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Removal And Installation

WARNING: This page is about a different car, the 2004 Lincoln LS. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery ground cable.
  2. Remove the air cleaner outlet tube. For additional information, refer to INTAKE AIR, FUEL CHARGING, STARTING & ENGINE ELECTRONICS - 3.9L for additional information.
    3. CAUTION: The coolant drain procedure must be followed exactly or damage to the engine can occur.
  3. Drain the engine cooling system. For additional information, refer to ENGINE COOLING .
  4. Remove the cowl vent screen. For additional information, refer to INTERIOR TRIM .
  5. Remove the engine compartment brace.
    Fig 1: Identifying Tightening Torque Of Engine Compartment Brace
    G03200820Courtesy of FORD MOTOR CO.
  6. Disconnect the fuel line. For additional information, refer to FUEL SYSTEM .
  7. Illustration 1 of 4. Remove the components in the order indicated in the following illustration and table. See Fig 2.
    Fig 2: Disconnecting Electrical Connectors
    G03200821Courtesy of FORD MOTOR CO.
  8. Illustration 2 of 4. Remove the components in the order indicated in the following illustration and table. See Fig 3.
    Fig 3: Disconnecting Exhaust Gas Recirculation (EGR) System Module Vacuum Connector
    G03200822Courtesy of FORD MOTOR CO.
  9. Illustration 3 of 4. Remove the components in the order indicated in the following illustration and table. See Fig 4.
    Fig 4: Identifying Tightening Torque Of RH Engine Cover Support Bracket Nuts
    G03200823Courtesy of FORD MOTOR CO.
  10. Illustration 4 of 4. Remove the components in the order indicated in the following illustration and table. See Fig 5.
    Fig 5: Identifying Tightening Torque Of Intake Manifold Bolts And Studs
    G03200824Courtesy of FORD MOTOR CO.
  11. To install, reverse the removal procedure.

Items 11 and 13: Engine Appearance Cover Support Bracket Removal Note 

    NOTE: LH is shown, RH is similar.
    Fig 6: Disconnecting Engine Wiring Harness Retainers From Engine Appearance Cover Support Bracket
    G03200825Courtesy of FORD MOTOR CO.
  1. Disconnect the engine wiring harness retainers from the engine appearance cover support bracket.

Items 14, 15, and 16: Intake Manifold Removal Note 

    NOTE: LH is shown, RH is similar.
    Fig 7: Disconnecting Fuel Injector And RFI Suppressor Electrical Connectors
    G03200826Courtesy of FORD MOTOR CO.
  1. Disconnect the fuel injector and RFI suppressor electrical connectors
  2. Remove the nuts and the engine wiring harness retainer and position aside.
    Fig 8: Removing Nuts And Engine Wiring Harness Retainer And Positioning Aside
    G03200827Courtesy of FORD MOTOR CO.
    3. NOTE: RH is shown, LH is similar.
    Fig 9: Removing RFI Suppressor With Nuts
    G03200828Courtesy of FORD MOTOR CO.
  3. Remove the nut and the RFI suppressor.
  4. Disconnect the throttle body heater hoses.
    Fig 10: Disconnecting Throttle Body Heater Hoses
    G03200829Courtesy of FORD MOTOR CO.
    5. NOTE: The throttle body and adapter are shown removed for clarity. It is not necessary to remove the throttle body and adapter to remove the intake manifold.
    Fig 11: Identifying Intake Manifold Bolts And Studs Removal Sequence
    G03200830Courtesy of FORD MOTOR CO.
  5. Remove the bolts and studs in the sequence shown.
  6. Remove the intake manifold.
    7. 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. Use a plastic scraping tool to clean the surfaces.
    Fig 12: Locating Sealing Surfaces For Cleaning
    G03200831Courtesy of FORD MOTOR CO.
  7. Clean the sealing surfaces.

Items 14, 15, and 16: Intake Manifold Installation Note 

  1. Install new intake manifold gaskets.
    2. NOTE: The throttle body and adapter are shown removed for clarity. It is not necessary to remove the throttle body and adapter to remove the intake manifold.
    Fig 13: Identifying Intake Manifold Bolts And Studs Tightening Sequence
    G03200832Courtesy of FORD MOTOR CO.
  2. Install the intake manifold and tighten the bolts in the sequence shown.
  3. Connect the throttle body heater hoses.
    Fig 14: Connecting Throttle Body Heater Hoses
    G03200833Courtesy of FORD MOTOR CO.
    4. NOTE: RH is shown, LH is similar.
    Fig 15: Installing RFI Suppressor And Nut
    G03200834Courtesy of FORD MOTOR CO.
  4. Install the RFI suppressor and the nut.
  5. Install the engine wiring harness retainer and the nuts.
    Fig 16: Installing Engine Wiring Harness Retainer And Nuts
    G03200835Courtesy of FORD MOTOR CO.
    6. NOTE: LH is shown, RH is similar.
    Fig 17: Connecting Fuel Injector And RFI Suppressor Electrical Connectors
    G03200836Courtesy of FORD MOTOR CO.
  6. Connect the fuel injector and RFI suppressor electrical connectors

Item 7 and 9: Engine Appearance Cover Support Bracket Installation Note 

    NOTE: LH is shown, RH is similar.
    Fig 18: Connecting Engine Wiring Harness Retainers To Engine Appearance Cover Support Bracket
    G03200837Courtesy of FORD MOTOR CO.
  1. Connect the engine wiring harness retainers to the engine appearance cover support bracket.
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