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Home >> Ford >> 2000 >> Contour SE, 2.5 L, Standard >> Repair and Diagnosis >> External Pages >> Different car >> Section 84 (Engine Controls - Removal, Overhaul & Installation -- ECONOLINE, Excursion & F250-F550 Super Duty - Gasoline) >> Air Induction Systems >> Intake Manifold (4.6L & 5.4L) >> Removal

Intake Manifold (4.6L & 5.4L): Removal

WARNING: This page does not describe the selected car, but rather 9 other vehicles, including the 2002 Ford RV Cutaway, 2002 Ford Pickup, 2002 Ford F550 Super Duty, 2002 Ford F450 Super Duty, and 2002 Ford Excursion. However, it is still accessible from the selected car via links, so may be relevant.
  1. Disconnect the battery ground cable. Remove the air cleaner outlet pipe. Drain the engine cooling system. Remove upper radiator hose.
  2. Disconnect the throttle body cam. Disconnect the accelerator cable, speed control actuator cable and accelerator return spring. Remove the accelerator cable bracket bolts and position the bracket and cables aside. Remove the Idle Air Control (IAC) fresh air hose.
  3. Disconnect Exhaust Gas Recirculation (EGR) vacuum regulator solenoid, IAC and Throttle Position (TP) sensor electrical connectors. See Figure or Figure . Disconnect EGR valve vacuum hose and evaporative emission canister purge valve hose.
  4. Disconnect fuel pressure regulator vacuum hose. Disconnect differential pressure feedback EGR system electrical connector. Disconnect evaporative emission canister purge valve vacuum hose. Remove brake booster vacuum tube from upper intake manifold and position bracket and tube aside.
  5. Disconnect and move crankcase ventilation hose and exhaust manifold-to-EGR valve tube aside. Disconnect main vacuum harness. Remove PCV hose.
  6. Remove four bolts and throttle body adapter. Inspect the throttle body and adapter for damage. Remove power steering reservoir upper mounting bracket. Remove eight ignition coils. See IGNITION COILS  under IGNITION SYSTEMS . Disconnect fuel injector harness connectors. Remove drive belt from the alternator pulley.
  7. Remove generator upper mounting bracket. Remove generator lower mounting bolts and position generator aside. Disconnect heater hose. Relieve fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE . Disconnect fuel lines. See FUEL LINE CONNECTORS . Remove thermostat housing. Discard thermostat housing O-ring seal.
    8. CAUTION: Do not use metal scrapers, power abrasive discs or any abrasive means to clean the sealing surfaces, these tools cause scratches and gouges that make leak paths. Use a plastic scraper only.
  8. Remove nine upper intake manifold bolts. Lift the intake manifold assembly. Disconnect intake manifold tuning valve connector. Remove intake manifold assembly. Discard the gaskets. Inspect the intake manifold assembly for damage. Clean all the sealing surfaces. If lower intake manifold removal is necessary, go to next step.
  9. Remove fuel lines and injectors. Remove noise shield from lower intake manifold. Remove lower intake manifold bolts. Remove lower intake manifold. Clean all mating surfaces.
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