Intake Manifold: Removal

WARNING: This page is about a different car, the 2002 Ford Escape. However, it is still accessible from the selected car via links, so may be relevant.

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 may be ignited. Failure to follow these instructions may result in personal injury.

WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury.

Release the fuel system pressure. For additional information, refer to REMOVAL, OVERHAUL & INSTALLATION .
Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the air cleaner outlet pipe..
Using the special tool, disconnect the fuel tube.

Fig 1: Disconnecting Fuel Tube
Courtesy of FORD MOTOR CO.
Disconnect the accelerator cable and, if equipped, the speed control actuator cable.

Fig 2: Disconnecting Accelerator Cable & Speed Control Actuator Cable
Courtesy of FORD MOTOR CO.
Disconnect the fuel pulse damper vacuum hose.

Fig 3: Disconnecting Fuel Pulse Damper Vacuum Hose
Courtesy of FORD MOTOR CO.
Disconnect the fuel injector electrical connectors.
- Remove the harness from the valve cover stud bolt.
Fig 4: Disconnecting Fuel Injector Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the throttle position (TP) sensor electrical connector.

Fig 5: Disconnecting Throttle Position (TP) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Disconnect the idle air control (IAC) electrical connector and unclip the harness from the bracket.

Fig 6: Disconnecting Idle Air Control (IAC) Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the main engine control sensor wiring connector from the mounting bracket.

Fig 7: Removing Main Engine Control Sensor Wiring Connector
Courtesy of FORD MOTOR CO.
Disconnect the powertrain control module (PCM) wire harness from the bracket.

Fig 8: Disconnecting Powertrain Control Module (PCM) Wire Harness From Bracket
Courtesy of FORD MOTOR CO.
Disconnect the heated oxygen sensor (HO2S) wiring harness from the bracket.

Fig 9: Disconnecting Heated Oxygen Sensor (HO2S) Wiring Harness From Bracket
Courtesy of FORD MOTOR CO.
Remove the HO2S wiring harness retainer.

Fig 10: Removing HO2S Wiring Harness Retainer
Courtesy of FORD MOTOR CO.
Disconnect the cylinder head temperature (CHT) sensor electrical connector.

Fig 11: Disconnecting Cylinder Head Temperature (CHT) Sensor Electrical Connector
Courtesy of FORD MOTOR CO.
Detach the CHT sensor wiring harness from the clip, and remove the clip.

Fig 12: Detaching CHT Sensor Wiring Harness From Clip
Courtesy of FORD MOTOR CO.
Disconnect the brake booster vacuum supply hose.

Fig 13: Disconnecting Brake Booster Vacuum Supply Hose
Courtesy of FORD MOTOR CO.
Disconnect the four vacuum hoses.

Fig 14: Disconnecting Four Vacuum Hoses
Courtesy of FORD MOTOR CO.
Disconnect the positive crankcase ventilation (PCV) vacuum hose.

Fig 15: Disconnecting Positive Crankcase Ventilation (PCV) Vacuum Hose
Courtesy of FORD MOTOR CO.
Remove the exhaust gas recirculation (EGR) valve bolts.

Fig 16: Removing Exhaust Gas Recirculation (EGR) Valve Bolts
Courtesy of FORD MOTOR CO.

NOTE: Illustration shown with throttle body removed for clarity.

Fig 17: Identifying Intake Manifold Nuts & Bolts Removal Sequence

Courtesy of FORD MOTOR CO.

Remove the intake manifold.
- Remove the two nuts and five bolts in the sequence shown.
Remove the right side intake manifold stud.

Fig 18: Removing Right Side Intake Manifold Stud
Courtesy of FORD MOTOR CO.
Remove the intake manifold and the gaskets.
- Inspect the gaskets and discard if damaged.