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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 34 (Engine Controls - Removal, Overhaul & Installation - BLACKWOOD, Expedition, F150 Pickup & Navigator - Gasoline) >> Air Induction Systems >> Intake Manifold >> Removal & Installation (4.6L & 5.4L 2V)

Removal & Installation (4.6L & 5.4L 2V)

WARNING: This page is about a different car, the 2002 Lincoln Navigator, 2002 Lincoln Blackwood, 2002 Ford Pickup, and 2002 Ford Expedition. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery ground cable. Remove the air cleaner outlet pipe. Drain the engine cooling system. Remove upper radiator hose.
  2. Disconnect the throttle body cam. Disconnect the accelerator cable, speed control actuator cable and accelerator return spring. Remove the accelerator cable bracket bolts and position the bracket and cables aside. Remove the Idle Air Control (IAC) fresh air hose.
  3. Disconnect Exhaust Gas Recirculation (EGR) vacuum regulator solenoid, IAC and Throttle Position (TP) sensor electrical connectors. See Fig 1 or Fig 2 . Disconnect EGR valve vacuum hose and evaporative emission canister purge valve hose.
  4. Disconnect fuel pressure regulator vacuum hose. Disconnect differential pressure feedback EGR system electrical connector. Disconnect evaporative emission canister purge valve vacuum hose. Remove brake booster vacuum tube from intake manifold and position bracket and tube aside.
  5. Disconnect and move crankcase ventilation hose and exhaust manifold-to-EGR valve tube aside. Disconnect main vacuum harness. Remove PCV hose.
  6. Remove four bolts and throttle body adapter. Inspect the throttle body and adapter for damage. Remove power steering reservoir upper mounting bracket. Remove eight ignition coils. See IGNITION COILS  under IGNITION SYSTEMS. Disconnect fuel injector harness connectors. Remove drive belt from the alternator pulley.
  7. Remove generator upper mounting bracket. Remove generator lower mounting bolts and position generator aside. Disconnect heater hose. Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE  under FUEL SYSTEMS. Disconnect fuel lines. Remove thermostat housing. Discard thermostat housing "O" ring seal.
    8. CAUTION: Do not use metal scrapers, power abrasive discs or any abrasive means to clean the sealing surfaces, these tools cause scratches and gouges that make leak paths. Use a plastic scraper only.
  8. Remove nine intake manifold bolts. Lift the intake manifold. Disconnect intake manifold tuning valve connector. Remove intake manifold assembly. Discard the gaskets. Inspect the intake manifold assembly for damage. Clean all the sealing surfaces.
    9. NOTE: The thermostat housing bolts are tightened in sequence with the intake manifold bolts.
  9. Position the new intake manifold gaskets. Position intake manifold. Loosely install nine intake manifold bolts. Connect the intake manifold tuning valve electrical connector. Install the thermostat housing using a NEW "O" ring seal and loosely install the bolts. Tighten fasteners in sequence. See Fig 3. See TORQUE SPECIFICATIONS .
  10. To complete installation, reverse removal procedure. Install the exhaust manifold to EGR valve tube hand-tight. Tighten upper fitting, then lower fitting. Fill and bleed the engine cooling system. See COOLING SYSTEM BLEEDING  under COOLING SYSTEMS.
Fig 1: Exploded View Of Intake Manifold Components (4.6L)
G00132428Courtesy of FORD MOTOR CO.
Fig 2: Exploded View Of Intake Manifold Components (5.4L 2V)
G00132429Courtesy of FORD MOTOR CO.
Fig 3: Intake Manifold Tightening Sequence (4.6L & 5.4L 2V)
G00132438Courtesy of FORD MOTOR CO.
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