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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 - 5.4L >> Removal

Intake Manifold - 5.4L: 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 couplings. 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. NOTE: The red clip must be pulled out before disconnecting the electrical connector.
    Fig 4: Disconnecting Electronic Throttle Body (TB) Electrical Connector
    G03885094Courtesy of FORD MOTOR CO.
  8. Disconnect the electronic throttle body (TB) electrical connector.
  9. Disconnect the throttle position (TP) sensor electrical connector.
    Fig 5: Locating Throttle Position (TP) Sensor Electrical Connector
    G03885095Courtesy 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. If equipped, disconnect the coolant hoses from the TB.
    Fig 8: Disconnecting Coolant Hoses From TB
    G03885145Courtesy of FORD MOTOR CO.
  13. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) system.
    1. Disconnect the electrical connector.
    2. Disconnect the two hoses.
      Fig 9: Disconnecting Electrical Connector
      G03885146Courtesy of FORD MOTOR CO.
  14. Remove the differential pressure feedback EGR system bracket.
    Fig 10: Removing Differential Pressure Feedback EGR System Bracket
    G03885147Courtesy of FORD MOTOR CO.
  15. Remove the bolts and the generator upper support bracket.
    Fig 11: Removing Generator Upper Support Bracket
    G03885148Courtesy of FORD MOTOR CO.
  16. Remove the retaining bolt for the transmission fluid indicator and tube.
    Fig 12: Removing Transmission Fluid Indicator And Tube Bolts
    G03887936Courtesy of FORD MOTOR CO.
  17. Remove the nut for the transmission fluid indicator and tube. Position the transmission fluid indicator and tube aside.
    Fig 13: Removing Transmission Fluid Indicator And Tube
    G03885597Courtesy of FORD MOTOR CO.
  18. Disconnect the evaporative emissions hose.
    Fig 14: Disconnecting Evaporative Emissions Hose
    G03885151Courtesy 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 EGR vacuum regulator solenoid connections.
    Fig 16: Disconnecting EGR Vacuum Regulator Solenoid Connections
    G03885153Courtesy of FORD MOTOR CO.
    21. NOTE: Valve shown disconnected for clarity.
    Fig 17: Removing Evaporative Emission Canister Purge Valve
    G03885154Courtesy of FORD MOTOR CO.
  21. Press the tab, remove and position aside the evaporative emission canister purge valve.
  22. Disconnect the EGR valve vacuum hose.
    Fig 18: Disconnecting EGR Valve Vacuum Hose
    G03885155Courtesy of FORD MOTOR CO.
  23. Disconnect the brake booster and main engine vacuum harness and position aside.
    Fig 19: Disconnecting Brake Booster And Main Engine Vacuum Harness
    G03885156Courtesy of FORD MOTOR CO.
  24. Remove the exhaust manifold-to-EGR valve tube.
    • Disconnect the upper fitting.
    • Disconnect the lower fitting and remove the tube.
      Fig 20: Removing Exhaust Manifold-To-EGR Valve Tube
      G03885157Courtesy of FORD MOTOR CO.
  25. Remove the four bolts, and the throttle body and adapter as an assembly.
    • Discard the throttle body adapter gasket.
      Fig 21: Removing Throttle Body Bolts
      G03885158Courtesy of FORD MOTOR CO.
  26. Disconnect and remove the positive crankcase ventilation (PCV) hose.
    Fig 22: Disconnecting Positive Crankcase Ventilation (PCV) Hose
    G03885159Courtesy of FORD MOTOR CO.
  27. Disconnect the fuel pressure sensor vacuum hose and the electrical connector.
    Fig 23: Disconnecting Fuel Pressure Sensor Vacuum Hose
    G03885160Courtesy of FORD MOTOR CO.
    28. NOTE: LH shown; RH similar.
    Fig 24: Disconnecting Eight Ignition Coil Electrical Connectors
    G03885104Courtesy of FORD MOTOR CO.
  28. Disconnect the eight ignition coil electrical connectors.
    29. NOTE: LH shown; RH similar.
    Fig 25: Disconnecting Eight Fuel Injector Electrical Connectors
    G03885105Courtesy of FORD MOTOR CO.
  29. Disconnect the eight fuel injector electrical connectors.
  30. Remove the eight bolts and the eight ignition coils.
    Fig 26: Removing Eight Ignition Coils
    G03885163Courtesy of FORD MOTOR CO.
  31. Remove the bolts, the thermostat housing and the thermostat.
    • Disconnect the O-ring seal.
      Fig 27: Removing Thermostat Housing Bolts
      G03885109Courtesy of FORD MOTOR CO.
  32. Remove the nine bolts retaining the intake manifold.
    Fig 28: Removing Nine Bolts Retaining Intake Manifold
    G03885110Courtesy of FORD MOTOR CO.
  33. Remove the intake manifold.
    • Discard the intake manifold gaskets.
      Fig 29: Removing Intake Manifold
      G03905345Courtesy of FORD MOTOR CO.
  34. Inspect the throttle body, the intake manifold and their sealing surfaces for damage.
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