LEMON Manuals: Even more car manuals for everyone
Home >> Ford >> 2003 >> Excursion 7.3 F, RWD >> Repair and Diagnosis >> External Pages >> Different variant/trim >> Section 18 (Engine - 5.4L 2V) >> In-Vehicle Repair >> Intake Manifold >> Removal

Intake Manifold: Removal

WARNING: This page is about a different variant/trim than selected.

All vehicles 

WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and can be ignited, resulting in possible personal injury.
WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running.
  1. Disconnect the battery ground cable (14301). Refer to BATTERY, MOUNTING AND CABLES .
  2. Relieve the fuel system pressure. Refer to REMOVAL & INSTALLATION .
  3. Drain the cooling system. Refer to ENGINE COOLING .
  4. Disconnect the idle air control (IAC) fresh air tube and crankcase ventilation tube from the air cleaner outlet pipe.
    Fig 1: Disconnecting Idle Air Control (IAC) Fresh Air Tube And Crankcase Ventilation Tube From Air Cleaner Outlet Pipe
    G01548172Courtesy of FORD MOTOR CO.
  5. Loosen the clamp and disconnect the air cleaner outlet pipe from the throttle body.
    Fig 2: Loosening Clamp
    G01548173Courtesy of FORD MOTOR CO.
  6. Release the clamp and separate the air cleaner outlet housing from the air cleaner inlet housing.
    Fig 3: Releasing Clamp
    G01548174Courtesy of FORD MOTOR CO.
  7. Disconnect the mass air flow (MAF) sensor electrical connector and remove the air cleaner, air cleaner outlet housing and the air cleaner outlet pipe from the vehicle.
    Fig 4: Disconnecting Mass Air Flow (MAF) Sensor Electrical Connector
    G01548175Courtesy of FORD MOTOR CO.
  8. Compress and slide the hose clamp and disconnect the upper radiator hose (8260).
    Fig 5: Compressing And Sliding Hose Clamp
    G01548176Courtesy of FORD MOTOR CO.

    Vehicles with A/C 

  9. Rotate the belt tensioner clockwise and remove the belt from the generator pulley.
    Fig 6: Removing Belt From Generator Pulley
    G01548177Courtesy of FORD MOTOR CO.

    Vehicles without A/C 

  10. Rotate the belt tensioner counterclockwise and remove the belt from the generator pulley.
    Fig 7: Removing Belt From Generator Pulley
    G01548178Courtesy of FORD MOTOR CO.

    All vehicles 

  11. Remove the harness routing clips from the generator stud and the engine front cover.
    Fig 8: Removing Harness Routing Clips From Generator Stud And Engine Front Cover
    G01548179Courtesy of FORD MOTOR CO.
  12. Remove the generator upper mounting bracket stud and bolt.
    Fig 9: Removing Generator Upper Mounting Bracket Stud And Bolt
    G01548180Courtesy of FORD MOTOR CO.
  13. Remove the generator lower mounting bolts and position the generator aside.
    Fig 10: Removing Generator Lower Mounting Bolts
    G01548181Courtesy of FORD MOTOR CO.
  14. Remove the accelerator control splash shield.
    Fig 11: Removing Accelerator Control Splash Shield
    G01548182Courtesy of FORD MOTOR CO.
  15. Disconnect the throttle body cam.
    • Disconnect the accelerator cable (9A758).
    • If equipped, disconnect the speed control cable.
    • Remove the throttle return spring.
    Fig 12: Removing Throttle Return Spring
    G01548183Courtesy of FORD MOTOR CO.
  16. Position the accelerator cable bracket aside.
    • Remove the bolts.
    • Position the accelerator cable bracket aside.
    Fig 13: Positioning Accelerator Cable Bracket Aside
    G01548184Courtesy of FORD MOTOR CO.
  17. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 14: Disconnecting Throttle Position (TP) Sensor Electrical Connector
    G01548185Courtesy of FORD MOTOR CO.
  18. Release the IAC fresh air tube from the routing clip and remove it from the vehicle.
    Fig 15: Releasing IAC Fresh Air Tube From Routing Clip
    G01548186Courtesy of FORD MOTOR CO.
  19. Disconnect the evaporative emission canister purge valve vacuum hose from the throttle body adapter.
    Fig 16: Disconnecting Evaporative Emission Canister Purge Valve Vacuum Hose From Throttle Body Adapter
    G01548187Courtesy of FORD MOTOR CO.
  20. Disconnect the brake booster vacuum hose and main vacuum harness from the throttle body adapter.
    Fig 17: Disconnecting Brake Booster Vacuum Hose And Main Vacuum Harness From Throttle Body Adapter
    G01548188Courtesy of FORD MOTOR CO.
  21. Disconnect the IAC electrical connector.
    Fig 18: Disconnecting IAC Electrical Connector
    G01548189Courtesy of FORD MOTOR CO.

    Vehicles with EGR system 

  22. Position the exhaust manifold to EGR valve tube aside.
    • Disconnect the upper fitting.
    • Loosen the lower fitting.
    • Position the exhaust manifold to EGR valve tube aside.
    Fig 19: Disconnecting Upper Fitting
    G01548190Courtesy of FORD MOTOR CO.
  23. Position the differential pressure feedback exhaust gas recirculation (EGR) system bracket aside.
    • Remove the bolts.
    • Position the bracket aside.
    Fig 20: Removing Bolts
    G01548191Courtesy of FORD MOTOR CO.
  24. Disconnect the EGR vacuum regulator solenoid connections.
    Fig 21: Disconnecting EGR Vacuum Regulator Solenoid Connections
    G01548192Courtesy of FORD MOTOR CO.
  25. Disconnect the EGR valve vacuum hose.
    Fig 22: Disconnecting EGR Valve Vacuum Hose
    G01548193Courtesy of FORD MOTOR CO.

    All vehicles 

  26. Remove the throttle body adapter.
    • Remove the four bolts.
    • Remove the throttle body adapter.
    • Remove and discard the throttle body gasket.
    Fig 23: Removing Bolts
    G01548194Courtesy of FORD MOTOR CO.
  27. Disconnect the fuel tubes.
    Fig 24: Disconnecting Fuel Tubes
    G01548195Courtesy of FORD MOTOR CO.
  28. Disconnect the positive crankcase ventilation (PCV) valve tube from the intake manifold.
    Fig 25: Disconnecting Positive Crankcase Ventilation (PCV) Valve Tube From Intake Manifold
    G01548196Courtesy of FORD MOTOR CO.
  29. Disconnect the fuel pressure regulator vacuum hose.
    Fig 26: Disconnecting Fuel Pressure Regulator Vacuum Hose
    G01548197Courtesy of FORD MOTOR CO.
  30. Disconnect the eight ignition coil electrical connectors and remove the coils.
    Fig 27: Disconnecting Ignition Coil Electrical Connectors
    G01548198Courtesy of FORD MOTOR CO.
  31. Disconnect the eight fuel injector electrical connectors.
    Fig 28: Disconnecting Eight Fuel Injector Electrical Connectors
    G01548199Courtesy of FORD MOTOR CO.
  32. Disconnect the hose clamp and remove the heater water hose (18472).
    Fig 29: Disconnecting Hose Clamp
    G01548200Courtesy of FORD MOTOR CO.
  33. Remove the bolts, water thermostat housing, O-ring seal and the water thermostat.
    • Discard the O-ring seal.
    Fig 30: Removing Bolts, Water Thermostat Housing
    G01548201Courtesy of FORD MOTOR CO.
  34. Remove the bolts.
    Fig 31: Removing Bolts
    G01548202Courtesy of FORD MOTOR CO.
  35. Remove the intake manifold (9424).
    • Lift the intake manifold.
    • Remove and discard the intake manifold gaskets (9439).
    Fig 32: Removing And Discarding Intake Manifold Gaskets
    G01548203Courtesy of FORD MOTOR CO.
    36. 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 that make leak paths.
  36. Clean all mating surfaces.
scientia non olet · About LEMON Manuals