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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 320 (Engine - 4.6L & 5.4L) >> In-Vehicle Repair >> Intake Manifold - 4.6L >> Removal

Intake Manifold - 4.6L: Removal

WARNING: This page is about a different car, the 2003 Ford RV Cutaway, 2003 Ford Econoline, 2003 Ford E450 Super Duty, and 2003 Ford Cutaway. 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 engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  3. Disconnect the fuel hose spring lock couplings. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL or FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS .
  4. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  5. Position the engine air cleaner (ACL).
    1. Remove the four bolts.
    2. Loosen the clamp.
    3. Position the ACL to gain access to the mass airflow (MAF) sensor electrical connector.
      4. Fig 1: Removing Engine Air Cleaner Bolts
      G01536133Courtesy of FORD MOTOR CO.
  6. Disconnect the MAF sensor electrical connector and remove the ACL.
    Fig 2: Disconnecting MAF Sensor Electrical Connector
    G01536134Courtesy of FORD MOTOR CO.
  7. Disconnect the two hoses.
    Fig 3: Disconnecting Hoses
    G01536135Courtesy of FORD MOTOR CO.
  8. Loosen the clamp and remove the air cleaner outlet pipe.
    Fig 4: Removing Air Cleaner Outlet Pipe
    G01536136Courtesy of FORD MOTOR CO.
  9. Remove the accelerator cable snow shield.
    Fig 5: Removing Accelerator Cable Snow Shield
    G01536137Courtesy of FORD MOTOR CO.
  10. Compress and slide the hose clamp and disconnect the upper radiator hose.
    Fig 6: Disconnecting Upper Radiator Hose
    G01536138Courtesy of FORD MOTOR CO.
    11. NOTE: Typical is shown.
    Fig 7: Disconnecting Throttle Body Control Linkage
    G01536139Courtesy of FORD MOTOR CO.
  11. Disconnect the throttle body control linkage.
    1. Disconnect the accelerator cable.
    2. Disconnect the speed control actuator cable.
    3. Disconnect the throttle control return spring.
    12. NOTE: Typical is shown.
    Fig 8: Removing Bolts Retaining Accelerator Cable Bracket To Throttle Body
    G01536140Courtesy of FORD MOTOR CO.
  12. Remove the bolts retaining the accelerator cable bracket to the throttle body. Remove the accelerator cable bracket.
    13. NOTE: Typical is shown.
    Fig 9: Disconnecting Connector From Throttle Position (TP) Sensor
    G01536141Courtesy of FORD MOTOR CO.
  13. Disconnect the connector from the throttle position (TP) sensor.
  14. Remove the differential pressure feedback exhaust gas recirculation (EGR) system.
    • Disconnect the electrical connector.
    • Remove the system and hoses from the exhaust manifold to EGR valve tube.
    Fig 10: Disconnecting Electrical Connector
    G01536142Courtesy of FORD MOTOR CO.
  15. Remove the exhaust manifold to EGR valve tube.
    • Disconnect the upper and lower fittings.
    • Remove the tube.
    Fig 11: Removing Exhaust Manifold To EGR Valve Tube
    G01536143Courtesy of FORD MOTOR CO.
  16. Disconnect the EGR vacuum regulator solenoid electrical connector.
    Fig 12: Disconnecting EGR Vacuum Regulator Solenoid Electrical Connector
    G01536144Courtesy of FORD MOTOR CO.
  17. Disconnect the following vacuum hoses:
    • The brake booster hose.
    • The positive ventilation (PCV) valve tube.
    Fig 13: Disconnecting Brake Booster Hose
    G01536145Courtesy of FORD MOTOR CO.
  18. Remove the two evaporative emission canister purge valve nuts and position the valve aside.
    Fig 14: Removing Evaporative Emission Canister Purge Valve Nuts
    G01536146Courtesy of FORD MOTOR CO.
  19. Disconnect the IAC valve electrical connector.
    Fig 15: Disconnecting IAC Valve Electrical Connector
    G01536147Courtesy of FORD MOTOR CO.
  20. Disconnect the following vacuum connections:
    1. EGR valve vacuum hose.
    2. Engine vacuum supply hose.
    3. EGR vacuum regulator solenoid vacuum hose.
    4. Fuel pressure regulator vacuum hose.
    5. Evaporative emission canister purge valve vacuum hose.
    Fig 16: Disconnecting Vacuum Connections
    G01536148Courtesy of FORD MOTOR CO.
  21. Remove the four bolts, and the throttle body and adapter as an assembly.
    • Discard the throttle body adapter gasket.
    Fig 17: Removing Bolts, Throttle Body And Adapter
    G01536149Courtesy of FORD MOTOR CO.
    22. NOTE: LH shown, RH similar.
    Fig 18: Disconnecting Coil-On-Plug Electrical Connectors
    G01536150Courtesy of FORD MOTOR CO.
  22. Disconnect the eight coil-on-plug electrical connectors.
    23. NOTE: RH shown, LH similar.
    Fig 19: Disconnecting Fuel Injector Electrical Connectors
    G01536151Courtesy of FORD MOTOR CO.
  23. Disconnect the eight fuel injector electrical connectors.
    24. NOTE: LH shown, RH similar.
    Fig 20: Removing Ignition Coils
    G01536152Courtesy of FORD MOTOR CO.
  24. Remove the bolts and the eight ignition coils.
  25. Remove the bolts and the generator upper support bracket.
    Fig 21: Removing Generator Upper Support Bracket
    G01536153Courtesy of FORD MOTOR CO.
  26. Disconnect the hose clamp and remove the heater hose.
    Fig 22: Disconnecting Hose Clamp
    G01536154Courtesy of FORD MOTOR CO.
    27. NOTE: Typical is shown.
    Fig 23: Removing Thermostat Housing Bolts
    G01536155Courtesy of FORD MOTOR CO.
  27. Remove the bolts, thermostat housing and thermostat.
    • Discard the O-ring seal.
  28. Remove the nine bolts.
    Fig 24: Removing Intake Manifold Securing Bolts
    G01536156Courtesy of FORD MOTOR CO.
  29. Remove the intake manifold assembly.
    1. Lift the intake manifold.
    2. Disconnect the intake manifold tuning valve electrical connector.
    3. Remove the intake manifold and discard the gaskets.
    • Inspect the intake manifold assembly for damage.
    Fig 25: Inspecting Intake Manifold Assembly
    G01536157Courtesy of FORD MOTOR CO.
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