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Removal & Installation (5.4L 4V - Upper Intake Manifold)

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 cowl grille. Remove the bolts and five clips and the wiring harness shield. Remove the air cleaner outlet tube. Disconnect the Mass Air Flow (MAF) sensor electrical connector and remove the air cleaner assembly. Partially drain the cooling system. Remove the three bolts and the engine cover.
  2. Disconnect the accelerator cable, speed control cable, and the return spring. Remove the bolts and position the cables and bracket out of the way. Disconnect Evaporative (EVAP) emission return line, Positive Crankcase Ventilation (PCV) tube and coolant lines. Disconnect the electrical connector from the intake tuning valve. Remove the bolts, stud and balance tube.
  3. Use a plastic scraping tool to remove all traces of old sealant. Remove and discard the gaskets and clean the sealing surfaces. Disconnect the throttle position (TP) sensor. Disconnect the Idle Air Control (IAC) motor. Disconnect the vacuum lines and the electrical connector from the EGR Vacuum Regulator (EVR). Disconnect the two hoses and the electrical connector from the differential pressure feedback EGR. Remove the EGR valve nut and bolts. Remove the bolts from power steering reservoir bracket, located at the front side of the LH cylinder head and position aside.
  4. Remove the stud and position the oil fill tube aside. Disconnect the brake booster vacuum line and other vacuum lines and position vacuum harness aside. Remove the bolts from the EGR adapter. Remove and discard upper intake retaining bolts. Remove upper intake manifold and gaskets.
    5. CAUTION: Do not use metal scrapers, wire brushes, power abrasive discs or other abrasive means to clean the sealing surfaces. These tools cause scratches and gouges which make leak paths. Upper intake gasket may be reused, if undamaged. Upper intake manifold bolts must be replaced.
  5. Install the upper intake manifold gaskets. Position the upper intake manifold and loosely install NEW bolts. Tighten upper intake manifold bolts in sequence to specification. See Fig 1. See TORQUE SPECIFICATIONS . To complete installation, reverse removal procedure.
Fig 1: Upper Intake Manifold Tightening Sequence (5.4L 4V)
G00132430Courtesy of FORD MOTOR CO.
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