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Intake Manifold (4.6L): Removal

WARNING: This page is about a different car, the 2003 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect negative battery cable. On vehicles with dual batteries, see DUAL BATTERIES  under MISCELLANEOUS. Remove engine cover. See ENGINE COVER  under MISCELLANEOUS. Relieve fuel pressure and disconnect fuel hose spring lock couplings. See FUEL SYSTEM PRESSURE RELEASE  and FUEL LINE CONNECTORS  under FUEL SYSTEMS. Drain cooling system.
  2. Remove 4 air cleaner assembly bolts and loosen air cleaner outlet pipe clamp. Position air cleaner assembly to gain access to Mass Airflow (MAF) sensor electrical connector and disconnect MAF sensor electrical connector. Remove air cleaner assembly. Disconnect 2 hoses on air cleaner outlet pipe, loosen clamp at throttle body and remove air cleaner outlet pipe.
  3. Remove accelerator cable splash shield. Disconnect accelerator cable, speed control actuator cable and remove throttle return spring.
  4. Compress and slide upper radiator hose clamp back and disconnect upper radiator hose from thermostat housing. Disconnect heater hose at intake manifold.
  5. Remove bolts for accelerator cable bracket and position accelerator cable bracket and cables aside.
  6. Disconnect the following electrical and vacuum connections:
    • Throttle Position (TP) sensor and harness routing clip.
    • Differential pressure feedback Exhaust Gas Recirculation (EGR) system connector and hoses. Remove differential pressure feedback EGR system from exhaust manifold to EGR tube.
    • EGR vacuum regulator solenoid.
    • Idle Air Control (IAC) valve.
  7. Remove 2 EVAP canister purge valve nuts and position valve aside. Remove exhaust manifold-to-EGR valve tube. Disconnect and remove Positive Crankcase Ventilation (PCV) hose.
  8. Remove the following hoses:
    • EGR valve vacuum hose.
    • Engine vacuum supply hose.
    • EGR vacuum regulator solenoid vacuum hose.
    • Fuel pressure regulator vacuum hose.
    • Evaporative emission canister purge valve vacuum hose.
    See Figure.
  9. Remove generator upper support bracket bolts and generator upper support bracket. Remove 4 throttle body bolts, and remove throttle body and adapter as an assembly. Discard throttle body adapter gasket.
  10. Disconnect 8 coil-on-plug connectors and 8 fuel injector connectors. Remove bolts and 8 ignition coils.
  11. Remove thermostat housing bolts and thermostat. Discard "O" ring seal. Remove 9 intake manifold retaining bolts and lift intake manifold. Disconnect intake manifold tuning valve electrical connector and remove intake manifold. Discard intake manifold gaskets.
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