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Home › Lincoln › 2003 › Navigator RWD › Repair and Diagnosis › Engine Mechanical › Mechanical › Engine-5.4L › In-Vehicle Repair › Upper Intake Manifold › Removal

Upper Intake Manifold: Removal

  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the cowl grille. For additional information, refer to FRONT END BODY PANELS .
  3. Remove the bolts and five clips and the wiring harness shield.
    Fig 1: Removing Bolts And Clips And Wiring Harness Shield
    G01562822Courtesy of FORD MOTOR CO.
  4. Remove the air cleaner outlet tube and the air cleaner assembly. For additional information, refer to REMOVAL & INSTALLATION - BLACKWOOD, EXPEDITION, F150 PICKUP & NAVIGATOR - GASOLINE .
  5. Partially drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  6. Remove the engine appearance cover.
    Fig 2: Removing Engine Appearance Cover
    G01562823Courtesy of FORD MOTOR CO.
  7. Disconnect the accelerator cable, speed control cable, and the return spring.
    Fig 3: Disconnecting Accelerator Cable, Speed Control Cable, And Return Spring
    G01562824Courtesy of FORD MOTOR CO.
  8. Remove the bolts and position the cables and bracket out of the way.
    Fig 4: Removing Bolts And Position Cables And Bracket Out Of Way
    G01562825Courtesy of FORD MOTOR CO.
  9. Disconnect the evaporative emission (EVAP) return hose.
    Fig 5: Disconnecting Evaporative Emission (Evap) Return Hose
    G01562826Courtesy of FORD MOTOR CO.
  10. Disconnect and remove the positive crankcase ventilation (PCV) tube.
    Fig 6: Disconnecting And Removing Positive Crankcase Ventilation (Pcv) Tube
    G01562827Courtesy of FORD MOTOR CO.
  11. Disconnect the coolant hoses.
    Fig 7: Disconnecting Coolant Hoses
    G01562828Courtesy of FORD MOTOR CO.
  12. Disconnect the electrical connector from the intake tuning valve.
    Fig 8: Disconnecting Electrical Connector From Intake Tuning Valve
    G01562829Courtesy of FORD MOTOR CO.
  13. Remove the bolts, studs and the balance tube.
    Fig 9: Removing Bolts, Studs And Balance Tube
    G01562830Courtesy of FORD MOTOR CO.
    14. 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 10: Removing And Discarding Gaskets
    G01562831Courtesy of FORD MOTOR CO.
  14. Remove and discard the gaskets and clean the sealing surfaces.
  15. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 11: Disconnecting Throttle Position (Tp) Sensor Electrical Connector
    G01562832Courtesy of FORD MOTOR CO.
  16. Disconnect the idle air control (IAC) valve electrical connector.
    Fig 12: Disconnecting Idle Air Control (Iac) Valve Electrical Connector
    G01562833Courtesy of FORD MOTOR CO.
  17. Disconnect the vacuum hoses and the electrical connector from the EGR vacuum regulator solenoid.
    Fig 13: Disconnecting Vacuum Hoses And Electrical Connector From Egr Vacuum Regulator Solenoid
    G01562834Courtesy of FORD MOTOR CO.
  18. Disconnect the two hoses and the electrical connector from the differential pressure feedback EGR system.
    Fig 14: Disconnecting Two Hoses And Electrical Connector From Differential Pressure Feedback Egr System
    G01562835Courtesy of FORD MOTOR CO.
  19. Remove the nut.
    Fig 15: Removing Nut
    G01562836Courtesy of FORD MOTOR CO.
    20. NOTE: The bolts are located at the front side of the LH cylinder head.
    Fig 16: Removing Bolts From Power Steering Reservoir Bracket
    G01562837Courtesy of FORD MOTOR CO.
  20. Remove the bolts from the power steering reservoir bracket and position it aside.
  21. Remove the stud and position the oil fill tube aside.
    Fig 17: Removing Stud And Position Oil Fill Tube Aside
    G01562838Courtesy of FORD MOTOR CO.
  22. Disconnect the brake booster vacuum hose.
    Fig 18: Disconnecting Brake Booster Vacuum Hose
    G01562839Courtesy of FORD MOTOR CO.
  23. Disconnect the vacuum hose.
    Fig 19: Disconnecting Vacuum Hose
    G01562840Courtesy of FORD MOTOR CO.
  24. Disconnect the vacuum hose from the exhaust gas recirculation (EGR) valve.
    Fig 20: Disconnecting Vacuum Hose From Exhaust Gas Recirculation (Egr) Valve
    G01562841Courtesy of FORD MOTOR CO.
  25. Disconnect the vacuum hose.
    Fig 21: Disconnecting Vacuum Hose
    G01562842Courtesy of FORD MOTOR CO.
  26. Disconnect the vacuum hose at the right rear of the intake manifold.
    Fig 22: Disconnecting Vacuum Hose At Right Rear Of Intake Manifold
    G01562843Courtesy of FORD MOTOR CO.
  27. Remove the bolts from the EGR adapter.
    • Discard the gasket.
      Fig 23: Removing Bolts From Egr Adapter
      G01562844Courtesy of FORD MOTOR CO.
  28. Remove the bolts and the upper intake manifold.
    • Discard the upper intake retaining bolts.
      Fig 24: Removing Bolts And Upper Intake Manifold
      G01562845Courtesy of FORD MOTOR CO.
    29. 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.
  29. Remove and inspect the intake gasket. Install a new gasket if necessary.
    • Clean and inspect the sealing surfaces.
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