Intake Manifold Assembly - 4.6L: Disassembly

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.

Remove the fuel infection supply manifold.

Fig 1: Removing Fuel Infection Supply Manifold
Courtesy of FORD MOTOR CO.
Remove the fuel injectors from the fuel injection supply manifold.

Fig 2: Removing Fuel Injectors From Fuel Injection Supply Manifold
Courtesy of FORD MOTOR CO.
Inspect the two O-ring seals from each fuel injector. Install new O-ring seals as needed.

Fig 3: Inspecting Two O-Ring Seals
Courtesy of FORD MOTOR CO.
Remove the engine noise shield.

Fig 4: Removing Engine Noise Shield
Courtesy of FORD MOTOR CO.
Remove the bolts.

Fig 5: Removing Bolts
Courtesy of FORD MOTOR CO.
Separate the upper and lower intake manifolds and discard the lower intake manifold gasket.

Fig 6: Separating Upper And Lower Intake Manifolds
Courtesy of FORD MOTOR CO.
Remove the bolts from the intake manifold tuning valve and remove the valve.

Fig 7: Removing Bolts From Intake Manifold Tuning Valve
Courtesy of FORD MOTOR CO.

CAUTION: If the engine has been internally damaged and metal or other foreign material has entered the manifold, it is recommended the manifold be discarded.

NOTE: If there is no residual gasket material present, metal surface prep can be used to clean and prepare the sealing surfaces.

Inspect all external and internal surfaces of the upper intake manifold.
- Inspect for cracks or other damage.
- Inspect for foreign material inside of the manifold.
- Clean the upper intake manifold sealing surfaces with silicone gasket remover and metal surface prep. Follow the directions on the packaging.
Allow the upper and lower intake manifolds to dry completely.