Upper Intake Manifold: Removal

WARNING: This page is about a different car, the 2003 Mercury Sable and 2003 Ford Taurus. However, it is still accessible from the selected car via links, so may be relevant.

Disconnect the battery ground cable. For additional information, refer to BATTERY, MOUNTING AND CABLES .
Remove the air cleaner assembly and the air cleaner outlet tube. For additional information, refer to REMOVAL & INSTALLATION .
Remove the pin-type retainers and the snow shield.

Fig 1: Removing Pin-Type Retainers Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Disconnect the accelerator cable, speed control actuator cable and the throttle return spring from the throttle body.

Fig 2: Disconnecting Accelerator Cable, Speed Control Actuator Cable And Throttle Return Spring
Courtesy of FORD MOTOR CO.
Remove the bolts, then position the accelerator cable bracket aside.

Fig 3: Removing Bolts Of Position Accelerator Cable Bracket Aside
Courtesy of FORD MOTOR CO.
Disconnect the hoses.
- Disconnect the vacuum hose.
- Disconnect the evaporative emissions (EVAP) return tube.
Fig 4: Disconnecting Vacuum Hose Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Disconnect the idle air control (IAC) valve and the throttle position (TP) sensor electrical connectors.

Fig 5: Disconnecting Idle Air Control (IAC) Valve And Throttle Position (TP) Sensor Electrical Connectors
Courtesy of FORD MOTOR CO.
Disconnect the engine wiring harness from the intake manifold support bracket.

Fig 6: Disconnecting Engine Wiring Harness
Courtesy of FORD MOTOR CO.
Remove the upper intake manifold support bracket.

Fig 7: Removing Support Bracket Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Disconnect the positive crankcase ventilation (PCV) tube from the upper intake manifold.

Fig 8: Disconnecting Positive Crankcase Ventilation (PCV) Tube Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Loosen the nut and disconnect the exhaust gas recirculation (EGR) tube from the EGR valve.

Fig 9: Loosening Nut And Exhaust Gas Recirculation (EGR) Tube
Courtesy of FORD MOTOR CO.
Disconnect the vacuum hose from the EGR valve.

Fig 10: Disconnecting Vacuum Hose
Courtesy of FORD MOTOR CO.
Disconnect the vacuum regulator solenoid vacuum and electrical connections. Disconnect the vacuum hose from the upper intake manifold.

Fig 11: Disconnecting Vacuum Regulator Solenoid Vacuum And Electrical Connections Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Disconnect the wire harness retaining clip.

Fig 12: Disconnecting Wire Harness Retaining Clip Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.
Disconnect the spark plug holder and the radio interference capacitor electrical connector.

Fig 13: Disconnecting Spark Plug Holder And Radio Interference Capacitor Electrical Connector
Courtesy of FORD MOTOR CO.
Remove the bolts and the upper intake manifold.

Fig 14: Removing Bolts Of Upper Intake Manifold
Courtesy of FORD MOTOR CO.