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Intake Manifold: Removal: Notes

  1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to JACKING & LIFTING .
  2. Remove the Air Cleaner (ACL) and outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION & FILTERING .
  3. Remove the oil level indicator and tube. For additional information, refer to OIL LEVEL INDICATOR AND TUBE  .
  4. Remove the fuel rail. For additional information, refer to FUEL CHARGING AND CONTROLS - 2.0L .
  5. Remove the transaxle fluid indicator.
  6. Remove the intake manifold lower bolt.
    Fig 1: Locating Intake Manifold Lower Bolt
    G06328636Courtesy of FORD MOTOR CO.
  7. Detach the engine wiring harness pin-type retainer from the intake manifold.
    Fig 2: Locating Engine Wiring Harness Pin-Type Retainer From Intake Manifold
    G06328635Courtesy of FORD MOTOR CO.
  8. Disconnect the Engine Oil Pressure (EOP) switch electrical connector and detach the wire harness retainer from the starter stud bolt.
  9. Disconnect the electronic throttle control electrical connector.
  10. Disconnect the fuel vapor return hose.
  11. Disconnect the power brake booster vacuum tube.
    • Depress the quick release locking ring.
    • Pull the vacuum tube out of the quick release fitting.
      Fig 3: Locating Vacuum Tube Of Quick Release Fitting
      G06328628Courtesy of FORD MOTOR CO.
  12. Disconnect the Manifold Absolute Pressure (MAP) sensor electrical connector.
  13. Detach the wiring harness retainer from the intake manifold and disconnect the Knock Sensor (KS) electrical connector.
  14. Detach the 4 wiring harness pin-type retainers from the intake manifold.
    15. NOTE: The 2 intake manifold bolts differ in length from rest of the bolts and also retain a crash bracket to the intake manifold. The 2 bolts are equipped with an attachment feature that allows them to be loosened but remain attached to the intake manifold. Do not attempt to remove the 2 bolts or the crash bracket from the intake manifold.
    Fig 4: Locating Intake Manifold Bolts
    G06328632Courtesy of FORD MOTOR CO.
  15. Loosen the 2 intake manifold bolts.
  16. Remove the 5 intake manifold bolts.
    Fig 5: Locating Intake Manifold Bolts
    G06328633Courtesy of FORD MOTOR CO.
  17. Remove the EGR tube from the cylinder head.
  18. Disconnect the PCV hose and remove the intake manifold.
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