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Intake Manifold (5.4L): 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. Disconnect the following electrical and vacuum connections:
    • Engine Coolant Temperature (ECT) sensor.
    • Throttle Position (TP) sensor and harness routing clip.
    • Differential pressure feedback Exhaust Gas Recirculation (EGR) system connector and 2 hoses.
    • Idle Air Control (IAC) valve.
  6. Remove the following brackets and supports:
    • Differential pressure feedback EGR system bracket.
    • Bolt and bracket at thermostat housing.
    • Bolts and generator upper support bracket.
    • Bolt retaining transmission fluid filler tube support bracket.
    • Bolts for accelerator cable bracket and position accelerator cable bracket and cables aside.
  7. Remove the following hoses:
    • Auxiliary heater hoses and position aside, if equipped.
    • Idle Air control (IAC) valve fresh air hose.
    • Evaporative Emission (EVAP) canister purge valve hose and vacuum hose.
    • Fuel pressure regulator vacuum hose.
    • EGR vacuum regulator solenoid connections and EGR valve vacuum hose.
    • Brake booster and main engine vacuum harness and position aside.
  8. 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.
  9. 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 remove intake manifold. Discard intake manifold gaskets.
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