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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 589 (Engine 4.6 & 5.4L) >> In-Vehicle Repair >> Intake Manifold - 4.6L >> Removal

Intake Manifold - 4.6L: Removal

WARNING: This page is about a different car, the 2004 Ford Econoline. However, it is still accessible from the selected car via links, so may be relevant.
  1. Release the fuel system pressure. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL .
  2. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  3. Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  4. Disconnect the fuel hose spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION-GASOLINE & DIESEL or FUEL SYSTEM-GENERAL INFORMATION-NATURAL GAS .
  5. Drain the cooling system. For additional information, refer to ENGINE COOLING .
  6. 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 Engine Air Cleaner Bolts
    G02762628Courtesy of FORD MOTOR CO.
  7. Disconnect the MAF sensor electrical connector and remove the ACL.
    Fig 2: Disconnecting MAF Sensor Electrical Connector
    G02762629Courtesy of FORD MOTOR CO.
  8. Disconnect the two hoses.
    Fig 3: Disconnecting Two Hoses
    G02762630Courtesy of FORD MOTOR CO.
  9. Loosen the clamp and remove the air cleaner outlet pipe.
    Fig 4: Removing Air Cleaner Outlet Pipe
    G02762631Courtesy of FORD MOTOR CO.
  10. Remove the accelerator cable snow shield.
    Fig 5: Removing Accelerator Cable Snow Shield
    G02762632Courtesy of FORD MOTOR CO.
  11. Compress and slide the hose clamp and disconnect the upper radiator hose.
    Fig 6: Disconnecting Upper Radiator Hose
    G02762633Courtesy of FORD MOTOR CO.
  12. Remove the bolt retaining the transmission fluid filler tube support bracket.
    Fig 7: Removing Bolt Retaining Transmission Fluid Filler Tube Support Bracket
    G02762634Courtesy of FORD MOTOR CO.
  13. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 8: Disconnecting Auxiliary Heater Hoses
    G02762635Courtesy of FORD MOTOR CO.
  14. Disconnect the evaporative emission canister purge valve hose and vacuum hose.
    Fig 9: Disconnecting Evaporative Emission Canister Purge Valve Hose And Vacuum Hose
    G02762636Courtesy of FORD MOTOR CO.
  15. Remove the two evaporative emission canister purge valve nuts and position the valve aside.
    Fig 10: Removing Evaporative Emission Canister Purge Valve Nuts
    G02762637Courtesy of FORD MOTOR CO.
    16. NOTE: Typical is shown.
    Fig 11: Disconnecting Throttle Control Return Spring
    G02762638Courtesy of FORD MOTOR CO.
  16. 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.
    17. NOTE: Typical is shown.
    Fig 12: Removing Bolts Retaining Accelerator Cable Bracket To Throttle Body
    G02762639Courtesy of FORD MOTOR CO.
  17. Remove the bolts retaining the accelerator cable bracket to the throttle body. Remove the accelerator cable bracket.
    18. NOTE: Typical is shown.
    Fig 13: Disconnecting Connector From Throttle Position (TP) Sensor
    G02762640Courtesy of FORD MOTOR CO.
  18. Disconnect the connector from the throttle position (TP) sensor.
  19. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) sensor electrical connector.
    Fig 14: Disconnecting Differential Pressure Feedback Exhaust Gas Recirculation (EGR) Sensor Electrical Connector
    G02762641Courtesy of FORD MOTOR CO.
  20. Disconnect the vacuum hoses from the EGR valve tube.
    Fig 15: Disconnecting Vacuum Hoses From EGR Valve Tube
    G02762642Courtesy of FORD MOTOR CO.
  21. Remove the exhaust manifold to EGR valve tube.
    • Disconnect the upper and lower fittings.
    • Remove the tube.
    Fig 16: Removing Exhaust Manifold To EGR Valve Tube
    G02762643Courtesy of FORD MOTOR CO.
  22. Disconnect the EGR vacuum regulator solenoid electrical connector and the vacuum hoses.
    Fig 17: Disconnecting EGR Vacuum Regulator Solenoid Electrical Connector And Vacuum Hoses
    G02762644Courtesy of FORD MOTOR CO.
  23. Disconnect the following hoses:
    • The brake booster vacuum hose.
    • The positive crankcase ventilation (PCV) valve hose.
    • The coolant hose.
    • The IAC valve fresh air hose.
    Fig 18: Disconnecting Hoses
    G02762645Courtesy of FORD MOTOR CO.
  24. Disconnect the IAC valve electrical connector and the EGR valve vacuum connector.
    Fig 19: Disconnecting IAC Valve Electrical Connector And EGR Valve Vacuum Connector
    G02762646Courtesy of FORD MOTOR CO.
  25. Disconnect the coolant hoses and the emissions tube.
    Fig 20: Disconnecting Coolant Hoses And Emissions Tube
    G02762647Courtesy of FORD MOTOR CO.
  26. Remove the four bolts, and the throttle body and adapter as an assembly.
    • Discard the throttle body adapter gasket.
    Fig 21: Removing Bolts, And Throttle Body And Adapter Assembly
    G02762648Courtesy of FORD MOTOR CO.
    27. NOTE: LH is shown, RH is similar.
    Fig 22: Disconnecting Coil-On-Plug Electrical Connectors
    G02762649Courtesy of FORD MOTOR CO.
  27. Disconnect the eight coil-on-plug electrical connectors.
    28. NOTE: RH shown, LH similar.
    Fig 23: Disconnecting Fuel Injector Electrical Connectors
    G02762650Courtesy of FORD MOTOR CO.
  28. Disconnect the eight fuel injector electrical connectors.
  29. Remove the eight bolts and the eight ignition coils.
    Fig 24: Removing Bolts And Eight Ignition Coils
    G02762651Courtesy of FORD MOTOR CO.
  30. Remove the bolts and the generator upper support bracket.
    Fig 25: Removing Bolts And Generator Upper Support Bracket
    G02762652Courtesy of FORD MOTOR CO.
  31. Disconnect the fuel pressure sensor vacuum hose and the electrical connector.
    Fig 26: Disconnecting Fuel Pressure Sensor Vacuum Hose And Electrical Connector
    G02762653Courtesy of FORD MOTOR CO.
    32. NOTE: Typical is shown.
    Fig 27: Removing Bolts, Thermostat Housing And Thermostat
    G02762654Courtesy of FORD MOTOR CO.
  32. Remove the bolts, thermostat housing and thermostat.
    • Discard the O-ring seal.
  33. Remove the nine bolts.
    Fig 28: Removing Bolts
    G02762655Courtesy of FORD MOTOR CO.
  34. 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 29: Removing Intake Manifold Assembly
    G02762656Courtesy of FORD MOTOR CO.
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