





Make sure the holes in the manifold gaskets and the manifold are in alignment. Remove the guide pins. Install the intake manifold attaching bolts and tighten, in sequence, to 23-25 ft. lbs. (31-34 Nm).



Install the water pump bypass hose on the thermostat housing. Connect the upper radiator hose and the heater hose. Install the carburetor fuel line.



Install the distributor, aligning the distributor housing and rotor with the marks that were made during removal. Install the distributor cap. Position the spark plug wires in the harness brackets on the rocker arm cover attaching stud and connect the wires to the spark plugs.



Connect the crankcase vent tube. Connect the coil wire and primary wiring connector.



Connect the accelerator cable and cable bracket. Connect the throttle valve rod and the cruise control linkage, if equipped.



Attach all electrical connections and vacuum lines detached during removal. Fill the cooling system.



Connect the negative battery cable, start the engine and check for leaks. Adjust the ignition timing and connect the vacuum hoses to the distributor.



Operate the engine at fast idle. When engine temperatures have stabilized, tighten the intake manifold bolts to 23-25 ft. lbs. (31-34 Nm).



Connect the air cleaner and intake duct assembly and the crankcase vent hose.

5.8L Engine


Disconnect the negative battery cable and drain the cooling system.

CAUTION When draining the coolant, keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze, and are quite likely to drink any that is left in an uncovered container or in puddles on the ground. This will prove fatal in sufficient quantity. Always drain the coolant into a sealable container. Coolant should be reused unless it is contaminated or several years old.


Remove the air cleaner, crankcase ventilation hose and intake duct assembly. If equipped, disconnect the automatic choke heat tube.

Disconnect the accelerator cable and cruise control linkage, if equipped, from the carburetor. Disconnect the throttle valve rod, if equipped, and remove the accelerator cable bracket.

Tag and disconnect the vacuum lines at the intake manifold and the wires from the coil.

Tag and disconnect the spark plug wires from the spark plugs. Remove the wires and bracket assembly from the rocker arm cover attaching stud. Remove the distributor cap and spark plug wires assembly.

Remove the carburetor fuel inlet line.

Detach the vacuum hoses and the wiring connector from the distributor. Mark the position of the rotor on the distributor housing and the position of the distributor housing in the block. Remove the hold-down bolt and remove the distributor.

Disconnect the upper radiator hose at the thermostat housing and the water temperature sending unit wire at the sending unit. Disconnect the heater hose from the intake manifold. Disconnect the EGR cooler T-fitting from the heater return hose, if equipped.

Disconnect the water pump bypass hose at the thermostat housing. Disconnect the crankcase vent hose at the rocker arm cover. Disconnect the fuel evaporative purge tube, if equipped.

Remove the intake manifold and carburetor as an assembly.

If it is necessary to pry the intake manifold away from the cylinder heads, be careful to avoid damaging the gasket sealing surfaces.



Intake manifold and gaskets—5.8L engine


Intake manifold bolt torque sequence—5.8L engine

To install:

Clean all gasket mating surfaces. Apply a 1/8 in. bead of silicone sealer to the points where the cylinder block rails meet the cylinder heads.

Position new seals on the cylinder block and new gaskets on the cylinder heads with the gaskets interlocked with the seal tabs. Make sure the holes in the gaskets are aligned with the holes in the cylinder heads.

Apply a 3/16 in. bead of sealer to the outer end of each intake manifold seal for the full width of the seal.

Using guide pins to ease installation, carefully lower the intake manifold into position on the cylinder block and cylinder heads.

After the intake manifold is in place, run a finger around the seal area to make sure the seals are in place. If the seals are not in place, remove the intake manifold and position the seals.

Make sure the holes in the manifold gaskets and the manifold are in alignment. Remove the guide pins. Install the intake manifold attaching bolts and tighten, in sequence, to 23-25 ft. lbs. (31-34 Nm).

Install the water pump bypass hose on the thermostat housing. Connect the upper radiator hose and the heater hose. Install the carburetor fuel line.

Install the distributor, aligning the distributor housing and rotor with the marks that were made during removal. Install the distributor cap. Position the spark plug wires in the harness brackets on the rocker arm cover attaching stud and connect the wires to the spark plugs.

Connect the crankcase vent tube. Connect the coil wire and primary wiring connector.

Connect the accelerator cable and cable bracket. Connect the throttle valve rod and the cruise control linkage, if equipped.

Attach all electrical connections and vacuum lines detached during removal. Fill the cooling system.

Connect the negative battery cable, start the engine and check for leaks. Adjust the ignition timing and connect the vacuum hoses to the distributor.

Operate the engine at fast idle. When engine temperatures have stabilized, tighten the intake manifold bolts to 23-25 ft. lbs. (31-34 Nm).

Connect the air cleaner and intake duct assembly and the crankcase vent hose.