Intake Manifold: Removal

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford F550 Super Duty, 2004 Ford F450 Super Duty, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

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

Disconnect the fuel line spring lock couplings. Refer to FUEL SYSTEM-GENERAL INFORMATION .
Disconnect the battery ground cable. Refer to BATTERY, MOUNTING AND CABLES .
Drain the engine cooling system. Refer to ENGINE COOLING
Remove the air cleaner outlet tube. Refer to INTAKE AIR DISTRIBUTION & FILTERING .
Remove the generator. Refer to GENERATORS & REGULATORS .
Compress and slide the hose clamp and disconnect the coolant outlet hose.

Fig 1: Disconnecting Coolant Outlet Hose
Courtesy of FORD MOTOR CO.
Remove the accelerator cable splash shield.

Fig 2: Removing Accelerator Cable Splash Shield
Courtesy of FORD MOTOR CO.
Disconnect the accelerator and speed control cables and remove the return spring.

Fig 3: Disconnecting Accelerator And Speed Control Cables
Courtesy of FORD MOTOR CO.
Position the accelerator cable bracket aside.
- Remove the bolts.
- Position the bracket and cables aside.
  
  Fig 4: Removing Accelerator Cable Bracket
  Courtesy of FORD MOTOR CO.
Disconnect the positive crankcase valve (PCV) tube and the vacuum lines.

Fig 5: Disconnecting Positive Crankcase Valve (PCV) Tube And Vacuum Lines
Courtesy of FORD MOTOR CO.
Disconnect the heated PCV coolant hose.

Fig 6: Disconnecting Heated PCV Coolant Hose
Courtesy of FORD MOTOR CO.
Disconnect the vacuum line.

Fig 7: Disconnecting Vacuum Line
Courtesy of FORD MOTOR CO.
Disconnect the five RH fuel injector electrical connectors and five ignition coil electrical connectors.

Fig 8: Disconnecting RH Fuel Injector Electrical Connectors And Ignition Coil Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the idle air control (IAC) motor electrical connector and the bypass hose.

Fig 9: Disconnecting Idle Air Control (IAC) Motor Electrical Connector And Bypass Hose
Courtesy of FORD MOTOR CO.
Disconnect the heater hose.

Fig 10: Disconnecting Heater Hose
Courtesy of FORD MOTOR CO.
Disconnect the five LH fuel injector throttle position (TP) sensor electrical connectors and ignition coil connectors.

Fig 11: Disconnecting LH Fuel Injector Throttle Position (TP) Sensor Electrical Connectors And Ignition Coil Connectors
Courtesy of FORD MOTOR CO.
Remove the ignition coils.
- Remove the 10 bolts.
- Remove the 10 ignition coils.
  
  Fig 12: Removing Ignition Coils
  Courtesy of FORD MOTOR CO.
Disconnect the vacuum connector from the fuel pressure regulator.
Remove the thermostat and housing.
Remove the bolts, the upper intake manifold and the intake manifold gaskets. Discard the intake manifold gaskets.

Fig 13: Removing Bolts, Upper Intake Manifold And Intake Manifold Gaskets
Courtesy of FORD MOTOR CO.

CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the aluminum retainer plate. These tools cause scratches and gouges, which make leak paths.

Clean all mating surfaces.
- Clean the intake manifold mating surface of the cylinder heads with silicone gasket remover and metal surface prep. Follow the directions on the packaging.