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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 797 (Engine - 4.6L And 5.4L) >> In-Vehicle Repair >> Intake Manifold - 4.6L >> Removal

Intake Manifold - 4.6L: Removal

WARNING: This page is about a different car, the 2005 Ford RV Cutaway, 2005 Ford Econoline, 2005 Ford E450 Super Duty, and 2005 Ford Cutaway. However, it is still accessible from the selected car via links, so may be relevant.
  1. Remove the engine cover. For additional information, refer to INTERIOR TRIM AND ORNAMENTATION .
  2. Disconnect the fuel hose spring lock coupling. For additional information, refer to FUEL SYSTEM-GENERAL INFORMATION .
  3. Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
  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 Four Bolts
      G03885138Courtesy of FORD MOTOR CO.
  6. Disconnect the MAF sensor electrical connector and remove the ACL.
    Fig 2: Disconnecting MAF Sensor Electrical Connector
    G03885139Courtesy of FORD MOTOR CO.
  7. Disconnect the engine vent tube. Loosen the clamp and remove the air cleaner outlet pipe.
    Fig 3: Disconnecting Engine Vent Tube
    G03885089Courtesy of FORD MOTOR CO.
  8. Remove the bolt for the transmission fluid level indicator and tube.
    Fig 4: Removing Transmission Fluid Level Indicator And Tube
    G03885090Courtesy of FORD MOTOR CO.
  9. Remove the bolt for the transmission fluid level indicator and tube. Position the transmission fluid indicator and tube aside.
    Fig 5: Removing Transmission Fluid Level Indicator And Tube
    G03885091Courtesy of FORD MOTOR CO.
  10. Compress and slide the hose clamp and disconnect the upper radiator hose.
    Fig 6: Disconnecting Upper Radiator Hose
    G03885092Courtesy of FORD MOTOR CO.
  11. Disconnect the coolant hose.
    Fig 7: Disconnecting Coolant Hose
    G03885093Courtesy of FORD MOTOR CO.
    12. NOTE: The red clip must be pulled out before disconnecting the electrical connector.
    Fig 8: Disconnecting Electronic Throttle Body (TB) Electrical Connector
    G03885094Courtesy of FORD MOTOR CO.
  12. Disconnect the electronic throttle body (TB) electrical connector.
    13. NOTE: The red clip must be pulled out before disconnecting the electrical connector.
    Fig 9: Locating Throttle Position (TP) Sensor Electrical Connector
    G03885095Courtesy of FORD MOTOR CO.
  13. Disconnect the throttle position (TP) sensor electrical connector.
  14. Disconnect the exhaust gas recirculation (EGR) system module electrical connector.
    Fig 10: Disconnecting Exhaust Gas Recirculation (EGR) System Module Electrical Connector
    G03885096Courtesy of FORD MOTOR CO.
  15. Disconnect the vacuum hoses from the EGR system module valve.
    Fig 11: Disconnecting Vacuum Hoses From EGR System Module Valve
    G03885097Courtesy of FORD MOTOR CO.
  16. Remove the exhaust manifold to EGR system module tube.
    • Disconnect the upper and lower fittings.
    • Remove the tube.
      Fig 12: Identifying EGR System Module Tube
      G03885098Courtesy of FORD MOTOR CO.
  17. Disconnect the following hoses:
    • The brake booster vacuum hose.
    • The positive crankcase ventilation (PCV) valve hose.
    • The coolant hoses.
      Fig 13: Removing Brake Booster Vacuum Hose
      G03885099Courtesy of FORD MOTOR CO.
  18. Disconnect the vacuum harness connector.
    Fig 14: Disconnecting Vacuum Harness Connector
    G03885100Courtesy of FORD MOTOR CO.
  19. If equipped, disconnect the auxiliary heater hoses and position aside. For additional information, refer to CLIMATE CONTROL SYSTEM-GENERAL INFORMATION .
    Fig 15: Disconnecting Auxiliary Heater Hoses
    G03885101Courtesy of FORD MOTOR CO.
  20. Disconnect the emissions vapor hose.
    Fig 16: Disconnecting Emissions Vapor Hose
    G03885102Courtesy of FORD MOTOR CO.
  21. Remove the four bolts, and the throttle body and adapter as an assembly.
    • Discard the throttle body adapter gasket.
      Fig 17: Removing Throttle Body Bolts
      G03885103Courtesy of FORD MOTOR CO.
    22. NOTE: LH shown; RH similar.
    Fig 18: Disconnecting Eight Coil-On-Plug Electrical Connectors
    G03885104Courtesy of FORD MOTOR CO.
  22. Disconnect the eight coil-on-plug electrical connectors.
    23. NOTE: RH shown; LH similar.
    Fig 19: Disconnecting Eight Fuel Injector Electrical Connectors
    G03885105Courtesy of FORD MOTOR CO.
  23. Disconnect the eight fuel injector electrical connectors.
  24. Remove the eight bolts and the eight ignition coils.
    Fig 20: Removing Eight Bolts And Eight Ignition Coils
    G03885163Courtesy of FORD MOTOR CO.
  25. Remove the bolts and the generator upper support bracket.
    Fig 21: Removing Generator Upper Support Bracket
    G03885107Courtesy of FORD MOTOR CO.
  26. Disconnect the fuel pressure sensor vacuum hose and the electrical connector.
    Fig 22: Disconnecting Fuel Pressure Sensor Vacuum Hose
    G03885108Courtesy of FORD MOTOR CO.
  27. Remove the bolts, thermostat housing and thermostat.
    • Discard the O-ring seal.
      Fig 23: Removing Thermostat Housing Bolts
      G03885109Courtesy of FORD MOTOR CO.
  28. Remove the nine bolts.
    Fig 24: Removing Nine Bolts
    G03885110Courtesy of FORD MOTOR CO.
  29. Remove the intake manifold assembly.
    1. Lift the intake manifold.
    2. Remove the intake manifold and discard the gaskets.
      • Inspect the intake manifold assembly for damage.
        Fig 25: Removing Intake Manifold Assembly
        G03885111Courtesy of FORD MOTOR CO.
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