Friday, March 16, 2012

How To Replace Intake Manifold On Ford Ranger?

Intake Manifold Replacing for Ford Ranger:----


Intake Manifold
REMOVAL & INSTALLATION Details are as follows:---

3.0L Engine
Lower Manifold
Specific to:
Ford Ranger 2008
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the engine cooling system.
  3. Remove both the valve covers.
  4. Disconnect the upper radiator hose, heater hose and coolant bypass hose.
  5. Disconnect the engine coolant temperature (ECT) sensor and coolant temperature sender electrical connectors.
  6. Disconnect the crankshaft position (CKP) sensor and detach the wiring from the stud bolt.
  7. Disconnect the fuel injector electrical connectors and position the engine control wiring aside.
  8. Release the fuel pressure and disconnect the fuel tube.
  9. Loosen the rocker arm bolts.
    NOTE
    Identify the location of each pushrod. Each pushrod is to be installed in the original location to prevent premature wear.
  10. Remove all the pushrods.
  11. Remove the bolts from the lower intake manifold.
    NOTE
    Gently loosen the intake manifold to separate the silicone sealant from the cylinder block.
  12. Remove the lower intake manifold.
  13. Remove and discard the intake manifold gaskets and end seals. 

    image
    Fig. Lower intake manifold-3.0L engine
To install:

NOTE
Clean and inspect all mating surfaces.


NOTE
If the lower intake manifold is not installed within four minutes, remove the sealant and reapply.

  1. Apply a drop of silicone gasket and sealant at the four cylinder block-to-cylinder head seams.

    Click image to see an enlarged view
    Fig. Apply a drop of silicone gasket and sealant at the four cylinder block-to-cylinder head seams
  2. Install the intake manifold gaskets and end seals.
  3. Position the lower intake manifold.
  4. Install the bolts and tighten in 2 stages in the sequence shown:

    Stage 1: Tighten to 11 ft. lbs. (15 Nm)
    Stage 2: Tighten to 24 ft. lbs. (32 Nm)

    Click image to see an enlarged view
    Fig. Lower intake manifold tightening sequence-3.0L engine
  5. Install the pushrods.
  6. Tighten the rocker arms to 24 ft. lbs. (32 Nm).
  7. Connect the fuel tube.
  8. Connect the fuel injector electrical connectors.
  9. Connect the Crankshaft Position (CKP) sensor and attach the wiring from the stud bolt.
  10. Connect the Engine Coolant Temperature (ECT) sensor and coolant temperature sender electrical connectors.
  11. Connect the upper radiator hose, heater hose and coolant bypass hose.
  12. Install both valve covers.
  13. Fill and bleed the engine cooling system.
  14. Start the engine and check for leaks, repair if necessary.
Upper Manifold
Specific to:
Ford Ranger 2008
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the battery ground cable.
  3. Remove the air cleaner outlet pipe.
  4. Remove the bolt and the snow shield.
  5. Disconnect the accelerator cable, speed control cable and the return spring.
  6. Disconnect the accelerator cable and speed control cable from the accelerator bracket.
  7. Disconnect the Throttle Position (TP) sensor and Idle Air Control (IAC) valve electrical connectors.
  8. Disconnect the engine vacuum harness-to-vacuum reservoir hose connection.
  9. Disconnect the exhaust manifold-to-EGR valve tube from the EGR valve.
  10. Disconnect the fuel vapor hose from the intake manifold.
  11. Disconnect the EGR vacuum regulator solenoid electrical connector.
  12. Disconnect the brake booster vacuum hose and the Positive Crankcase Ventilation (PCV) valve tube.
  13. Remove the oil level indicator tube bracket nut and position the tube and bracket out of the way.
  14. Remove the nut and the upper intake manifold brace.
  15. Remove the bolts, the stud bolt and the upper intake manifold.

    Click image to see an enlarged view
    Fig. Upper intake manifold-3.0L engine
  16. To install, reverse the removal procedure and note the following:

    Install new gaskets
    Tighten the manifold bolts and stud to 89 inch lbs. (10 Nm) in the sequence shown
    Tighten the upper intake manifold brace to 53 inch lbs. (6 Nm)
    Tighten the oil level indicator tube bracket nut to 13 ft. lbs. (18 Nm).

    Click image to see an enlarged view
    Fig. Upper intake manifold tightening sequence-3.0L engine
2.3L Engine
Specific to:
Ford Ranger 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Drain the engine cooling system.
  3. Release the fuel pressure.
  4. Remove the Air Cleaner (ACL) outlet pipe.
  5. Remove the 2 bolts and the Throttle Body (TB) shield.
  6. Disconnect the acceleration control cable from the intake manifold and the TB.
  7. If equipped, disconnect the speed control cable from the intake manifold and the TB.
  8. Disconnect the Throttle Position (TP) sensor electrical connector.
  9. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
  10. Disconnect the Idle Air Control (IAC) valve electrical connector.
  11. Disconnect the vapor purge tube quick connect coupling.
  12. Disconnect the engine vacuum harness, brake booster hose, the crankcase breather hose and the 2 coolant hoses.
  13. Disconnect 2 engine wiring harness pin-type retainers from the intake manifold.
  14. Disconnect the pin-type retainer from the rear of the intake manifold.
  15. Remove the EGR tube support bracket bolt.
  16. Remove the 2 bolts from the EGR tube flange.
  17. Detach the fuel supply tube and the electrical connectors from the bracket and disconnect the Evaporative Emission (EVAP) tube quick connect coupling.
  18. Disconnect the Knock Sensor (KS) electrical connector and disconnect the connector retainer from the intake manifold.
  19. Remove the wiring harness pushpin from the bottom of the intake manifold.
  20. Disconnect the fuel supply tube spring lock coupling.
    NOTE
    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.
  21. Remove the 5 bolts and the intake manifold.
  22. Clean the sealing surface of the cylinder head with silicone gasket remover and metal surface prep. Observe all warnings and cautions and follow all application directions contained on the packaging of the silicone gasket remover and metal surface prep.
  23. Remove and discard the 4 intake manifold gaskets.

    Click image to see an enlarged view
    Fig. Intake manifold-2.3L engine
To install:
  1. Install 4 new intake manifold gaskets.
  2. Position the intake manifold and install the 5 bolts. Tighten to 159 inch lbs. (18 Nm).
  3. Connect the wiring pushpin to the bottom of the intake manifold.
  4. Connect the KS connector retainer to the intake manifold and connect the electrical connector.
  5. Attach the electrical connectors and the fuel supply tube to the bracket and connect the EVAP tube quick connect coupling.
  6. Install the 2 EGR flange mounting bolts and tighten to 159 inch lbs. (18 Nm).
  7. Install the EGR tube support bracket bolt and tighten to 159 inch lbs. (18 Nm).
  8. Position the engine wiring harness and connect the 2 pin-type retainers.
  9. Connect the engine vacuum harness, brake booster hose, the crankcase breather hose and the 2 coolant hoses.
  10. Connect the IAC valve electrical connector and the fuel supply tube spring lock coupling.
  11. Connect the MAP sensor electrical connector.
  12. Connect the TP sensor electrical connector.
  13. Connect the acceleration control cable to the intake manifold and the TB.
  14. If equipped, connect the speed control cable to the intake manifold and the TB.
  15. Position the TB shield and install the 2 bolts.
  16. Install the ACL outlet tube.
  17. Fill and bleed the engine cooling system.
  18. Start the engine and check for leaks, repair if necessary.
4.0L Engine
Specific to:
Ford Ranger 2008-2009
  1. Before servicing the vehicle, refer to the Precautions Section.
  2. Disconnect the negative battery cable.
  3. Relieve the fuel system pressure.
  4. Remove the Air Cleaner (ACL) outlet pipe.
  5. Disconnect the accelerator cable from the Throttle Body (TB).
  6. If equipped, disconnect the speed control actuator cable from the TB.
  7. Disconnect the Throttle Position (TP) sensor electrical connector.
  8. Detach the wiring harness retainer.
  9. Disconnect the Idle Air Control (IAC) motor electrical connector.
  10. Disconnect the EGR valve vacuum hose connector.
  11. Disconnect the exhaust manifold-to-EGR valve tube from the EGR valve.
  12. Disconnect the Evaporative Emission (EVAP) purge valve-to-intake manifold hose from the intake manifold.
  13. Disconnect the EGR vacuum regulator solenoid electrical connector.
  14. Disconnect the EGR vacuum regulator solenoid vacuum connector.
  15. Disconnect the brake booster vacuum hose from the intake manifold.
    NOTE
    It is important to twist the spark plug wire boots while pulling upward to avoid possible damage to the spark plug wire.


    NOTE
    Spark plug wires must be connected to the correct ignition coil terminal. Mark the spark plug wire locations before removing them.
  16. Disconnect the RH spark plug wires from the ignition coil.
  17. Detach the RH spark plug wire retainer from the intake manifold and position the spark plug wires aside.
  18. Disconnect the ignition coil electrical connector.
  19. Detach the wiring harness retainer from the ignition coil bracket.
  20. Detach the accelerator cable retainer from the ignition coil bracket.
  21. Disconnect the radio interference capacitor electrical connector.
  22. Remove the 4 bolts and position the ignition coil and bracket aside.
  23. Disconnect the vacuum harness main vacuum connector from the intake manifold.
  24. Remove the wiring harness-to-cowl bracket nut.
  25. Disconnect the 3 PCM electrical connectors.
  26. Remove the wiring harness ground wire stud bolt and position the wiring harness aside.
  27. Detach the Knock Sensor (KS) electrical connector from the intake manifold.
  28. Loosen the 8 bolts and lift up the intake manifold.
  29. Remove the 2 heated PCV fitting bolts and detach the heated PCV fitting from the intake manifold.
  30. Remove the intake manifold.
  31. Inspect the intake manifold gaskets. Install new gaskets if necessary.
  32. To install, reverse the removal procedure and note the following:

    Tighten the 2 heated PCV fitting bolts to 71 inch lbs. (8 Nm).
    Tighten the 8 intake manifold to 89 inch lbs. (10 Nm).
    Tighten the wiring harness ground wire stud bolt to 89 inch lbs. (10 Nm).
    Tighten the ignition coil and bracket bolts, lower rear bolt to 21 ft. lbs. (28 Nm), lower front bolt to 17 ft. lbs. (23 Nm), 2 upper bolts to 71 inch lbs. (8 Nm).
    Tighten the exhaust manifold-to-EGR valve tube to 25 ft. lbs. (34 Nm).
  33. Start the engine and check for leaks, repair if necessary.

    Click image to see an enlarged view
    Fig. Intake manifold-4.0L engine



These details will help.
Thanks.

FOR MORE HELP GO TO: ---

Car repair guide?

http://technoanswers.blogspot.in/2012/03/car-repair-guide.html



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