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Old 08-15-2012, 08:46 PM   #1
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Default 2001 intake manifold

Ive looked several places to find the information I need and haven't been able to find it. I'm having to replace the intake manifold on my truck. It's a 2001 super crew lariat with the 5.4. I'm looking for "directions" on how to take everything apart and replace the manifold and how to put everything back together. Any help is greatly appreciated.
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Old 08-16-2012, 10:40 AM   #2
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1-bleed off fuel pressure
2-drain coolant
3-disconnect all vacuum hoses and both heater hoses
3-disconnect both fuel lines and air intake ducts
4-disconnect throttle linkage and battery neg. connector
5-remove egr tube
6-disconnect all wiring connectors
7-unbolt manifold and remove it
8-thoruoghly clean all gasket surfaces
9-install new gasket
10-reinstall manifold and torque to specs.
11-reverse dissassembly procedure and refill with coolant.
12-change engine oil before starting

I don't think I left anything out.
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Old 08-16-2012, 10:02 PM   #3
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part 1


Removal

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited. Failure to follow these instructions may result in personal injury.


  1. Disconnect the battery ground cable.
  2. Relieve the fuel system pressure.
  3. Drain the engine cooling system.
  4. Remove the engine air cleaner (ACL) and the air cleaner outlet tube.

Click the image to open in full size.



  1. Compress and slide the hose clamp and disconnect the upper radiator hose.

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  1. Remove the accelerator cable snow shield.
  1. Remove the bolts.
  2. Remove the accelerator cable snow shield.

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  1. Disconnect the throttle body cam.
  1. Disconnect the accelerator cable.
  2. Disconnect the speed control actuator cable.
  3. Remove the accelerator return spring.

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  1. Remove the accelerator cable bracket bolts and position the bucket and cables aside.

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  1. Disconnect the vapor management valve hose.

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  1. Remove the crankcase ventilation tube and the idle air control (IAC) valve fresh air tube.

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  1. Disconnect the exhaust gas recirculation (EGR) valve vacuum line and the main vacuum harness.

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  1. Disconnect the throttle position sensor electrical connector and the engine vacuum regulator electrical and vacuum connectors.

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  1. Disconnect the fuel pressure regulator vacuum line.

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Disconnect the vapor management valve vacuum line
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Old 08-16-2012, 10:05 PM   #4
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part 2



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  1. Disconnect the differential pressure feedback EGR.

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  1. Remove the bolt and disconnect the brake booster vacuum line and bracket.

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  1. Remove the nut.
  2. Disconnect the fuel lines.

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  1. Disconnect the idle air control (IAC) motor electrical connector.

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  1. Position the EGR valve to exhaust manifold tube aside.
    • Disconnect the upper fitting.
    • Loosen the lower fitting.
    • Disconnect the two differential pressure feedback EGR sensor hoses.
    • Position the tube aside.

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  1. Remove the four bolts and remove the throttle body adapter.

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  1. Disconnect and remove the positive crankcase ventilation (PCV) hose.

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  1. Position the power steering reservoir aside.
    • Remove the upper bolt.
    • Remove the lower bolts.
    • Position the reservoir aside.

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  1. Disconnect the eight fuel injectors.
  2. Disconnect and remove the eight ignition coils.
  3. Remove the generator.

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  1. Disconnect the heater hose.
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Old 08-16-2012, 10:07 PM   #5
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part 3


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  1. Disconnect the two radio interference capacitors.
  2. Remove the water thermostat.

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  1. Remove the nine bolts.

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  1. Remove the upper intake manifold.
    • Lift the intake manifold.
    • Disconnect the intake manifold tuning valve connector.
    • Remove the intake manifold and discard the gaskets.

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  1. If required, remove the bolts and the water crossover.
Installation


  1. CAUTION: Do not use metal scrapers, power abrasive discs or any abrasive means to clean the sealing surfaces, these tools cause scratches and gouges that make leak paths. Use a plastic scraper only.
Clean all the sealing surfaces.


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  1. If removed, install the water crossover.

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  1. Install the intake manifold.
  1. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts. Do not tighten the thermostat housing bolts during thermostat installation.
Install the water thermostat.


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  1. Tighten the 11 bolts in two stages in the sequence shown.
    • Stage 1: Tighten to 2 Nm (18 inch lbs.) .
    • Stage 2: Tighten to 10 Nm (89 inch lbs.) .

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  1. Connect the two radio ignition interference capacitor electrical connectors.

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  1. Connect the heater hose.
  2. Install the generator.
  3. Install and connect eight ignition coils.

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  1. Connect the eight fuel injector electrical connectors.
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Old 08-16-2012, 10:09 PM   #6
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part 4



Click the image to open in full size.



  1. Install the power steering reservoir.
    • Position the reservoir.
    • Install the two lower bolts.
    • Install the upper bolt.

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  1. Install the PCV hose.

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  1. Install the throttle body adapter and the four bolts. Tighten the bolts in two stages.
    • Stage 1: Tighten to 10 Nm 89 (inch lbs.) .
    • Stage 2: Tighten an additional 90 degrees.

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  1. Install the EGR valve to exhaust manifold tube.
    • Hand-tighten the fittings.
    • Tighten the upper fitting.
    • Tighten the lower fitting.
    • Connect the two differential pressure feedback EGR sensor hoses.

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  1. Connect the idle air control motor.
  2. Connect the fuel lines.

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  1. Install the nut.

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  1. Connect the brake booster vacuum line and bracket and install the bolt.

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  1. Connect the differential pressure feedback EGR sensor electrical connector.

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  1. Connect the vapor management valve vacuum line.

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  1. Connect the fuel pressure regulator vacuum line.
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Old 08-16-2012, 10:11 PM   #7
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part 5 and final



Click the image to open in full size.



  1. Connect the throttle position sensor connector and the engine vacuum regulator electrical and vacuum connectors.

Click the image to open in full size.



  1. Connect the EGR valve the main vacuum harness vacuum connections.

Click the image to open in full size.



  1. Install the crankcase ventilation tube and the IAC fresh air tube.

Click the image to open in full size.



  1. Connect the vapor management hose.

Click the image to open in full size.



  1. Install the accelerator cable bracket and the bolts.

Click the image to open in full size.



  1. Connect the throttle body cam.
  1. Connect the accelerator cable.
  2. Connect the speed control actuator cable.
  3. Install the throttle return spring.

Click the image to open in full size.



  1. Install the accelerator cable snow shield and the bolts.

Click the image to open in full size.



  1. Connect the upper radiator hose and position the clamp.
  2. Install the engine air cleaner and the air cleaner outlet tube.
  3. Connect the battery ground cable.
  4. Fill and bleed the engine cooling system.
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Old 08-16-2012, 10:19 PM   #8
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its kind of a bitch to disconnect the fuel lines. in fact i am not mechanical but once i got the fuel line disconnected everything else was easy. you will need a special tool thats a few bucks and a lot of patience, also some deep creep or wd40 to spray into the fitting

once you get the intake off might as well replace the plugs since it will be simple and easy. but becarefull not to strip the threads. i also replaced the coils and the injectors while i was in there. a local shop wanted 350-400 for labor since i did it myself i put that money in to new parts.

i have never done anything like this before and was able to do it so go for it.
also- the new intake (dont remeber who made it, i think dorman) looks total different than the original but works perfect with the gaskets already installed
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Old 08-16-2012, 10:20 PM   #9
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Default Can you make it any clearer?

maybe come to my house and do it for me? Good grief- nice post! That's exceptional help for someone who needed it. Very nice.

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Old 08-16-2012, 10:27 PM   #10
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If i can do it anyone can
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Old 08-16-2012, 10:27 PM
 
 
 
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