LEMON Manuals: Even more car manuals for everyone
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 - 5.4L >> Removal

Intake Manifold - 5.4L: 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 interior 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.
    Fig 1: Removing Four Bolts
    G01536185Courtesy of FORD MOTOR CO.
  6. Disconnect the MAF sensor electrical connector and remove the ACL.
    Fig 2: Disconnecting MAF Sensor Electrical Connector
    G01536186Courtesy of FORD MOTOR CO.
  7. Disconnect the two hoses.
    Fig 3: Disconnecting Hoses
    G01536187Courtesy of FORD MOTOR CO.
  8. Loosen the clamp and remove the air cleaner outlet pipe.
    Fig 4: Removing Air Cleaner Outlet Pipe
    G01536188Courtesy of FORD MOTOR CO.
  9. Remove the accelerator cable snow shield.
    Fig 5: Removing Accelerator Cable Snow Shield
    G01536189Courtesy of FORD MOTOR CO.
  10. Disconnect the throttle body controls.
    1. Disconnect the accelerator cable.
    2. Disconnect the speed control actuator cable.
    3. Remove the throttle return spring.
    Fig 6: Disconnecting Accelerator Cable
    G01536190Courtesy of FORD MOTOR CO.
  11. Compress and slide the hose clamp and disconnect the upper radiator hose.
    Fig 7: Disconnecting Upper Radiator Hose
    G01536191Courtesy of FORD MOTOR CO.
  12. Disconnect the heater hose.
    Fig 8: Disconnecting Heater Hose
    G01536192Courtesy of FORD MOTOR CO.
  13. Disconnect the water temperature sensor electrical connector.
    Fig 9: Disconnecting Water Temperature Sensor Electrical Connector
    G01536193Courtesy of FORD MOTOR CO.
  14. Disconnect the throttle position (TP) sensor.
    1. Disconnect the TP sensor electrical connector.
    2. Detach the harness routing clip.
    Fig 10: Disconnecting Throttle Position (TP) Sensor
    G01536194Courtesy of FORD MOTOR CO.
  15. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system.
    1. Disconnect the electrical connector.
    2. Disconnect the two hoses.
    Fig 11: Disconnecting Electrical Connector
    G01536195Courtesy of FORD MOTOR CO.
  16. Remove the differential pressure feedback EGR system bracket.
    Fig 12: Removing Differential Pressure Feedback EGR System Bracket
    G01536196Courtesy of FORD MOTOR CO.
  17. Remove the bolt and the bracket.
    Fig 13: Removing Bolt And Bracket
    G01536197Courtesy of FORD MOTOR CO.
  18. Remove the bolts and the generator upper support bracket.
    Fig 14: Removing Generator Upper Support Bracket
    G01536198Courtesy of FORD MOTOR CO.
  19. Remove the bolt retaining the transmission fluid filler tube support bracket.
    Fig 15: Removing Transmission Fluid Filler Tube Support Bracket
    G01536199Courtesy of FORD MOTOR CO.
  20. Remove the bolts and position the accelerator cable bracket and cables aside.
    Fig 16: Removing Accelerator Cable Bracket
    G01536200Courtesy of FORD MOTOR CO.
  21. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 17: Disconnecting Auxiliary Heater Hoses
    G01536201Courtesy of FORD MOTOR CO.
  22. Disconnect and remove the idle air control (IAC) valve fresh air hose.
    Fig 18: Removing Idle Air Control (IAC) Valve Fresh Air Hose
    G01536202Courtesy of FORD MOTOR CO.
  23. Disconnect the evaporative emission canister purge valve hose and vacuum hose.
    Fig 19: Disconnecting Evaporative Emission Canister Purge Valve Hose And Vacuum Hose
    G01536203Courtesy of FORD MOTOR CO.
  24. Remove the two evaporative emission canister purge valve nuts and position the valve aside.
    Fig 20: Removing Evaporative Emission Canister Purge Valve Nuts
    G01536204Courtesy of FORD MOTOR CO.
  25. Disconnect the fuel pressure regulator vacuum hose.
    Fig 21: Disconnecting Fuel Pressure Regulator Vacuum Hose
    G01536205Courtesy of FORD MOTOR CO.
  26. Disconnect the EGR vacuum regulator solenoid connections.
    Fig 22: Disconnecting EGR Vacuum Regulator Solenoid Connections
    G01536206Courtesy of FORD MOTOR CO.
  27. Disconnect the EGR valve vacuum hose.
    Fig 23: Disconnecting EGR Valve Vacuum Hose
    G01536207Courtesy of FORD MOTOR CO.
  28. Disconnect the IAC valve electrical connector.
    Fig 24: Disconnecting IAC Valve Electrical Connector
    G01536208Courtesy of FORD MOTOR CO.
  29. Disconnect the brake booster and main engine vacuum harness and position aside.
    Fig 25: Disconnecting Brake Booster And Main Engine Vacuum Harness
    G01536209Courtesy of FORD MOTOR CO.
  30. Remove the exhaust manifold-to-EGR valve tube.
    • Disconnect the upper fitting.
    • Disconnect the lower fitting and remove the tube.
    Fig 26: Removing Exhaust Manifold-To-EGR Valve Tube
    G01536210Courtesy of FORD MOTOR CO.
  31. Remove the four bolts, and the throttle body and adapter as an assembly.
    • Discard the throttle body adapter gasket.
    Fig 27: Removing Bolts And Throttle Body
    G01536211Courtesy of FORD MOTOR CO.
  32. Disconnect and remove the positive crankcase ventilation hose.
    Fig 28: Disconnecting Positive Crankcase Ventilation Hose
    G01536212Courtesy of FORD MOTOR CO.
    33. NOTE: LH shown, RH similar.
    Fig 29: Disconnecting Coil-On-Plug Electrical Connectors
    G01536213Courtesy of FORD MOTOR CO.
  33. Disconnect the eight coil-on-plug electrical connectors.
    34. NOTE: RH shown, LH similar.
    Fig 30: Disconnecting Fuel Injector Electrical Connectors
    G01536214Courtesy of FORD MOTOR CO.
  34. Disconnect the eight fuel injector electrical connectors.
    35. NOTE: LH shown, RH similar.
    Fig 31: Removing Ignition Coils
    G01536215Courtesy of FORD MOTOR CO.
  35. Remove the bolts and the eight ignition coils.
  36. Remove the bolts, the thermostat housing and the thermostat.
    • Disconnect the O-ring seal.
    Fig 32: Removing Thermostat Housing Bolts
    G01536216Courtesy of FORD MOTOR CO.
  37. Remove the nine bolts retaining the intake manifold.
    Fig 33: Removing Intake Manifold Retaining Bolts
    G01536217Courtesy of FORD MOTOR CO.
  38. Remove the intake manifold.
    • Discard the intake manifold gaskets.
    Fig 34: Removing Intake Manifold
    G01536218Courtesy of FORD MOTOR CO.
  39. Inspect the throttle body, the intake manifold, and their sealing surfaces for damage.
scientia non olet · About LEMON Manuals