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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 1153 (Engine -- 4.0L SOHC) >> In-Vehicle Repair >> Intake Manifold >> Removal and Installation

Removal and Installation

WARNING: This page is about a different car, the 2005 Mercury Mountaineer and 2005 Ford Explorer. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  2. Remove the air cleaner outlet pipe. For additional information, refer to INTAKE AIR DISTRIBUTION AND FILTERING .
  3. Disconnect the positive crankcase ventilation (PCV) tube from the intake manifold.
  4. Release the clamp and disconnect the brake booster vacuum hose from the intake manifold.
  5. Disconnect the main vacuum harness fitting from the intake manifold.
  6. Disconnect the evaporative emissions (EVAP) tube from the intake manifold. Detach the EVAP tube retainer.
  7. Disconnect the exhaust gas recirculation (EGR) system module electrical connector. Detach the wiring harness retainer.
  8. Disconnect the EGR system module vacuum fitting.
  9. Loosen the fitting and disconnect the exhaust manifold-to-EGR system module tube from the EGR system module.
    • To install, tighten to 34 Nm (25 lb-ft).
  10. Disconnect the throttle position (TP) sensor electrical connector.
  11. Disconnect the electronic throttle body electrical connector.
  12. Remove the bolts and the electronic throttle body.
    • To install, tighten to 9 Nm (80 lb-in).
  13. Remove the bolts, the intake manifold and the gaskets.
    • To install, tighten to 11 Nm (8 lb-ft).
    14. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools can cause scratches and gouges which can make leak paths.
  14. Clean the sealing surfaces and inspect the gaskets. Install new gaskets if necessary.
  15. To install, reverse the removal procedure.
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