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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 - 5.4L >> Removal

Intake Manifold - 5.4L: 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. 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 Bolts
    G02762688Courtesy of FORD MOTOR CO.
  6. Disconnect the MAF sensor electrical connector and remove the ACL.
    Fig 2: Disconnecting MAF Sensor Electrical Connector
    G02762689Courtesy of FORD MOTOR CO.
  7. Disconnect the two hoses.
    Fig 3: Disconnecting Hoses
    G02762690Courtesy of FORD MOTOR CO.
  8. Loosen the clamp and remove the air cleaner outlet pipe.
    Fig 4: Removing Air Cleaner Outlet Pipe
    G02762691Courtesy of FORD MOTOR CO.
  9. Remove the accelerator cable snow shield.
    Fig 5: Removing Accelerator Cable Snow Shield
    G02762692Courtesy 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: Removing Throttle Return Spring
    G02762693Courtesy of FORD MOTOR CO.
  11. Compress and slide the hose clamp and disconnect the upper radiator hose.
    Fig 7: Disconnecting Upper Radiator Hose
    G02762694Courtesy of FORD MOTOR CO.
  12. Disconnect the coolant hose.
    Fig 8: Disconnecting Coolant Hose
    G02762695Courtesy of FORD MOTOR CO.
  13. Disconnect the coolant hose.
    Fig 9: Disconnecting Coolant Hose
    G02762696Courtesy 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
    G02762697Courtesy 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 Differential Pressure Feedback Exhaust Gas Recirculation
    G02762698Courtesy of FORD MOTOR CO.
  16. Remove the differential pressure feedback EGR system bracket.
    Fig 12: Removing Differential Pressure Feedback EGR System Bracket
    G02762699Courtesy of FORD MOTOR CO.
  17. Remove the bolt and the bracket.
    Fig 13: Removing Bolt And Bracket
    G02762700Courtesy of FORD MOTOR CO.
  18. Remove the bolts and the generator upper support bracket.
    Fig 14: Removing Bolts And Generator Upper Support Bracket
    G02762701Courtesy of FORD MOTOR CO.
  19. Remove the bolt retaining the transmission fluid filler tube support bracket.
    Fig 15: Removing Bolt Retaining Transmission Fluid Filler Tube Support Bracket
    G02762702Courtesy of FORD MOTOR CO.
  20. Remove the bolts and position the accelerator cable bracket and cables aside.
    Fig 16: Removing Bolts
    G02762703Courtesy 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
    G02762704Courtesy 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
    G02762705Courtesy 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
    G02762706Courtesy 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
    G02762707Courtesy of FORD MOTOR CO.
  25. Disconnect the fuel pressure sensor vacuum hose and the electrical connector.
    Fig 21: Disconnecting Fuel Pressure Sensor Vacuum Hose And Electrical Connector
    G02762708Courtesy of FORD MOTOR CO.
  26. Disconnect the EGR vacuum regulator solenoid connections.
    Fig 22: Disconnecting EGR Vacuum Regulator Solenoid Connections
    G02762709Courtesy of FORD MOTOR CO.
  27. Disconnect the EGR valve vacuum hose.
    Fig 23: Disconnecting EGR Valve Vacuum Hose
    G02762710Courtesy of FORD MOTOR CO.
  28. Disconnect the IAC valve electrical connector.
    Fig 24: Disconnecting IAC Valve Electrical Connector
    G02762711Courtesy 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
    G02762712Courtesy of FORD MOTOR CO.
  30. Disconnect the differential pressure feedback EGR sensor hoses from the EGR valve.
    Fig 26: Disconnecting Differential Pressure Feedback EGR Sensor Hoses From EGR Valve
    G02762713Courtesy of FORD MOTOR CO.
  31. Remove the exhaust manifold-to-EGR valve tube.
    • Disconnect the upper fitting.
    • Disconnect the lower fitting and remove the tube.
    Fig 27: Removing Exhaust Manifold-To-EGR Valve Tube
    G02762714Courtesy of FORD MOTOR CO.
  32. Remove the four bolts, and the throttle body and adapter as an assembly.
    • Discard the throttle body adapter gasket.
    Fig 28: Removing Bolts, And Throttle Body And Adapter
    G02762715Courtesy of FORD MOTOR CO.
  33. Disconnect and remove the positive crankcase ventilation hose.
    Fig 29: Removing Positive Crankcase Ventilation Hose
    G02762716Courtesy of FORD MOTOR CO.
    34. NOTE: LH is shown, RH is similar.
    Fig 30: Disconnecting Ignition Coil Electrical Connectors
    G02762717Courtesy of FORD MOTOR CO.
  34. Disconnect the eight ignition coil electrical connectors.
    35. NOTE: LH is shown, RH is similar.
    Fig 31: Disconnecting Fuel Injector Electrical Connectors
    G02762718Courtesy of FORD MOTOR CO.
  35. Disconnect the eight fuel injector electrical connectors.
  36. Remove the eight bolts and the eight ignition coils.
    Fig 32: Removing Bolts And Eight Ignition Coils
    G02762719Courtesy of FORD MOTOR CO.
  37. Remove the bolts, the thermostat housing and the thermostat.
    • Disconnect the O-ring seal.
    Fig 33: Removing Bolts, Thermostat Housing And Thermostat
    G02762720Courtesy of FORD MOTOR CO.
  38. Remove the nine bolts retaining the intake manifold.
    Fig 34: Removing Nine Bolts Retaining Intake Manifold
    G02762721Courtesy of FORD MOTOR CO.
  39. Remove the intake manifold.
    • Discard the intake manifold gaskets.
    Fig 35: Removing Intake Manifold
    G02762722Courtesy of FORD MOTOR CO.
  40. Inspect the throttle body, the intake manifold, and their sealing surfaces for damage.
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