Intake Manifold-Lower: Removal

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

Remove the upper intake manifold. For additional information, refer to INTAKE MANIFOLD-UPPER .
Disconnect the fuel lines. For additional information, refer to REMOVAL, OVERHAUL & INSTALLATION - BLACKWOOD, EXPEDITION, F150 PICKUP & NAVIGATOR - GASOLINE .
Disconnect the engine water bypass hose (8597).

Fig 1: Disconnecting Engine Water Bypass Hose (8597)
Courtesy of FORD MOTOR CO.
Disconnect the electrical connector from the water temperature indicator sender (10884).

Fig 2: Disconnecting Electrical Connector From Water Temperature Indicator Sender (10884)
Courtesy of FORD MOTOR CO.
Disconnect the upper radiator hose (8260), the heater water inlet hose and the heated positive crankcase ventilation (PCV) water heated fitting inlet hose.

Fig 3: Disconnecting Upper Radiator Hose (8260)
Courtesy of FORD MOTOR CO.
Remove the four bolts and the upper generator support bracket (10153).

Fig 4: Removing Upper Generator Support Bracket (10153) Bolts
Courtesy of FORD MOTOR CO.
Disconnect the eight fuel injectors (9F593).

Fig 5: Disconnecting Eight Fuel Injectors (9F593)
Courtesy of FORD MOTOR CO.
Disconnect the vacuum line from the fuel injector pressure regulator (9C968) and position out of the way.

Fig 6: Disconnecting Vacuum Line From Fuel Injector Pressure Regulator (9C968)
Courtesy of FORD MOTOR CO.
Disconnect the wire harness pin-type retainer.

Fig 7: Disconnecting Wire Harness Pin-Type Retainer
Courtesy of FORD MOTOR CO.
Remove the bolts and lower intake manifold (9424).
- Discard the lower intake retaining bolts.
  
  Fig 8: Removing Lower Intake Manifold (9424) Bolts
  Courtesy of FORD MOTOR CO.
Remove the bolts and the radio ignition interference capacitors (18801).

Fig 9: Removing Radio Ignition Interference Capacitors (18801) Bolts
Courtesy of FORD MOTOR CO.
Remove and inspect the gaskets, install new gaskets if necessary.

Fig 10: Identifying Gasket
Courtesy of FORD MOTOR CO.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Use a plastic scraping tool to remove all traces of old sealant.

Fig 11: Cleaning Sealing Surfaces

Courtesy of FORD MOTOR CO.

Clean the sealing surfaces.