griffigr
Member
- Joined
- April 14, 2008
- Messages
- 18
- Reaction score
- 0
- City, State
- Grand Haven, MI
- Year, Model & Trim Level
- 1994 Explorer Sport
You can do this by yourself. I did it a couple of weeks ago, and I am by no means a mechanic. You may want to procure an alternate mode of transportation for a few days, though. This job does take a little time. I'll give you a step-by-step write up on how to do it, and how to save yourself a little money in the process. First, go to AutoZone or Advanced Auto Parts and pick up the lower intake gasket and valve cover gaskets. Do not buy the entire, all inclusive kit. Oddly enough, it is cheaper to purchase the valve cover gaskets and lower intake gasket separately. Both the Felpro valve cover kit and the Felpro lower intake gasket kit comes with the upper intake gasket, so there's no worry there. You'll just have an extra lying around when it's all said and done. You'll also need a 1 1/16" wrench to remove the EGR tube from the upper intake manifold. Invest in a grease pen (white or yellow) to label all connections and vacuum lines, as well. This will be crucial. You won't need to purchase any RTV sealant because the gaskets come with a tube of it. You will also want to invest in a hook set. This will aid in the removal of all the old plug connections without breaking them. After you've attained everything you need to do the job, pop your hood and label every plug and vacuum line connected to the upper intake. Label them in a way so that the male and female portions have the same label, as to avoid any confusion with re-assembly. Remove the air intake tube, disconnect the battery, and remove the throttle body shroud. You'll also want to remove the alternator, upper radiator hose and water neck, as you'll need the room. After that, remove all plugs and vacuum lines from the upper intake manifold, unscrew the EGR nut (this is much easier said than done), and remove all eight bolts connecting the upper intake manifold to the lower. After the upper intake is off, disconnect both fuel lines, unplug the fuel injector sensors (make sure to label these, as well), and remove the coil (with the brace) from the passenger side of the block. There is no need to remove the fuel rail or spark plug wires. Just make sure you label the location of the wires on the coil pack. Next, remove the valve cover gaskets. Remember to stuff rags inside the intake runners so that debris does not fall inside the motor. After the valve covers are off, cover the heads up with some shop rags to prevent dirt from falling inside. Next, remove all eight bolts from the lower intake manifold. Now, re-install the water neck to use as a handle to remove the lower intake. After the lower intake is out, scrape the mating surface of the block and lower intake, as well as the mating surface of the block and valve cover gaskets. Your goal is to remove all old gasket material and old silicone RTV. You will also want to scrape the underside of the lower intake manifold, as well. Next, apply a thick bead of RTV sealant on the front and rear of the block. This is the area where the gasket doesn't properly seal. Install your gasket, then bolt on the lower intake manifold. This is tricky. You have to make sure all lower intake bolts clear the designated holes on the gasket. Once you've gotten everything lined up and bolted down, re-assembly is a breeze.
