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Intake Manifold: Removal

    WARNING: Before servicing a vehicle equipped with a fire suppression system, depower the system by following the procedure in FIRE SUPPRESSION SYSTEM article. Failure to follow the instructions may result in serious personal injury.
  1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING article.
  2. Disconnect the fuel tube spring lock coupling. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING & CABLES article.
  4. Drain the engine cooling system. For additional information, refer to ENGINE COOLING article.
  5. Remove the air cleaner and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING article.
  6. Remove the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS & WASHERS article.
  7. Disconnect the 8 fuel injector electrical connectors.
  8. Remove the 8 ignition coil-on-plugs. For additional information, refer to ENGINE IGNITION - 4.6L (2V) article.
  9. Remove the 2 bolts and the intake manifold shield.
  10. Disconnect the brake booster vacuum hose from the intake manifold.
  11. Disconnect the quick connect coupling Evaporative Emission (EVAP) canister purge valve hoses from the Throttle Body (TB) spacer and from the EVAP canister purge valve. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  12. Disconnect the quick connect coupling PCV tube from the TB spacer. For additional information, refer to FUEL SYSTEM - GENERAL INFORMATION article.
  13. Disconnect the EGR system module vacuum and electrical connectors.
  14. Disconnect the intake manifold-to-TB spacer vacuum hose.
  15. Disconnect the generator electrical connector.
  16. Detach the 2 generator wiring harness retainers from the generator bracket.
  17. Remove the 4 generator bracket bolts and the bracket.
  18. Remove the coolant thermostat. For additional information, refer to ENGINE COOLING article.
  19. Disconnect the throttle control and the Throttle Position (TP) sensor electrical connectors.
  20. Release the heater hose spring clamp and disconnect the heater hose.
  21. Remove the EGR system module tube. For additional information, refer to ENGINE EMISSION CONTROL article.
  22. If equipped, detach the wire harness retainer from the intake manifold crash bracket.
  23. Remove the intake manifold crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
    24. Fig 1: Removing Crash Bracket Bolt
    GF0013545Courtesy of FORD MOTOR CO.
  24. Remove the intake manifold crash bracket bolt.
  25. Disconnect the fuel rail pressure and temperature sensor vacuum and electrical connectors.
  26. Remove the wire harness retainer from the rear of the intake manifold.
  27. Remove the 8 bolts and the intake manifold.
    • Remove and discard the intake manifold gaskets.
  28. Clean the sealing surfaces.
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