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Intake Manifold: Removal

  1. Disconnect the fuel tube spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  4. Remove the air cleaner outlet pipe resonator assembly. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  5. Remove the wiper mounting arm and pivot shaft. For additional information, refer to WIPERS AND WASHERS .
  6. Remove the RH cowl extension.
    1. Remove the pin-type retainers.
    2. Remove the nuts.
    3. Remove the bolts.
    4. Remove the extension.
    Fig 1: Removing RH Cowl Extension
    G04001832Courtesy of FORD MOTOR CO.
  7. Remove the LH cowl extension.
    1. Disconnect the electrical connector.
    2. Remove the bolts.
    3. Remove the extension.
    Fig 2: Removing LH Cowl Extension
    G04001833Courtesy of FORD MOTOR CO.
  8. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils.
    Fig 3: Disconnecting Fuel Charging Wiring Electrical Connectors From Eight Ignition Coils
    G03881457Courtesy of FORD MOTOR CO.
  9. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors.
    Fig 4: Disconnecting Fuel Charging Wiring Electrical Connectors From Fuel Injectors
    G04001835Courtesy of FORD MOTOR CO.
  10. Remove the bolts and the exhaust gas recirculation (EGR) system module tube heat shield.
    Fig 5: Removing Exhaust Gas Recirculation System Module Tube Heat Shield
    G03881459Courtesy of FORD MOTOR CO.
  11. Disconnect the electrical connector and the vacuum hoses.
    Fig 6: Disconnecting Electrical Connector
    G04001837Courtesy of FORD MOTOR CO.
  12. Disconnect the evaporative emissions (EVAP) canister purge valve emissions tubes.
    Fig 7: Disconnecting Evaporative Emissions Canister Purge Valve Emissions Tubes
    G04001838Courtesy of FORD MOTOR CO.
  13. Disconnect the generator electrical connector.
    Fig 8: Disconnecting Generator Electrical Connector
    G04001875Courtesy of FORD MOTOR CO.
  14. Remove the bolts and the generator mounting bracket.
    Fig 9: Removing Generator Mounting Bracket Bolts
    G04002089Courtesy of FORD MOTOR CO.
  15. Disconnect the upper radiator hose.
    Fig 10: Disconnecting Upper Radiator Hose
    G04001841Courtesy of FORD MOTOR CO.
  16. Disconnect the throttle control and the throttle position (TP) sensor electrical connector.
    Fig 11: Locating Electrical Connectors
    G03881492Courtesy of FORD MOTOR CO.
  17. Disconnect the heater hose.
    Fig 12: Disconnecting Heater Hose
    G04001843Courtesy of FORD MOTOR CO.
  18. Disconnect the EGR system module tube nut from the EGR system module.
    Fig 13: Disconnecting EGR System Module Tube Nut From EGR System Module
    G04001844Courtesy of FORD MOTOR CO.
  19. Remove the nut at the exhaust manifold and remove the EGR tube.
    Fig 14: Removing EGR Tube
    G04001845Courtesy of FORD MOTOR CO.
  20. Separate the fuel charging wiring pin-type retainer from the crash bracket.
    Fig 15: Removing Fuel Charging Wiring Pin-Type Retainer From Crash Bracket
    G04001846Courtesy of FORD MOTOR CO.
  21. Remove the crash bracket bolt and prevent the bolt from contacting the cylinder head with a rubber band or tie strap.
    Fig 16: Preventing Bolt From Contacting Cylinder Head With Rubber Band Or Tie Strap
    G04001847Courtesy of FORD MOTOR CO.
  22. Remove the stud.
    Fig 17: Removing Stud
    G04001848Courtesy of FORD MOTOR CO.
  23. Disconnect the fuel pressure and temperature sensor electrical connector and the vacuum hose.
    Fig 18: Disconnecting Fuel Pressure And Temperature Sensor Electrical Connector And Vacuum Hose
    G04001849Courtesy of FORD MOTOR CO.
  24. Remove the generator harness position retainer from the LH front stud.
    Fig 19: Removing Generator Harness Position Retainer From LH Front Stud
    G04001850Courtesy of FORD MOTOR CO.
  25. Remove the fuel charging wiring pin-type retainer from the rear of the manifold.
    Fig 20: Removing Fuel Charging Wiring Pin-Type Retainer From Rear Of Manifold
    G04001851Courtesy of FORD MOTOR CO.
  26. Disconnect the ground wire connector from the RH rear stud.
    Fig 21: Disconnecting Ground Wire Connector From RH Rear Stud
    G04001852Courtesy of FORD MOTOR CO.
  27. Disconnect the coolant temperature sensor electrical connector.
    Fig 22: Disconnecting Coolant Temperature Sensor Electrical Connector
    G04001853Courtesy of FORD MOTOR CO.
  28. Remove the bolts and the eight ignition coils.
    Fig 23: Removing Ignition Coils
    G03881477Courtesy of FORD MOTOR CO.
  29. Remove the bolts and the coolant outlet adapter.
    Fig 24: Removing Coolant Outlet Adapter Bolts
    G04002104Courtesy of FORD MOTOR CO.
  30. Remove the thermostat and discard the O-ring.
    Fig 25: Removing Thermostat
    G04002392Courtesy of FORD MOTOR CO.
  31. Remove the bolts and the intake manifold.
    Fig 26: Removing Intake Manifold Bolts
    G04001857Courtesy of FORD MOTOR CO.
  32. Remove and discard the intake manifold gaskets.
    Fig 27: Removing Intake Manifold Gaskets
    G03881839Courtesy of FORD MOTOR CO.
  33. Clean the sealing surfaces.
Fig 28: Cleaning Sealing Surfaces
G04001859Courtesy of FORD MOTOR CO.
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