Here's a general outline of the process. The specifics might vary slightly depending on the engine (e.g., 4 cylinder vs. 6 cylinder).
1. Preparation:
* Safety First: Disconnect the negative battery terminal. This prevents accidental shorts.
* Gather Tools: You'll need a variety of sockets, wrenches (metric), screwdrivers (Phillips and flathead), pliers, a torque wrench, and possibly a breaker bar for stubborn bolts. A shop manual will list specific socket sizes.
* Work Area: Work in a clean, well-lit area. Have plenty of rags handy to catch spilled fluids.
* Gather Containers: Have containers ready to collect coolant, oil, and any other fluids that might spill.
2. Disconnect Components:
* Intake Air System: Disconnect the air filter housing, air intake tube, and any other components connected to the intake manifold.
* Fuel System: Disconnect the fuel lines. This is crucial; fuel under pressure can be dangerous. You might need to relieve pressure in the fuel system before disconnecting the lines. Consult your repair manual for the correct procedure.
* Coolant System: Drain the coolant from the engine. This is essential because the intake manifold is usually integrated with the coolant passages.
* Throttle Cable & Linkage: Disconnect the throttle cable and any linkages connected to the throttle body.
* Vacuum Hoses: Disconnect all vacuum hoses connected to the intake manifold. Carefully label them if you're not sure where they go.
* Electrical Connectors: Disconnect any electrical connectors attached to the manifold, such as those for sensors (e.g., MAP sensor, temperature sensors). Again, labeling is critical.
* Exhaust Manifold Gaskets: If the exhaust manifold bolts to the intake manifold, these will need to be removed carefully. Be prepared for potential stubborn bolts.
* Sensors: Remove any sensors mounted on the intake manifold.
3. Remove the Intake Manifold:
* Intake Manifold Bolts: Carefully remove all the bolts holding the intake manifold to the engine block. These bolts are often difficult to access, requiring patience and the right tools. Pay close attention to their location and orientation for reassembly.
* Lift Off: Once all the bolts are removed, gently lift the intake manifold off the engine. It's usually a relatively heavy piece. Be careful not to damage any gaskets or engine components.
4. Cleaning and Inspection:
* Clean Surfaces: Clean the mating surfaces of the engine block and intake manifold. Make sure they are free from any debris or gasket material.
* Inspect Gaskets: Inspect the old gaskets for any damage. Replace them with new ones during reassembly.
5. Reassembly:
* Installation: Reassembly is the reverse of removal. Follow the same steps in reverse order.
* Torque Specifications: Use a torque wrench to tighten all bolts to the manufacturer's specified torque settings. This is essential to prevent leaks and damage.
* Double-Check: Double-check all connections and hoses to ensure everything is properly connected and secured.
6. Refill and Test:
* Refill Coolant: Refill the engine's cooling system with the correct type and amount of coolant.
* Check for Leaks: Inspect for leaks around the intake manifold after starting the engine.
Important Considerations:
* Repair Manual: This is absolutely crucial. A Haynes or Chilton manual (or a factory service manual) specific to your 1994 Ford Falcon ED will provide detailed instructions, diagrams, torque specifications, and other vital information.
* Professional Help: If you're not comfortable performing this task, it's best to seek help from a qualified mechanic. Improperly installing the intake manifold can lead to serious engine damage.
This is a general guide. The exact procedure may differ based on the specific engine in your Falcon ED. Always consult your repair manual for accurate and detailed instructions before attempting this repair.
