Intake Manifold (4.2L): Removal
WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2002 Ford RV Cutaway, 2002 Ford Pickup, 2002 Ford F550 Super Duty, 2002 Ford F450 Super Duty, and 2002 Ford Excursion. However, it is still accessible from the selected car via links, so may be relevant.
- Disconnect negative battery cable. Remove air cleaner outlet tube. Mark spark plug wires for reassembly reference and remove. Disconnect accelerator and cruise control cable from throttle body. Disconnect harness connectors and vacuum hoses from upper intake manifold. See Figure.
- Disconnect PCV hose from upper intake manifold. If necessary, remove throttle body nuts and throttle body. Remove EGR bracket and position aside. Evenly loosen 12 upper intake manifold bolts. Remove upper intake manifold. Inspect gaskets and replace as necessary.
- Partially drain cooling system. Disconnect throttle position sensor. Disconnect brake booster hose, vapor management hose and PCV valve hose. Disconnect heater hoses and hose bracket. Remove vacuum connector. Disconnect EGR harness connector and hose. Remove bolts and intake manifold spacer.
- Disconnect injector harness connectors. Disconnect wiring harness from fuel supply lines. Disconnect EGR valve vacuum hose and upper tube fitting. Disconnect upper radiator hose from engine. Disconnect fuel lines, IMRC harness connector and fuel pressure regulator hose. See FUEL LINE CONNECTORS .
- Disconnect by-pass hose and PCV heater hose from lower intake manifold. Remove lower intake manifold bolts, noting position of short and long bolts. See Figure. Remove lower intake manifold. Clean all mating surfaces.