Ford Falcon. Manual — part 149

303-01c-17

Engine — V8 (4V)

303-01c-17

DIAGNOSIS AND TESTING

Engine

For basic engine mechanical concerns, refer to

Section 303-00. For driveability concerns, Refer to
Powertrain Control/Module in Section 303-14.

G89772 en

303-01c-18

Engine — V8 (4V)

303-01c-18

IN-VEHICLE REPAIR

4. Tighten the bolts to 8-12 Nm (89 lb-in) in the

Intake Manifold Upper

sequence shown.

Removal
All vehicles

1. Disconnect the battery ground cable. For

additional information, refer to Section 414-01.

2. Remove PCV hose from LH valve cover.
3. Remove the air cleaner outlet from throttle body.

For additional information, refer to Section

303-12.

4. Disconnect the electrical connectors from throttle

body motor.

5. Disconnect the electrical connectors from the

MAP sensor.

All vehicles

5. Fit the appearance plate to the top of the manifold

1. Remove the screws and bracket for alternator

cover with four (4) screws.

support.

NOTE: Allow engine to sit unstarted for min 2 hrs

to allow manifold to seal.

2. Remove the four (4) appearance plate screws and

lift the appearance plate off.

O-Ring is now used.

3. Remove the eight (8) upper manifold mounting

6. Fit the alternator mounting bracket with four (4)

screws.

screws.

4. Disconnect brake booster hose from brake

7. Connect the brake booster vacuum line to brake

booster.

booster.

5. Lift upper intake manifold from throttle body,

8. Fit electrical connectors to throttle body motor.

resting LHS on lower manifold. Release the quick

9. Fit electrical connector to MAP sensor.

connectors for purge and PCV tubes and remove

the tubes.

10. Fit air cleaner tube to throttle body.

6. Disconnect the brake booster vacuum line from

11. Install PCV hose to LH valve cover.

brake booster.

12. Connect the battery ground cable. For additional

7. Remove the bolts and the upper intake manifold.

information, refer to Section 414-01.

8. Remove the intake gasket.

13. Refill the engine cooling system. For additional

information, refer to Section 303-03.

CAUTION: Do not use metal scrapers,

NOTE: If this procedure is being performed in

wire brushes, power abrasive discs or other

conjunction with the engine installation procedure,

abrasive means to clean the sealing surfaces.

do not fill the engine cooling system at this time.

These tools cause scratches and gouges

which make leak paths. Use a plastic scraping

Intake Manifold — Lower

tool to remove all traces of old sealant.

Clean and inspect the sealing surfaces.

Removal

Installation

1. Remove the upper intake manifold. For additional

1. Apply

intake

sealant.

information, refer to Intake Manifold — Upper.

2. Position upper intake manifold and loosely install

2. Disconnect the fuel lines. For additional

new bolts.

information, refer to Section 310-00.

3. Install purge and PCV tube connections by

pushing tubes onto quick connectors.
NOTE: Ensure quick connectors are on the upper

manifold before installing upper to lower.

G89773 en

303-01c-19

Engine — V8 (4V)

303-01c-19

IN-VEHICLE REPAIR (Continued)

3. Disconnect the electrical connector from the water 6. Remove the bolts and the radio ignition

temperature indicator sender.

interference capacitors.

4. Disconnect the eight fuel injectors.

7. Remove the gaskets, install new gaskets.

5. Remove the bolts and lower intake manifold.

8. Clean the sealing surfaces.

CAUTION: 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.

G89774 en

303-01c-20

Engine — V8 (4V)

303-01c-20

IN-VEHICLE REPAIR (Continued)

Installation

4. Tighten the retaining bolts to 8-10 Nm in following

order.

1. Install the lower intake gaskets.

2. Install the radio ignition interference capacitors.

5. Connect the water temperature indicator sensor.

3. Position the lower intake manifold. Loosely install

the retaining bolts.

6. Connect the eight fuel injectors.
7. Connect the fuel lines. For additional information,

refer to Section 310-00.

8. Install the upper intake manifold. For additional

information, refer to Intake Manifold—Upper in

this section.

Valve Cover — RH

Materials
Silicone Gasket and

WSE-M4G323-A4

Sealant

F7AZ-19554-EA or

equivalent

Removal and Installation
1. Remove surge tank from vehicle.
2. Disconnect brake lines from brake booster.
3. Partially drain the cooling system. For additional

information, refer to Section 303-03.

4. Disconnect the battery ground cable. For

additional information, refer to Section 414-01.

G89774 en